Method and apparatus for the production of fuel-gas, syngas and other constituent gas species

Abstract

A method for producing fuel gases includes the steps of: providing a pool of molten sodium carbonate and sodium hydroxide salts within a reactor; introducing water, in the form of steam, and at least one solid carbonaceous material into the pool of molten salts; reacting the water, the carbonaceous material and the molten salts at a pressure less than 13.89 MPa and at temperatures below 929° C. to produce an output stream containing methane, hydrogen, carbon monoxide and carbon dioxide. The carbonaceous material can be refuse-derived materials, sewer solids, coal and shredded discarded tires.

What is claimed is: 
     
         1 . A method of producing gas by decomposition, the method comprising the steps of:
 providing a molten pool of alkaline salts, including sodium carbonate and sodium hydroxide, within a reactor;   introducing an oxidizing material into the molten pool;   introducing a carbonaceous material into the molten pool;   reacting the oxidizing material, the carbonaceous material and the molten pool at a temperature less than 929° C. to produce an output stream of methane and other constituent gas species.   
     
     
         2 . The method of  claim 1 , wherein the oxidizing material, the carbonaceous material and the molten salts are reacted at a pressure less than 13.89 MPa. 
     
     
         3 . The method of  claim 1 , wherein the oxidizing material is water in the form of steam. 
     
     
         4 . The method of  claim 3 , wherein the alkaline salts, the carbonaceous material and the steam react in accordance with the following dominant equilibrium equation:
   10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O   
     
     
         5 . The method of  claim 1 , wherein the output stream further comprises hydrogen, carbon monoxide, carbon dioxide, water vapor, and entrained non-gases. 
     
     
         6 . The method of  claim 5 , which further comprises the steps of:
 separating individual gases from the output stream;   extracting water from the output stream and recycling it back to the molten pool of alkaline salts;   separating any entrained non-gases from the output stream; and   separating any water-soluble material from the non-gases and returning the water soluble materials back to the molten pool of alkaline salts.   
     
     
         7 . The method of  claim 1 , wherein the carbonaceous materials are selected from the group consisting of refuse-derived materials, sewer solids, coal and shredded discarded tires. 
     
     
         8 . A method of producing gas by decomposition, the method comprising the steps of:
 providing a molten pool of alkaline salts including sodium carbonate and sodium hydroxide within a reactor;   introducing an oxidizing material into the molten pool;   introducing a carbonaceous material into the molten pool;   reacting the oxidizing material, the carbonaceous material and the molten pool at a pressure less than 13.89 MPa. to produce an output stream of methane and other constituent gas species.   
     
     
         9 . The method of  claim 8 , wherein the oxidizing material, the carbonaceous material and the molten salts are reacted at a temperature less than 929° C. 
     
     
         10 . The method of  claim 8 , wherein the oxidizing material is water in the form of steam. 
     
     
         11 . The method of  claim 10 , wherein the alkaline salts, the carbonaceous material and the steam react in accordance with the following dominant equilibrium equation:
   10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O   
     
     
         12 . The method of  claim 8 , wherein the output stream further comprises hydrogen, carbon monoxide, carbon dioxide, water vapor, and entrained non-gases. 
     
     
         13 . The method of  claim 12 , which further comprises the steps of:
 separating individual gases from the output stream;   extracting water from the output stream and recycling it back to the molten pool of alkaline salts;   separating any entrained non-gases from the output stream; and   separating any water-soluble material from the non-gases and returning the water soluble materials back to the molten pool of alkaline salts.   
     
     
         14 . The method of  claim 8 , wherein the carbonaceous materials are selected from the group consisting of refuse-derived materials, sewer solids, coal and shredded discarded tires. 
     
     
         15 . A method for producing carbonaceous fuel gas by decomposition, the method comprising the steps of:
 providing a pool of molten sodium carbonate and sodium hydroxide salts within a reactor;   introducing water, in the form of steam, and at least one solid carbonaceous material into the pool of molten salts;   reacting the water, the carbonaceous material and the molten salts at a pressure less than 13.89 MPa to produce an output stream containing methane and other gaseous species.   
     
     
         16 . The method of  claim 15 , wherein the reaction of the water, the carbonaceous material and the molten salts proceeds in accordance with the following dominant equilibrium equation:
   10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O   
     
     
         17 . The method of  claim 15 , wherein the reaction of the water, the carbonaceous material and the molten salts proceeds at a temperature of less than 929° C. 
     
     
         18 . The method of  claim 15 , wherein the output stream further comprises hydrogen, carbon monoxide, carbon dioxide, water vapor, and entrained non-gases. 
     
     
         19 . The method of  claim 18 , which further comprises the steps of:
 separating individual gases from the output stream;   extracting water from the output stream and recycling it back to the molten pool of alkaline salts;   separating any entrained non-gases from the output stream; and   separating any water-soluble material from the non-gases and returning the water soluble materials back to the molten pool of alkaline salts.   
     
     
         20 . The method of  claim 15 , wherein the carbonaceous materials are selected from the group consisting of refuse-derived materials, sewer solids, coal and shredded discarded tires.