Herein disclosed are apparatus and associated methods related to producing an enhanced surface area biochar product with a desired activation level based on receiving biochar into a processing vessel configured with multiple independently temperature-controlled chambers and counter-flow steam injection, controlling activation levels of the biochar by moving the biochar through the processing vessel and adjusting the temperature of the biochar by injecting steam into at least one temperature-controlled chamber of the processing vessel, recovering volatiles driven off through dehydration using a thermal oxidizer, cooling the biochar to a desired discharge temperature using steam and retention time, and discharging the activated biochar product. The processing vessel may be a calciner, a rotary calciner, or a kiln. Biochar may be heated or cooled to a desired thermochemical processing temperature depending on the temperature of the received biochar. Counter-flow saturated steam may sweep volatile gases to a thermal oxidizer using a vacuum system.
Apparatus and associated methods relate to drying a wet coated seed material stream comprising an incoming wet granular biosolids stream mixed with a controlled size dried seed material recycling stream to produce a moist air and pellet stream, separating an uncontrolled size dried pellet stream from the moist air and pellet stream, diverting a recycle portion of the uncontrolled size dried pellet stream to be recycled, diverting the remainder of the uncontrolled size dried pellet stream to an outlet, resizing oversized pellets from the recycle portion of the uncontrolled size dried pellet stream to produce the controlled size dried seed material recycling stream, and mixing the controlled size dried seed material recycling stream with the incoming wet granular biosolids stream to produce the wet coated seed material stream. Oversized pellets may be selected using a screen. The oversized pellets may be resized using a crusher inline with the recycle stream.
C10J 3/46 - Gasification of granular or pulverulent fuels in suspension
B01J 8/18 - Chemical or physical processes in general, conducted in the presence of fluids and solid particlesApparatus for such processes with fluidised particles
Exemplary apparatus or method implementations for a universal feeder system configured with a transfer screw feeder within a multi-section clamshell pipe permitting access to the feed screw and pipe interior for inspection, maintenance and/or cleaning during production, without disassembly or screw removal. The clamshell screw feeder pipe provides access to the screw by opening or removing the multi-section top portion of the clamshell pipe. The top pipe section is bolted and or hinges to the bottom portion of the clamshell pipe. The number of segmented multiple clamshell top sections depends on the length of the screw. One or more clamshell top sections may be configured with an inspection port. The universal feeder system configured with a transfer screw feeder within a multi-section clamshell pipe transfers feedstock feed from one or more feed vessels to one or more reactor vessel.
B65G 37/00 - Combinations of mechanical conveyors of the same kind, or of different kinds, of interest apart from their application in particular machines or use in particular manufacturing processes
B01J 8/18 - Chemical or physical processes in general, conducted in the presence of fluids and solid particlesApparatus for such processes with fluidised particles
B65G 33/10 - Screw or rotary spiral conveyors for fluent solid materials with non-enclosed screws
B65G 33/14 - Screw or rotary spiral conveyors for fluent solid materials comprising a screw or screws enclosed in a tubular housing
C10J 3/46 - Gasification of granular or pulverulent fuels in suspension
C02F 11/10 - Treatment of sludgeDevices therefor by pyrolysis
4.
METHOD OF ELIMINATION OF POLY- AND PERFLUOROALKYL SUBSTANCES (PFAS) IN A WASTEWATER BIOSOLIDS GASIFICATION PROCESS USING A THERMAL OXIDIZER AND HYDRATED LIME INJECTION
Apparatus and methods to eliminate PFAS from wastewater biosolids through fluidized bed gasification. The gasifier decomposes the PFAS in the biosolids at temperatures of 900-1800° F. Syngas exits the gasifier which is coupled to a thermal oxidizer and combusts at temperatures of 1600-2600° F. This decomposes PFAS in the syngas and creates flue gas. Heat is recovered from the flue gas by cooling the flue gas to temperatures of 400-1200° F. in a heat exchanger coupled with the thermal oxidizer. Various methods inject moisture into the gas stream, controlling temperature through evaporative cooling and/or injecting chemicals that react with gas stream components. Cooled flue gas mixes with hydrated lime capturing decomposed PFAS molecules with spent lime filtered from the cooled flue gas using a filter system that may incorporate catalyst impregnated filter elements, eliminating PFAS from wastewater biosolids and controlling emissions in the resulting flue gas.
