Microwave induction coupled plasma torch for robust gasification

Abstract

In one aspect, the disclosure relates to a system comprising a gasifier comprising at least one feedstock material, a means for heating the gasifier, and one or more microwave induction coupled torches, wherein the one or more microwave induction coupled torches are configured to produce plasma for gasification of the at least one feedstock material. Also disclosed is a method for gasification of the at least one feedstock material using the disclosed system to produce synthesis gas (syngas). In an aspect, the disclosed system and method do not experience corrosion from liquid cooling and do not make use of consumable parts such as electrodes, and are thus less expensive to operate than conventional technology as well as having a lower carbon footprint. In a further aspect, the syngas can be collected and further processed to produce power and / or one or more additional value-added products.

Description

MICROWAVE INDUCTION COUPLED PLASMA TORCH FOR ROBUST GASIFICATIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. provisional application Serial No. 63 / 613,851 filed December 22, 2023, which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] Gasification is a process commonly used to convert biomass or other organic materials into gases, which can in turn be used as fuels or feedstocks for production of useful chemicals including, but not limited to, methanol. Gasification is growing in popularity as an alternative to depositing waste materials in landfills and / or incinerating them, as gasification typically results in lower levels of release of atmospheric pollutants. Gasification conducted on biomass is, in some instances, considered a renewable energy process, since biomass production consumes atmospheric carbon dioxide.

[0003] Plasma torches typically used in conjunction with gasification reactors require liquid coolant and make use of consumable electrodes. Corrosive vapors generated during gasification can condense on the cooled torch, leading to corrosion damage that decreases the lifetime of the torches. Furthermore, the consumable electrodes must periodically be replaced. In some applications, carbon electrodes, functioning similarly to electric arc furnaces, can be used instead of plasma torches; while the carbon electrodes do not experience the same condensation problems as the plasma torches, they are also consumable. Furthermore, gasification reaction mixtures typically require purified oxygen gas as an oxidant; energy demands and other factors related to production of the purified oxygen have a high carbon footprint.

[0004] Despite advances in gasification research and development, there is still a scarcity of systems and methods for producing plasma for use in gasification reactions that does not rely on consumable electrodes or liquid coolant, and wherein components are not subject to corrosive degradation. An ideal system and / or method would also minimize the carbon footprint of the process while reducing operating and capital costs. These needs and other needs are satisfied by the present disclosure.SUMMARY

[0005] In accordance with the purpose(s) of the present disclosure, as embodied and broadly described herein, the disclosure, in one aspect, relates to a system comprising a gasifiercomprising at least one feedstock material, a means for heating the gasifier, and one or more microwave induction coupled torches, wherein the one or more microwave induction coupled torches are configured to produce plasma for gasification of the at least one feedstock material. Also disclosed is a method for gasification of the at least one feedstock material using the disclosed system to produce synthesis gas (syngas). In an aspect, the disclosed system and method do not experience corrosion from liquid cooling and do not make use of consumable parts such as electrodes, and are thus less expensive to operate than conventional technology as well as having a lower carbon footprint. In a further aspect, the syngas can be collected and further processed to produce power and / or one or more additional value-added products.

[0006] Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. In addition, all optional and preferred features and modifications of the described embodiments are usable in all aspects of the disclosure taught herein. Furthermore, the individual features of the dependent claims, as well as all optional and preferred features and modifications of the described embodiments are combinable and interchangeable with one another.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

[0008] FIG. 1 A is a top view of a gasification system as disclosed herein.

[0009] FIG. 1B is a side view of a gasification system as disclosed herein.

[0010] FIG. 1C is a perspective view of a gasification system as disclosed herein.

[0011] FIG. 1D is an alternate side view of a gasification system as disclosed herein.

[0012] Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or can be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to beunderstood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.DETAILED DESCRIPTIONGasification System

[0013] In one aspect, disclosed herein is a system including at least the following components:(a) a gasifier including or containing at least one feedstock material;(b) a means for heating the gasifier; and(c) one or more microwave induction coupled torches; wherein the one or more microwave induction coupled torches are configured to produce plasma for gasification of the at least one feedstock material.

