Gasifier comprising vertically successive processing regions

Abstract

The present invention provides a vertically oriented gasifier comprising vertically successive processing regions for conversion of carbonaceous feedstock into gas. The gasifier comprises of: one or more processing chambers with two or more vertically successive processing regions being distributed within said one or more processing chambers, within each one of which a respective process selected from the group consisting of drying, volatilization and carbon conversion is at least partially favoured. The processing regions are identified by temperature ranges respectively enabling each said respective process. One or more additive input elements are associated with the processing regions for inputting additives to promote each said at least partially favoured process therein. In addition, the gasifier comprises one or more material displacement control modules adapted to control a vertical movement of the feedstock through said processing regions to enhance each said at least partially favoured process, one or more feedstock inputs located near a first of said processing regions and one or more gas outputs and one or more residue outputs.

1 . A gasifier for conversion of carbonaceous feedstock into gas and residue, the gasifier comprising
 one or more processing chambers, two or more vertically successive processing regions being distributed within said one or more processing chambers, within each one of which a respective process selected from the group consisting of drying, volatilization and carbon conversion is at least partially favoured, said processing regions being identified by temperature ranges respectively enabling each said respective process;   one or more additive input elements associated with said processing regions for inputting additives to promote each said at least partially favoured process therein;   one or more material displacement control modules adapted to control a vertical movement of the feedstock through said processing regions to enhance each said at least partially favoured process;   one or more feedstock inputs located near a first of said processing regions;   one or more gas outputs; and   one or more residue outputs.   
     
     
         2 . The gasifier as claimed in  claim 1 , wherein said processing regions are promoted by a combination of said one or more processing chambers and by a positioning of said one or more additive input elements in each of said processing chambers. 
     
     
         3 . The gasifier as claimed in  claim 1 , the gasifier for use in a gasification system comprising a control system, the gasifier being configured to operate in accordance with control parameters provided by the control system determined in response to one or more sensed characteristics indicative of one or more process characteristic variations of the gasification system. 
     
     
         4 . The gasifier as claimed in  claim 3 , wherein the one or more material displacement control modules are operatively coupled to the control system and at least partially controlled thereby to affect a change in said one or more sensed characteristics. 
     
     
         5 . The gasifier as claimed in  claim 4 , wherein said one or more characteristics comprises one or more of a carbon content of the product gas, a heating value of the product gas, a hydrogen content of the product gas and a carbon monoxide content of the product gas, and wherein said one or more material displacement control modules are configured to adjust said vertical movement of the feedstock through said processing regions in response to a sensed variation in said one or more characteristics to affect a change in same. 
     
     
         6 . The gasifier as claimed in  claim 1 , the gasifier comprising two or more vertically successive processing chambers, one or more of said two or more vertically successive processing regions being defined within each of said two or more processing chambers. 
     
     
         7 . The gasifier as claimed in  claim 1 , the gasifier comprising one processing chamber, said one chamber comprising two or more additive input elements, each one of which being positioned and operated so to promote a respective one of said two or more vertically successive processing regions. 
     
     
         8 . The gasifier as claimed in  claim 1 , wherein said gas output is in fluid communication with a gas reformulating system for reformulating at least some of the gas output from the gasifier. 
     
     
         9 . The gasifier as claimed in  claim 1 , wherein said gas output is connected to a gas reformulating system via piping for reformulating at least some of the gas output from the gasifier. 
     
     
         10 . The gasifier as claimed in  claim 1 , wherein said gas output is in fluid communication with a gas storage tank for storing at least some of the gas output from the gasifier. 
     
     
         11 . The gasifier as claimed in  claim 1 , wherein said residue output is in operative communication with a residue processing system for further processing of the residue. 
     
     
         12 . The gasifier as claimed in  claim 1 , wherein said residue comprises a partially processed carbonaceous feedstock and wherein said residue output is in operative communication with a second gasifier for conversion of said partially processed carbonaceous feedstock. 
     
     
         13 . The gasifier as claimed in  claim 12 , wherein said second gasifier is a vertically oriented gasifier as claimed in  claim 1 . 
     
     
         14 . The gasifier as claimed in  claim 13 , wherein said second gasifier is a laterally oriented gasifier. 
     
     
         15 . The gasifier as claimed in  claim 1 , the feedstock being partially processed feedstock provided from an upstream gasifier and wherein said feedstock input is in operative communication with a residue output of said upstream gasifier for further processing of said partially processed carbonaceous feedstock. 
     
     
         16 . The gasifier as claimed in  claim 1 , wherein said material displacement control module is actively controlled for facilitating exit of residue from a final one of said processing regions, thereby indirectly controlling a downward movement of reactant material through others of said processing regions to said final one thereof. 
     
     
         17 . The gasifier as claimed in  claim 1 , wherein said material displacement control module comprises one or more of a rotating arm, a rotating wheel, a rotating paddle, a rotating grate, a moving shelf, a pusher ram, an extractor screw, and a conveyor. 
     
     
         18 . The gasifier as claimed in  claim 1 , wherein the gasifier is heated using separate, independently controlled means for heating said processing regions. 
     
     
         19 . The gasifier as claimed in  claim 18 , wherein said means for heating comprises one or more of said additive input elements for injection of pre-heated air. 
     
     
         20 . The gasifier as claimed in  claim 1 , wherein mechanical means are inserted into said processing chambers and adapted to mix the carbonaceous feedstock and said additive inputs. 
     
     
         21 . The gasifier as claimed in  claim 1 , wherein the feedstock input is in operative communication with a controllable feedstock input system. 
     
     
         22 . The gasifier as claimed in  claim 21 , wherein said controllable feedstock input system is in operative communication with a feedstock pre-processing system. 
     
     
         23 . The gasifier as claimed in  claim 1 , wherein said one or more processing chambers are chosen from a group comprising fixed bed processing chambers, gravity-induced vertical processing chambers, mechanically-assisted flow processing chambers, fluidised bed processing chambers and entrained flow processing chambers. 
     
     
         24 . A vertically oriented gasifier for conversion of carbonaceous feedstock into gas and residue, the gasifier comprising:
 one or more processing chambers, each one of which comprising one or more additive input elements for input of additives therein, wherein combination of said one or more processing chambers and a positioning of said one or more additive input elements thereof promoting creation of two or more vertically successive processing regions within the gasifier within each one of which a respective process is at least partially favoured, said processing regions being identified by temperature ranges respectively enabling each said respective process;   one or more feedstock inputs proximal to a first of said processing regions;   one or more material displacement control modules adapted to control a vertical movement of the feedstock through said processing regions to enhance each said at least partially favoured process;   one or more gas outputs; and   one or more residue outputs.   
     
     
         25 . A method for converting a carbonaceous feedstock into gas and residue comprising the steps of:
 providing a gasifier;   creating two or more vertically successive processing regions within said gasifier, within each one of which a respective process selected from the group consisting of drying, volatilization and carbon conversion is at least partially favoured, said processing regions being identified by temperature ranges respectively enabling each said respective process,   inputting additives within the gasifier to promote each said at least partially favoured process;   controlling a downward movement of the feedstock through said processing regions thereby optimizing each said at least partially favoured process; and   outputting the gas and residue from the gasifier.   
     
     
         26 . The method as claimed in  claim 25 , said gasifier comprising two or more vertically successive processing chambers, one or more of said two or more vertically successive processing regions being created within each of said two or more processing chambers. 
     
     
         27 . The method as claimed in  claim 25 , said gasifier comprising one processing chamber, said inputting additives step comprising inputting additives via two or more additive input elements, each one of which being positioned and operated so to promote a respective one of said two or more vertically successive processing regions.