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
B01D 45/16 - Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces by centrifugal forces generated by the winding course of the gas stream
B01D 46/71 - Regeneration of the filtering material or filter elements inside the filter by acting counter-currently on the filtering surface, e.g. by flushing on the non-cake side of the filter with pressurised gas, e.g. pulsed air
B01D 46/82 - Chemical processes for the removal of the retained particles, e.g. by burning with catalysts
5.
ELIMINATION OF POLY- AND PERFLUOROALKYL SUBSTANCES (PFAS) IN A WASTEWATER BIOSOLIDS GASIFICATION PROCESS USING A THERMAL OXIDIZER AND HYDRATED LIME INJECTION
An apparatus and methods to eliminate PFAS from wastewater biosolids through fluidized bed gasification. The gasifier decomposes the PFAS in the biosolids at temperatures of 900 - 1800 °F. Synthesis gas (syngas) exits the gasifier which is coupled to a thermal oxidizer and is combusted at temperatures of 1600 - 2600 °F. This decomposes PFAS in the syngas and creates flue gas. Heat can be recovered from the flue gas by cooling the flue gas to temperatures of 400 - 1200 °F in a heat exchanger that is coupled with the thermal oxidizer. Cooled flue gas is mixed with hydrated lime, enhancing PFAS decomposition, with the spent lime filtered from the cooled flue gas using a filter system that may incorporate catalyst impregnated filter elements. The apparatus and methods thereby eliminate PFAS from wastewater biosolids and control emissions in the resulting flue gas.
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
6.
Method of elimination of poly- and perfluoroalkyl substances (PFAS) in a wastewater biosolids gasification process using a thermal oxidizer and hydrated lime injection
An apparatus and methods to eliminate PFAS from wastewater biosolids through fluidized bed gasification. The gasifier decomposes the PFAS in the biosolids at temperatures of 900-1800° F. Synthesis gas (syngas) exits the gasifier which is coupled to a thermal oxidizer and is combusted at temperatures of 1600-2600° F. This decomposes PFAS in the syngas and creates flue gas. Heat can be recovered from the flue gas by cooling the flue gas to temperatures of 400-1200° F. in a heat exchanger that is coupled with the thermal oxidizer. Cooled flue gas is mixed with hydrated lime, enhancing PFAS decomposition, with the spent lime filtered from the cooled flue gas using a filter system that may incorporate catalyst impregnated filter elements. The apparatus and methods thereby eliminate PFAS from wastewater biosolids and control emissions in the resulting flue gas.
B01D 46/71 - Regeneration of the filtering material or filter elements inside the filter by acting counter-currently on the filtering surface, e.g. by flushing on the non-cake side of the filter with pressurised gas, e.g. pulsed air
B01D 45/16 - Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces by centrifugal forces generated by the winding course of the gas stream
B01D 46/82 - Chemical processes for the removal of the retained particles, e.g. by burning with catalysts
7.
ELIMINATION OF POLY- AND PERFLUOROALKYL SUBSTANCES (PFAS) IN A WASTEWATER BIOSOLIDS GASIFICATION PROCESS USING A THERMAL OXIDIZER AND HYDRATED LIME INJECTION
An apparatus and methods to eliminate PFAS from wastewater biosolids through fluidized bed gasification. The gasifier decomposes the PFAS in the biosolids at temperatures of 900 - 1800 °F. Synthesis gas (syngas) exits the gasifier which is coupled to a thermal oxidizer and is combusted at temperatures of 1600 - 2600 °F. This decomposes PFAS in the syngas and creates flue gas. Heat can be recovered from the flue gas by cooling the flue gas to temperatures of 400 - 1200 °F in a heat exchanger that is coupled with the thermal oxidizer. Cooled flue gas is mixed with hydrated lime, enhancing PFAS decomposition, with the spent lime filtered from the cooled flue gas using a filter system that may incorporate catalyst impregnated filter elements. The apparatus and methods thereby eliminate PFAS from wastewater biosolids and control emissions in the resulting flue gas.