[0014] In one aspect, numerous feedstock materials are contemplated and should be considered disclosed including, but not limited to, municipal solid waste (MSW), medical waste, biological waste, hazardous chemical waste, woody biomass, yard waste, coal, petroleum, natural gas, sewage sludge, or any combination thereof. In another aspect, the feedstock can include organic material, inorganic material, or a combination thereof.

[0015] In some aspects, the means for heating the gasifier can be a molten metal bath. In one aspect, the molten metal bath can include a ferrous-based metal, aluminum, or any combination thereof. In a further aspect, the molten metal bath can be induction heated. In one aspect, the metal can be selected depending on the desired operating temperature of the gasifier. For example, in one aspect, aluminum melts at about 660 °C, while steel (e.g., a ferrous-based metal) melts at from about 1425 to about 1540 °C. In a further aspect, higher- temperature gasification can result in the production of less tar. In a further aspect, metals in the feedstock can melt into the molten bath and mineral oxides (slag) may form. In some aspects, slag can accumulate and may need to be removed and the gasifier recharged with metal. In another aspect, the means for heating the gasifier can be a molten glass bath. In an alternative aspect, a molten glass bath is not used to heat the gasifier.

[0016] In any of these aspects, the molten bath can be agitated. In an aspect, agitation can be conducted using a plume from the one or more microwave induction coupled torches, by another means, or any combination thereof.

[0017] In one aspect, two microwave induction coupled torches can be used in the disclosed system. In a further aspect, the microwave induction coupled torches are mounted such that they aim at the surface of the molten metal bath and generate a circular current in the moltenmetal bath. In an aspect, the circular current evenly distributes heat within the gasifier. Further in this aspect, the torches can be positioned for optimal exposure of waste to plasma while also generating the circular current. Without wishing to be bound by theory, positioning of the torches improves heat transfer within the gasifier vessel; lower density feedstocks can float on the molten metal and are exposed to heat, plasma, and oxidant, all of which are necessary to break chemical bonds and provide for partial oxidation and / or gasification of feedstocks.

[0018] In a further aspect, the microwave induction coupled torches do not require liquid cooling. In another aspect, the microwave induction coupled torches can be cooled by a gas. In still another aspect, the microwave induction coupled torches do not make use of consumable electrodes.

[0019] In one aspect, the one or more microwave induction coupled torches each individually has an output power of from about 3 kW to about 10 kW, or of about 3, 4, 5, 6, 7, 8, 9, or about 10 kW, or a combination of any of the foregoing values, or a range encompassing any of the foregoing values. In another aspect, the one or more microwave induction coupled torches each individually produces microwave energy at about 2.45 GHz. In still another aspect, the torches are each configured to ignite using 0.5 L of Ar.

[0020] Plasma sources, such as microwave induction coupled torches, useful herein are described in, for example, U.S. Patents 9,491 ,841 and 9,706,635 and U.S. Patent Application Publications 2016 / 0025656 and 2017 / 0027051.

[0021] In one aspect, the one or more microwave induction coupled torches are configured to produce plasma from superheated steam.

[0022] The disclosed gasification system can be further described with reference to the drawings. FIG. 1A shows a top view of a gasification system as described herein. In this aspect, two microwave generators 100a and 100b are placed on opposite sides of the system. These connect to waveguides 104a and 104b for plasma torches. A rotary feeder 106 provides feedstock to a feed port 102 and syngas is produced, exiting the system through the syngas outlet 108. FIG. 1 B shows a side view of the system of FIG. 1A; rotary feeder 200 is placed atop the system. Directly under rotary feeder 200 are microwave induction coupled torches 202a and 202b, which are connected to microwave generators 206a and 206b. Gasifier vessel 204 rests below rotary feeder 200 and between the microwave generators 206a and 206b. FIG. 1C is a perspective view of the disclosed system showing feed port 300, rotary feeder 302, wave guide 304, and gasifier vessel 306, arranged and connected as described above for FIGs. 1A-1 B. FIG. 1 D shows the system of FIGs. 1A-1C in an alternative side view with a different view of rotary feeder 400.Method for Gasification of a Feedstock

[0023] In one aspect, disclosed herein is a method for gasification of at least one feedstock material using the disclosed system, the method including at least the steps of:(a) heating the gasifier using a molten metal bath;(b) producing plasma using the one or more microwave induction coupled torches; and(c) introducing the feedstock to the gasifier; wherein the plasma converts at least a portion of the feedstock into synthesis gas.

