Bio-energy conversion process

Abstract

The invention is a bioenergy and/or waste-to-energy process. The invention is a process using controlled pyrolysis reactions to convert biomass and carbon based waste material into carbon byproducts, biofuels and useable energy in the form of heat and/or electricity. The process includes one or more pyrolysis reaction chambers and a thermal oxidizer. Hot, oxygen-free exhaust gases from the thermal oxidizer are modulated through the pyrolysis reaction chambers to sustain the pyrolysis reaction. The exhaust gases along with the pyrolysis gases are drawn from the pyrolysis reaction chambers and routed to the thermal oxidizer. Combustion air is modulated into the thermal oxidizer through one or more ports to control combustion of the pyrolysis gases. After combustion, exhaust gases are recirculated to the pyrolysis reaction chambers to sustain the cycle. The invention proposes a process which is unique in four ways. Firstly, the process may convert any carboneous material, such as biocrops, animal waste, used tires, into bioproducts and biofuels. Secondly, the carbonization process is accomplished with no oxygen or combustion in the carbonization chambers. Thirdly, the modular arrangement of the process components allows easy adaptability to diverse process requirements. Fourthly, the mobility of the process material containers allows easy loading, transport, and unloading of the process material; and greatly reduces material handling requirements.

What is being claimed is as follows: 
     
         1 . The pyrolysis/gasification process which produces solid, liquid, gaseous fuels, carbon products and electricity from biomass and carbonaceous environmental waste materials, the process comprising:
 a. feeding by loading, conveying, or pneumatic transfer of feedstock comprising solid biomass and carbonaceous environmental waste materials into the negative pressure, non-catalyst, non-plasma, non-Fischer-Tropsch pyrolysis reaction chambers;   b. gasifying the feedstock in pyrolysis reaction chambers where solid materials are thermally carbonized to form solid carbonized products and pyrolysis gases;   c. removing by dumping, conveying, or pneumatic transfer of solid carbonized products from the pyrolysis chambers;   d. delivering by piping and/or ducting an optional portion of the pyrolysis gases from the pyrolysis reaction chambers into a gas-to-liquid condenser;   e. condensing of the optional portion of the pyrolysis gases in the condenser into liquid or gaseous biofuels which may be stored, sold, or used to fuel or heat other processes;   f. delivering by piping/ducting the remaining portion of the pyrolysis gases to the thermal oxidizer;   g. delivering by piping/ducting a controlled amount of combustion air from the atmosphere to the thermal oxidizer;   h. combusting of the remaining portion of the pyrolysis gases with controlled combustion air feed in the thermal oxidizer;   i. venting a portion of the exhaust gases from the thermal oxidizer through a heat exchanger/condenser to atmosphere;   j. delivering by piping and/or ducting the remaining portion of the hot, oxygen-free exhaust gases, from the thermal oxidizer to the pyrolysis reaction chambers in the pyrolysis phase thereby supplying energy to sustain the pyrolysis reaction;   k. delivering by piping and/or ducting a portion of the hot, oxygen-free exhaust gases, from the thermal oxidizer to the pyrolysis reaction chambers in the drying phase thereby supplying energy to evaporate moisture from the feedstock;   l. delivering by piping and/or ducting the oxygen-free gases and evaporated moisture from the pyrolysis reaction chambers in the drying phase to a heat exchanger/condenser whereby the oxygen-free gases are cooled and the moisture is condensed and removed;   m. circulating by piping and/or ducting the cool, dry, oxygen-free gases from the heat exchanger/condenser though the pyrolysis reaction chambers in the cooling phase and back to the heat exchanger/condenser thereby cooling the pyrolysis reaction chambers;   n. exchanging of heat from water vapor stream and vented exhaust stream to preheat the combustion air stream.   
     
     
         2 . The process according to  claim 1 , wherein the solid, liquid, and gaseous byproducts include methane, ethane, di-methyl ether, acetylene, hydrogen, butanol, alcohols, ethanol, methanol, ethylene, acetone, mineral spirits, activated carbon, charcoal and calcium carbide. 
     
     
         3 . The process according to  claim 1 , wherein the process is a self-sustainable process after start-up that utilizes its own internal thermal heat from the combustion reactions to maintain the temperatures in the pyrolysis reaction chambers, thermal oxidizer, and piping/ducting. 
     
     
         4 . The process according to  claim 1 , wherein the pyrolysis reaction is accomplished in oxygen-free conditions with no combustion in the pyrolysis reaction chambers. 
     
     
         5 . The process according to  claim 1 , wherein rapid cooling is accomplished by circulating oxygen-free gases through the pyrolysis reaction chambers and a heat exchanger. 
     
     
         6 . The process according to  claim 1 , wherein the pyrolysis reactions can be accelerated, slowed, or stopped by controlling the heat supply to the pyrolysis reaction chambers. 
     
     
         7 . The process according to  claim 1 , wherein the pyrolysis reaction chambers are mounted on wheel bases for easy transport between loading, process, and unloading stations. 
     
     
         8 . The process according to  claim 1 , wherein the number of pyrolysis reaction chambers can be varied to meet production requirements.