Method and apparatus for efficient production of activated carbon

Abstract

This invention relates to a system for regenerating or manufacturing activated carbon wherein the exhaust gases and vapors from various sections of the furnace are supplied to other sections of the furnace in a recycling manner or are simultaneously cleaned and transformed into fuel gas. In a down-flow embodiment, the water vapor and calorific gasses generated in excess in the drying and devolatilization sections, respectively, are provided, either directly or through a combustion chamber, to the activation section. In an up-flow embodiment, heat from the activation section is recycled to the drying and devolatilization section and the down-flow brings the water vapor from the drying section and volatile material from the devolatilization section into the activation section where it can be effectively used.

1 . A fuel gas cleaning and power generation method, comprising the steps of:
 a. acquiring a gas from one or more exhausts of a furnace utilized in transforming a carbon source into activated carbon;   b. heating the gas in a superheat chamber to a decomposition temperature sufficient to cause the condensable organics to decompose toward non-condensable organics;   c. separating H 2 O from the gas; and   d. combusting the gas to provide energy.   
     
     
         2 . The fuel gas cleaning and power generation method of  claim 1 , further comprising the steps of:
 a. mixing the gas with an oxygen source; and   b. utilizing the combustion energy to turn the shaft of an electrical generator.   
     
     
         3 . The fuel gas cleaning and power generation method of  claim 2 , further comprising the step of:
 a. compressing the oxygen source and gas.   
     
     
         4 . The fuel gas cleaning and power generation method of  claim 1 , further comprising the step of:
 a. pre-heating the gas prior to the step of heating the gas in the superheat chamber.   
     
     
         5 . The fuel gas cleaning and power generation method of  claim 1 , further comprising the step of:
 a. removing particulate matter from the gas.   
     
     
         6 . The fuel gas cleaning and power generation method of  claim 1 , wherein the step of separating H 2 O from the gas includes a condenser and liquid gas separator. 
     
     
         7 . The fuel gas cleaning and power generation method of  claim 1 , wherein the non-condensable organics are ethane and methane. 
     
     
         8 . A method of transforming exhaust from a furnace being utilized to manufacture activated carbon, the exhaust being a gas containing condensable organics and water vapor, into fuel gas and electrical energy, comprising the steps of:
 a. venting the gas from the furnace;   b. heating the gas to a temperature sufficient to cause the condensable organics to decompose toward non-condensable organics;   c. separating H 2 O from the gas;   d. compressing the gas;   e. mixing the gas with an oxygen source;   f. combusting the gas and oxygen mixture; and   g. utilizing the combustion energy to turn the shaft of an electrical generator.   
     
     
         9 . The method of  claim 8 , further comprising the step of:
 a. pre-heating the gas prior to the step of heating the gas.   
     
     
         10 . The method of  claim 8 , further comprising the step of:
 a. removing particulate matter from the gas.   
     
     
         11 . The method of  claim 8 , wherein the step of separating H 2 O from the gas includes a condenser and liquid gas separator. 
     
     
         12 . The method of  claim 8 , wherein the oxygen source is compressed atmospheric air. 
     
     
         13 . The method of  claim 8 , wherein the non-condensable organics are ethane and methane. 
     
     
         14 . A method for recycling and reusing a stream of exhaust gas from a furnace producing activated carbon comprising the steps of heating the exhaust gas to a temperature at which condensable organics are eliminated and non-condensable organics are created, removing water vapor from the exhaust gas, compressing the exhaust gas, mixing the exhaust gas with a source of oxygen, utilizing the exhaust gas/oxygen source mixture as fuel for a gas turbine and generating power with the gas turbine. 
     
     
         15 . The method of  claim 14 , further comprising the step of pre-heating the exhaust gas prior to the step of heating the exhaust gas. 
     
     
         16 . The method of  claim 15 , further wherein the pre-heating step utilizes extraneous heat contained in the exhaust gas subsequent to the heating step. 
     
     
         17 . The method of  claim 14 , wherein the step of removing water vapor from the gas includes a condenser and liquid gas separator. 
     
     
         18 . The method of  claim 14 , wherein the oxygen source is compressed atmospheric air. 
     
     
         19 . The method of  claim 14 , wherein the non-condensable organics are ethane and methane.