[0024] In one aspect, the gasifier is hot and the metal bath is molten, while the torches are generating plasma before the feedstock is introduced into the gasifier. In a further aspect, the feedstock can be introduced into the gasifier continuously through a rotary feeder. In an aspect, the rotary feeder can be hermetically sealed and steam purged. In a still further aspect, the rotary feeder sits on top of the gasifier. Further in this aspect, feedstock falls into the plasma and floats on the molten metal in the case of feedstock of lower density than the metal. In an alternative aspect, feedstock having a higher density than the molten metal will sink into the molten metal. In another aspect, the feedstock can be or include municipal solid waste (MSW), medical waste, biological waste, hazardous chemical waste, woody biomass, yard waste, coal, petroleum, natural gas, sewage sludge, or any combination thereof. In one aspect, the feedstock includes organic materials, inorganic materials, or both. In one aspect, organic material in the feedstock can be converted to synthesis gas. In another aspect, inorganic material in the feedstock can melt into the molten metal bath, convert into a mineral oxide, or any combination thereof.

[0025] In one aspect, the microwave induction coupled torches can produce plasma from whatever gas is fed through them. In a further aspect, the gas can be superheated steam. Without wishing to be bound by theory, superheated steam is efficient and cost-saving since it carries oxygen and hydrogen and is cheaper than purified oxygen. In one aspect, a high hydrogen content in the syngas is advantageous for production of methanol from syngas. In a further aspect, stoichiometrically, at least 2 H2molecules will be needed for every one CO in order to produce methanol.

[0026] In another aspect, the method further includes(d) subjecting the feedstock to an oxidant during treatment of the feedstock with the plasma.

[0027] In one aspect, the oxidant is not and does not include purified oxygen gas. In another aspect, the oxidant can be or include air, oxygen, steam, carbon dioxide, or another suitable oxidant.

[0028] In an aspect, the method further includes one or more additional processing steps to product at least one value-added product. In another aspect, the value-added product can be hydrogen, a Fischer-Tropsch fuel or chemical, methanol, ethanol, dimethyl ether, or any combination thereof. In an aspect, hydrogen can be produced by pressure swing absorption of syngas. In another aspect, Fischer-Tropsch fuels including, but not limited to, liquid hydrocarbons, can be produced in a downstream Fischer-Tropsch plant. In still another aspect, methanol can be produced from syngas in a methanol plant, ethanol from fermentation of syngas, or the like.

[0029] In an aspect, syngas is a versatile starting material for production of value-added chemicals because it contains the building blocks of organic molecules and is combustible. In an aspect, syngas can be burned directly as a clean fuel and is the basis of “clean coal” technology. In another aspect, syngas can be used as a source of hydrogen gas or can be used to produce diesel, gasoline, jet fuel, naphtha, and the like. In a further aspect, methanol produced using a syngas starting material can be used as a primary feedstock chemical for subsequent manufacture of new products, plastics, and packaging.

[0030] Many modifications and other embodiments disclosed herein will come to mind to one skilled in the art to which the disclosed compositions and methods pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosures are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. The skilled artisan will recognize many variants and adaptations of the aspects described herein. These variants and adaptations are intended to be included in the teachings of this disclosure and to be encompassed by the claims herein.

[0031] Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0032] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present disclosure.

[0033] Any recited method can be carried out in the order of events recited or in any other order that is logically possible. That is, unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

[0034] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and / or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided herein can be different from the actual publication dates, which can require independent confirmation.

[0035] While aspects of the present disclosure can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present disclosure can be described and claimed in any statutory class.