Herein disclosed are apparatus and associated methods related to producing an enhanced surface area biochar product with a desired activation level based on receiving biochar into a processing vessel configured with multiple independently temperature-controlled chambers and counter-flow steam injection, controlling activation levels of the biochar by moving the biochar through the processing vessel and adjusting the temperature of the biochar by injecting steam into at least one temperature-controlled chamber of the processing vessel, recovering volatiles driven off through dehydration using a thermal oxidizer, cooling the biochar to a desired discharge temperature using steam and retention time, and discharging the activated biochar product. The processing vessel may be a calciner, a rotary calciner, or a kiln. Biochar may be heated or cooled to a desired thermochemical processing temperature depending on the temperature of the received biochar. Counter-flow saturated steam may sweep volatile gases to a thermal oxidizer using a vacuum system.
Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered byproducts and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream byproduct.
Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered by products and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream by product.
Herein disclosed are apparatus and associated methods related to producing an enhanced surface area biochar product with a desired activation level based on receiving biochar into a processing vessel configured with multiple independently temperature-controlled chambers and counter-flow steam injection, controlling activation levels of the biochar by moving the biochar through the processing vessel and adjusting the temperature of the biochar by injecting steam into at least one temperature-controlled chamber of the processing vessel, recovering volatiles driven off through dehydration using a thermal oxidizer, cooling the biochar to a desired discharge temperature using steam and retention time, and discharging the activated biochar product. The processing vessel may be a calciner, a rotary calciner, or a kiln. Biochar may be heated or cooled to a desired thermochemical processing temperature depending on the temperature of the received biochar. Counter-flow saturated steam may sweep volatile gases to a thermal oxidizer using a vacuum system.
Exemplary apparatus or method implementations for a universal feeder system configured with a transfer screw feeder within a multi-section clamshell pipe permitting access to the feed screw and pipe interior for inspection, maintenance and/or cleaning during production, without disassembly or screw removal. The clamshell screw feeder pipe provides access to the screw by opening or removing the multi-section top portion of the clamshell pipe. The top pipe section is bolted and or hinges to the bottom portion of the clamshell pipe. The number of segmented multiple clamshell top sections depends on the length of the screw. One or more clamshell top sections may be configured with an inspection port. The universal feeder system configured with a transfer screw feeder within a multi-section clamshell pipe transfers feedstock feed from one or more feed vessels to one or more reactor vessel.
C10J 3/46 - Gasification of granular or pulverulent fuels in suspension
B01J 8/18 - Chemical or physical processes in general, conducted in the presence of fluids and solid particlesApparatus for such processes with fluidised particles
C02F 11/10 - Treatment of sludgeDevices therefor by pyrolysis
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
C02F 11/12 - Treatment of sludgeDevices therefor by de-watering, drying or thickening
C02F 11/121 - Treatment of sludgeDevices therefor by de-watering, drying or thickening by mechanical de-watering
13.
Elimination of poly- and perfluoro alkyl substances (PFAS) in a wastewater biosolids gasification process using a thermal oxidizer and hydrated lime injection
An apparatus and methods to eliminate PFAS from wastewater biosolids through fluidized bed gasification. The gasifier decomposes the PFAS in the biosolids at temperatures of 900-1800° F. Synthesis gas (syngas) exits the gasifier which is coupled to a thermal oxidizer and is combusted at temperatures of 1600-2600° F. This decomposes PFAS in the syngas and creates flue gas. Heat can be recovered from the flue gas by cooling the flue gas to temperatures of 400-1200° F. in a heat exchanger that is coupled with the thermal oxidizer. Cooled flue gas is mixed with hydrated lime, enhancing PFAS decomposition, with the spent lime filtered from the cooled flue gas using a filter system that may incorporate catalyst impregnated filter elements. The apparatus and methods thereby eliminate PFAS from wastewater biosolids and control emissions in the resulting flue gas.
