Multi-Zone Carbon Conversion System with Plasma Melting

Abstract

A multi-zone carbon converter for converting processed feedstock to syngas and slag is provided comprising a chamber comprising a carbon conversion zone in communication with a slag zone for melting ash into molten slag and/or for maintaining slag in a molten state by the application of plasma heat. The carbon conversion zone and the slag zone are separated by the inter-zonal region that comprises an impediment for restricting or limiting the movement of material between the two zones. The inter-zonal region may also provide for the initial melting of the ash into molten slag by affecting the transfer of plasma heat from the slag zone.

1 . A multi-zone carbon converter for converting processed feedstock to syngas and slag comprising
 a chamber comprising a carbon conversion zone in communication with a slag zone, wherein the carbon conversion zone and the slag zone are separated by an inter-zonal region;   the carbon conversion zone comprising a processed feedstock input for receiving processed feedstock from a source, a syngas outlet and an air input;   the inter-zonal region comprising an impediment to limits the flow of material between the carbon conversion zone and the slag zone by either partial or intermittently occluding the inter-zonal region;   the slag zone comprising a plasma heat source and a slag outlet; wherein the processed feedstock is converted to the syngas and ash in the carbon conversion zone, and the ash is converted into molten slag in the inter-zonal region and/or the slag zone through the application of heat from the plasma heat source.   
     
     
         2 . The multi-zone carbon converter of  claim 1 , wherein the air input is heated air inlets. 
     
     
         3 . The multi-zone carbon converter of  claim 1 , wherein the air input is one or more air boxes. 
     
     
         4 . The multi-zone carbon converter of  claim 1 ,  2  or  3 , wherein the impediment is a solid pre-cast refractory dome mounted in the inter-zonal region via four wedge-shaped refractory bricks and is sized to provide a gap or space between tin internal wall of the multi-zone carbon converter and the dome. 
     
     
         5 . The multi-zone carbon converter of  claim 4 , wherein the chamber is substantially vertically-oriented, cylindrical chamber and the inter-zonal forms a construction of the chamber. 
     
     
         6 . The multi-zone carbon converter of  claim 5 , wherein the slag zone tapers towards a conical slag outlet. 
     
     
         7 . The multi-zone carbon converter of  claim 1 , wherein the impediment is a grate. 
     
     
         8 . The multi-zone carbon converter of  claim 1 , wherein the inter-zonal region further comprises heat transfer elements for transferring plasma heat from the slag zone to the inter-zonal region. 
     
     
         9 . The multi-zone carbon converter of  claim 1 , further comprising a control system. 
     
     
         10 . The multi-zone carbon converter of  claim 1 , further comprising a processed feedstock pre-treatment module. 
     
     
         11 . The multi-zone carbon converter of  claim 1 , further comprising a slag cooling module. 
     
     
         12 . The multi-zone carbon converter of  claim 1 , wherein plasma heat sources is a plasma torch.