[0036] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed compositions and methods belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0037] Prior to describing the various aspects of the present disclosure, the following definitions are provided and should be used unless otherwise indicated. Additional terms may be defined elsewhere in the present disclosure.Definitions

[0038] As used herein, “comprising” is to be interpreted as specifying the presence of the stated features, integers, steps, or components as referred to, but does not preclude thepresence or addition of one or more features, integers, steps, or components, or groups thereof. Moreover, each of the terms “by”, “comprising,” “comprises”, “comprised of,” “including,” “includes,” “included,” “involving,” “involves,” “involved,” and “such as” are used in their open, non-limiting sense and may be used interchangeably. Further, the term “comprising” is intended to include examples and aspects encompassed by the terms “consisting essentially of’ and “consisting of.” Similarly, the term “consisting essentially of’ is intended to include examples encompassed by the term “consisting of.

[0039] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a feedstock,” “a gas,” or “an oxidant,” include, but are not limited to, mixtures or combinations of two or more such feedstocks, gases, or oxidants, and the like.

[0040] It should be noted that ratios, concentrations, amounts, and other numerical data can be expressed herein in a range format. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms a further aspect. For example, if the value “about 10” is disclosed, then “10” is also disclosed.

[0041] When a range is expressed, a further aspect includes from the one particular value and / or to the other particular value. For example, where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure, e.g. the phrase “xto y” includes the range from ‘x’ to ‘y’ as well as the range greater than ‘x’ and less than ‘y’. The range can also be expressed as an upper limit, e.g. ‘about x, y, z, or less’ and should be interpreted to include the specific ranges of ‘about x’, ‘about y’, and ‘about z’ as well as the ranges of ‘less than x’, less than y’, and ‘less than z’. Likewise, the phrase ‘about x, y, z, or greater’ should be interpreted to include the specific ranges of ‘about x’, ‘about y’, and ‘about z’ as well as the ranges of ‘greater than x’, greater than y’, and ‘greater than z’. In addition, the phrase “about ‘x’ to ‘y’”, where ‘x’ and ‘y’ are numerical values, includes “about x’ to about ‘y’”.

[0042] It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical valuesor sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a numerical range of “about 0.1% to 5%” should be interpreted to include not only the explicitly recited values of about 0.1% to about 5%, but also include individual values (e.g., about 1%, about 2%, about 3%, and about 4%) and the sub-ranges (e.g., about 0.5% to about 1.1%; about 5% to about 2.4%; about 0.5% to about 3.2%, and about 0.5% to about 4.4%, and other possible sub-ranges) within the indicated range.

[0043] As used herein, the terms “about,” “approximate,” “at or about,” and “substantially” mean that the amount or value in question can be the exact value or a value that provides equivalent results or effects as recited in the claims or taught herein. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art such that equivalent results or effects are obtained. In some circumstances, the value that provides equivalent results or effects cannot be reasonably determined. In such cases, it is generally understood, as used herein, that “about” and “at or about” mean the nominal value indicated ±10% variation unless otherwise indicated or inferred. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about,” “approximate,” or “at or about” whether or not expressly stated to be such. It is understood that where “about,” “approximate,” or “at or about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

[0044] As used herein, the term “effective amount” refers to an amount that is sufficient to achieve the desired modification of a physical property of the composition or material. For example, an “effective amount” of an oxidant refers to an amount that is sufficient to achieve the desired improvement in the property modulated by the formulation component, e.g. achieving the desired level of gasification and product mixture in the system and according to the method disclosed herein. The specific level required as an effective amount will depend upon a variety of factors including the amount and type of feedstock, desired product mixture, and the like.

[0045] As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0046] As used herein, a “gasifier” is an apparatus that uses a carbon-containing fuel such as biomass or a fossil fuel to gases such as, for example, syngas, or gas mixtures including syngas.

[0047] As used herein, “syngas” is a combustible fuel including hydrogen and carbon monoxide as well as trace amounts of other gases such as carbon dioxide, methane, nitrogen, and the like.

[0048] Unless otherwise specified, temperatures referred to herein are based on atmospheric pressure (i.e. one atmosphere).