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
B01D 45/16 - Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces by centrifugal forces generated by the winding course of the gas stream
A method and system for continuous production of contaminant free and size specific biochar using downdraft gasification of variable quality feedstock. The system and process of the present invention includes the transfer of biochar from a gasifier after gasification to a temperature-controlled cooling screw conveyor, into a drum magnet for ferrous metal removal into multiple diverters to separate and remove ungasified materials and non-ferrous metal contaminants, then transferred into a granulator for grinding and screening the biochar to a pre-selected size. By directly attaching a novel and continuous product treatment process to the biochar stream as it exits the gasifier, the particle size, moisture content, carbon content and yield of a contaminant free biochar product can be narrowly controlled and improved to meet strict product quality specifications required by specialty applications.
Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered byproducts and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream byproduct.
C10B 57/00 - Other carbonising or coking processesFeatures of destructive distillation processes in general
C10B 47/24 - Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge in dispersed form according to the "fluidised bed" technique
C10B 47/20 - Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge according to the "moving bed" technique
C01B 3/50 - Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
C01B 32/05 - Preparation or purification of carbon not covered by groups , , ,
C10B 53/02 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
B01D 53/02 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by adsorption, e.g. preparative gas chromatography
B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered byproducts and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream byproduct.
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
C10B 49/22 - Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with moving solid heat-carriers in divided form in dispersed form according to the "fluidised bed" technique
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
F28F 1/00 - Tubular elementsAssemblies of tubular elements
F28F 27/00 - Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
F28F 23/00 - Features relating to the use of intermediate heat-exchange materials, e.g. selection of compositions
C10B 53/02 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
C10J 3/26 - Arrangements or dispositions of valves or flues to permit flow of gases or vapours other than upwardly through the fuel bed downwardly
C01B 3/50 - Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
B01D 53/22 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by diffusion
C01B 3/32 - Production of hydrogen or of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered byproducts and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream byproduct.
C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
C10B 49/22 - Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with moving solid heat-carriers in divided form in dispersed form according to the "fluidised bed" technique
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
F28F 1/00 - Tubular elementsAssemblies of tubular elements
F28F 27/00 - Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
F28F 23/00 - Features relating to the use of intermediate heat-exchange materials, e.g. selection of compositions
C10B 53/02 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered byproducts and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream byproduct.
C10B 57/00 - Other carbonising or coking processesFeatures of destructive distillation processes in general
C10B 47/24 - Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge in dispersed form according to the "fluidised bed" technique
C10B 47/20 - Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge according to the "moving bed" technique
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
C01B 3/50 - Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
C01B 32/05 - Preparation or purification of carbon not covered by groups , , ,
C10B 53/02 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
B01D 53/02 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by adsorption, e.g. preparative gas chromatography
B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
Gasifiers for generating renewable energy through gasification of biomass products and replacement parts thereof; gasifiers for producing clean gas from carbon-based materials and replacement parts thereof
Gasifiers for generating renewable energy through gasification of biomass products and replacement parts thereof; Gasifiers for producing clean gas from carbon-based materials and replacement parts thereof
21.
System and process for continuous production of contaminate free, size specific biochar following gasification
A method and system for continuous production of contaminant free and size specific biochar using downdraft gasification of variable quality feedstock. The system and process of the present invention includes the transfer of biochar from a gasifier after gasification to a temperature-controlled cooling screw conveyor, into a drum magnet for ferrous metal removal into multiple diverters to separate and remove ungasified materials and non-ferrous metal contaminants, then transferred into a granulator for grinding and screening the biochar to a pre-selected size. By directly attaching a novel and continuous product treatment process to the biochar stream as it exits the gasifier, the particle size, moisture content, carbon content and yield of a contaminant free biochar product can be narrowly controlled and improved to meet strict product quality specifications required by specialty applications.
