Apparatus, system, and method for converting varied source industry waste into energy

Abstract

An apparatus, system, and method for processing hydrocarbon-containing wastes are described. The system and method include the use of a gasification apparatus comprising a rotary kiln reactor and a gas distributor. The rotary kiln reactor and gas distributor are configured to generate multiple reaction environments within the gasification apparatus. Each of the reaction environments has unique temperature reaction conditions to suit various physical and chemical properties associated with processing of the varied-source hydrocarbon-containing wastes.

1 . An system for gasification of varied-source hydrocarbon-containing wastes, comprising
 a rotary kiln configured to thermochemically transform varied-source hydrocarbon-containing wastes into combustible fuel gases, the varied-source hydrocarbon-containing wastes having varied physical and chemical properties, wherein a length and a diameter of the rotary kiln provides requisite residence time for gasification of the varied-source hydrocarbon-containing wastes and the reactor has at least two reaction zones;   a feeder in communication with the rotary kiln reactor;   a gas distributor substantially included within the rotary kiln, the gas distributor configured to introduce reaction gases into the rotary kiln reactor along a length of the rotary kiln;   a first cyclone in communication with the kiln, the first cyclone configured to separate carbonaceous ash from non-ash carbonaceous materials;   a quencher or wet heat exchanger in communication with the first cyclone, wherein a second cyclone in communication with the quencher;   a burner in communication with the quencher, the burner configured to combust the non-ash carbonaceous materials.   
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . The system of  claim 1 , wherein the gas distributor is configured to introduce different quantities of reaction gases along a length of the rotary kiln reactor to create reaction zones, the reaction zones created according to chemical properties of the varied-source hydrocarbon-containing wastes. 
     
     
         5 . The system of  claim 3 , wherein the gas distributor comprises about 2 to about 8 reaction zones, the gas distributor being configured to introduce the reaction gases into the rotary kiln reactor in equal or varying quantities. 
     
     
         6 . The system of  claim 3 , wherein at least two reaction zones have substantially equal lengths. 
     
     
         7 . (canceled) 
     
     
         8 . The system of  claim 1 , wherein the gas distributor is perforated along about 90 degrees to about 180 degrees of a radial circumference of the gas distributor a quencher in communication with the cyclone and the burner, the quencher contacting carbonaceous materials with water to reduce a temperature of the carbonaceous materials to about 250° C. 
     
     
         9 . (canceled) 
     
     
         10 . The system of  claim 1 , wherein a location of solids within the rotary kiln reactor is controlled by a rotational speed of the rotary kiln reactor. 
     
     
         11 . The system of  claim 1 , wherein the wet heat exchanger is in communication with the first cyclone and the kiln, the wet heat exchanger is at about 350° C. indirectly contacting carbonaceous materials with circulating liquid, the indirect contact of the carbonaceous materials with the circulating liquid causes a temperature of the carbonaceous materials to drop to about 200° C. 
     
     
         12 . The system of  claim 1 , wherein the system is utilized to perform at least one of drying wet solids, pyrolysis of the varied-source hydrocarbon-containing wastes, and combustion of the varied-source hydrocarbon-containing wastes. 
     
     
         13 . The system of  claim 1 , wherein the varied-source hydrocarbon-containing wastes are thermochemically transformed into a combustible fuel gas mixture comprising carbon monoxide, hydrogen, methane, ethane, carbon dioxide, water vapor, and nitrogen, the combustible fuel gas mixture having a caloric value in the range of about 80 to about 320 BTU per cubic foot irrespective of a composition of the varied-source hydrocarbon-containing waste. 
     
     
         14 . The system of  claim 1 , wherein an amount of water introduced into the rotary kiln reactor is about 25% to about 30% by weight of an amount of the varied-source hydrocarbon-containing waste on a dry basis. 
     
     
         15 . The system of  claim 1 , comprising a second cyclone in communication with the quencher and a wet heat anger in communication with the first cyclone, wherein ash particulates are removed, wherein the system uses a filter at the wet heat exchanger. 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . The system of  claim 3 , wherein the kiln has a first reaction zone, the first a reaction zone has a temperature below about 800° F. 
     
     
         19 . The system of  claim 18 , wherein the kiln has a second reaction zone, the second reaction zone has a temperature between about 1000° F. and about 1200° F. 
     
     
         20 . The system of  claim 19 , wherein the kiln has a third reaction zone, the third reaction zone has a temperature between about 1800° F. and about 2000° F. 
     
     
         21 . The system of  claim 20 , wherein the varied-source hydrocarbon-containing wastes leaving the rotary kiln reactor have a temperature of about 2000° F. 
     
     
         22 . A method for generating combustible fuel gases for energy, the method comprising:
 providing a source of varied industrial waste comprising carboneous materials; the varied-source hydrocarbon-containing wastes having varied physical and chemical properties   using a feeder to move the waste to a gasifier, wherein the gasifier is configured to thermochemically transform varied-source hydrocarbon-containing wastes into the combustible fuel gases;   burning the waste in the gasifier at first reaction zone, wherein the first reaction zone has a temperature between about 1000° F. and about 1200° F.   separating the waste from the burner using a cyclone in communication with the burner, the cyclone configured to separate carbonaceous gas from non-carbonaceous ash materials and the carbonaceous material;   cooling the combustible fuel gases from the cyclone using a quencher or a waste heat exchanger; and   cooling the carbonaceous materials   removing the non-carbonaceous ash from the system; and   burning the carbonaceous materials producing more of the combustible fuel gases.   
     
     
         23 . The method of  claim 22 , wherein the burner is a rotary kiln reactor configured to thermochemically transform varied-source hydrocarbon-containing wastes into combustible fuel gases, the varied-source hydrocarbon-containing wastes having varied physical and chemical properties, wherein a length and a diameter of the rotary kiln reactor provides requisite residence time for gasification of the varied-source hydrocarbon-containing wastes: 
     
     
         24 . The method of  claim 22 , wherein the feeder is a screw feeder. 
     
     
         25 . The method of  claim 22 , wherein the gasifier has at least four reaction zones. 
     
     
         26 . The method of  claim 25 , wherein the gasifier has a second reaction zone at a temperature below about 800° F. 
     
     
         27 . The method of  claim 26 , wherein the gasifier has a third reaction zone between about 1000° F. and about 1200° F. 
     
     
         28 . The method of  claim 27 , wherein the gasifier has a third reaction zone between about 1800° F. and about 2000° F. 
     
     
         29 . The method of  claim 28 , wherein the gasifier has a fourth reaction zone between a flash point and about 800° F.