[0049] Now having described the aspects of the present disclosure, in general, below are described describe some additional aspects of the present disclosure. While aspects of the present disclosure are described in connection with the following examples and the corresponding text and figures, there is no intent to limit aspects of the present disclosure to this description. On the contrary, the intent is to cover all alternatives, modifications, and equivalents included within the spirit and scope of the present disclosure.ASPECTS

[0050] The present disclosure can be described in accordance with the following numbered aspects, which should not be confused with the claims.

[0051] Aspect 1 . A system comprising:(a) a gasifier comprising at least one feedstock material;(b) a means for heating the gasifier; and(c) one or more microwave induction coupled torches; wherein the one or more microwave induction coupled torches are configured to produce plasma for gasification of the at least one feedstock material.

[0052] Aspect 2. The system of aspect 1 , wherein the feedstock comprises municipal solid waste (MSW), medical waste, biological waste, hazardous chemical waste, woody biomass, yard waste, coal, petroleum, natural gas, sewage sludge, or any combination thereof.

[0053] Aspect 3. The system of aspect 1 or 2, wherein the means for heating the gasifier comprises a molten metal bath.

[0054] Aspect 4. The system of aspect 3, wherein the molten metal comprises a ferrous based metal, aluminum, or any combination thereof.

[0055] Aspect 5. The system of aspect 3 or 4, wherein the molten metal bath is induction heated.

[0056] Aspect 6. The system of any one of aspects 3-5, further comprising agitating the molten metal bath.

[0057] Aspect 7. The system of aspect 6, wherein the molten metal bath is agitated using a plume from the one or more microwave induction coupled torches.

[0058] Aspect 8. The system of any one of aspects 1-7, wherein the one or more microwave induction coupled torches comprise two microwave induction coupled torches.

[0059] Aspect 9. The system of any one of aspects 1-8, wherein the one or more microwave induction coupled torches are mounted such that the one or more microwave induction coupled torches aim at the surface of the molten metal bath.

[0060] Aspect 10. The system of aspect 9, wherein the one or more microwave induction coupled torches are configured to generate a circular current in the molten metal bath.

[0061] Aspect 1 1. The system of aspect 10, wherein the circular current in the molten metal bath evenly distributes heat within the gasifier.

[0062] Aspect 12. The system of any one of aspects 1-11 , wherein the one or more microwave induction coupled torches do not require liquid cooling.

[0063] Aspect 13. The system of any one of aspects 1-12, wherein the one or more microwave induction coupled torches are cooled by a gas.

[0064] Aspect 14. The system of any one of aspects 1-13, wherein the one or more microwave induction coupled torches do not comprise consumable electrodes.

[0065] Aspect 15. The system of any one of aspects 1-14, wherein the one or more microwave induction coupled torches each individually comprise an output power of from about 3 kW to about 10 kW.

[0066] Aspect 16. The system of any one of aspects 1-15, wherein the one or more microwave induction coupled torches each individually produce microwave energy at about 2.45 GHz.

[0067] Aspect 17. The system of any one of aspects 1-16, wherein the one or more microwave induction coupled torches are configured to ignite using 0.5 L of Ar.

[0068] Aspect 18. The system of any one of aspects 1-17, wherein the one or more microwave induction coupled torches are configured to produce plasma from superheated steam.

[0069] Aspect 19. A method for gasification of the at least one feedstock material in the system of any one of aspects 1-18, the method comprising:(a) heating the gasifier using a molten metal bath;(b) producing plasma using the one or more microwave induction coupled torches; and(c) introducing the feedstock to the gasifier;wherein the plasma converts at least a portion of the feedstock into synthesis gas.

[0070] Aspect 20. The method of aspect 19, wherein the feedstock is introduced into the gasifier continuously through a rotary feeder.

[0071] Aspect 21 . The method of aspect 19 or 20, wherein the method further comprises:(d) subjecting the feedstock to an oxidant during treatment of the feedstock with the plasma.

[0072] Aspect 22. The method of aspect 21 , wherein the oxidant comprises air, oxygen, steam, carbon dioxide, or another suitable oxidant.

[0073] Aspect 23. The method of aspect 21 or 22, wherein the oxidant does not comprise purified oxygen gas.

[0074] Aspect 24. The method of any one of aspects 19-23, wherein the feedstock comprises municipal solid waste (MSW), medical waste, biological waste, hazardous chemical waste, woody biomass, yard waste, coal, petroleum, natural gas, sewage sludge, or any combination thereof.

[0075] Aspect 25. The method of any one of aspects 19-24, wherein organic material in the feedstock is converted to synthesis gas.

[0076] Aspect 26. The method of any one of aspects 19-25, wherein inorganic material in the feedstock melts into the molten metal bath, converts into mineral oxides, or any combination thereof.

[0077] Aspect 27. The method of any one of aspects 19-26, further comprising one or more additional processing steps to produce at least one value-added product.

[0078] Aspect 28. The method of aspect 27, wherein the at least one value-added product comprises hydrogen, a Fischer-Tropsch fuel or chemical, methanol, ethanol, dimethyl ether, or any combination thereof.

[0079] It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

CLAIMSWhat is claimed is:1 . A system comprising:(a) a gasifier comprising at least one feedstock material;(b) a means for heating the gasifier; and(c) one or more microwave induction coupled torches; wherein the one or more microwave induction coupled torches are configured to produce plasma for gasification of the at least one feedstock material.

2. The system of claim 1 , wherein the feedstock comprises municipal solid waste (MSW), medical waste, biological waste, hazardous chemical waste, woody biomass, yard waste, coal, petroleum, natural gas, sewage sludge, or any combination thereof.

3. The system of claim 1 , wherein the means for heating the gasifier comprises a molten metal bath.

4. The system of claim 3, wherein the molten metal comprises a ferrous based metal, aluminum, or any combination thereof.

5. The system of claim 3, wherein the molten metal bath is induction heated.

6. The system of claim 3, further comprising agitating the molten metal bath.

7. The system of claim 6, wherein the molten metal bath is agitated using a plume from the one or more microwave induction coupled torches.

8. The system of claim 1 , wherein the one or more microwave induction coupled torches comprise two microwave induction coupled torches.

9. The system of claim 1, wherein the one or more microwave induction coupled torches are mounted such that the one or more microwave induction coupled torches aim at the surface of the molten metal bath.

10. The system of claim 9, wherein the one or more microwave induction coupled torches are configured to generate a circular current in the molten metal bath.

11. The system of claim 10, wherein the circular current in the molten metal bath evenly distributes heat within the gasifier.

12. The system of claim 1, wherein the one or more microwave induction coupled torches do not require liquid cooling.

13. The system of claim 1 , wherein the one or more microwave induction coupled torches are cooled by a gas.

14. The system of claim 1, wherein the one or more microwave induction coupled torches do not comprise consumable electrodes.

15. The system of claim 1 , wherein the one or more microwave induction coupled torches each individually comprise an output power of from about 3 kWto about 10 kW.

16. The system of claim 1 , wherein the one or more microwave induction coupled torches each individually produce microwave energy at about 2.45 GHz.

17. The system of claim 1 , wherein the one or more microwave induction coupled torches are configured to ignite using 0.5 L of Ar.

18. The system of claim 1 , wherein the one or more microwave induction coupled torches are configured to produce plasma from superheated steam.

19. A method for gasification of the at least one feedstock material in the system of any one of claims 1-18, the method comprising:(a) heating the gasifier using a molten metal bath;(b) producing plasma using the one or more microwave induction coupled torches; and(c) introducing the feedstock to the gasifier; wherein the plasma converts at least a portion of the feedstock into synthesis gas.

20. The method of claim 19, wherein the feedstock is introduced into the gasifier continuously through a rotary feeder.

21. The method of claim 19, wherein the method further comprises:(d) subjecting the feedstock to an oxidant during treatment of the feedstock with the plasma.

22. The method of claim 21 , wherein the oxidant comprises air, oxygen, steam, carbon dioxide, or another suitable oxidant.

23. The method of claim 21, wherein the oxidant does not comprise purified oxygen gas.

24. The method of claim 19, wherein the feedstock comprises municipal solid waste (MSW), medical waste, biological waste, hazardous chemical waste, woody biomass, yard waste, coal, petroleum, natural gas, sewage sludge, or any combination thereof.

25. The method of claim 19, wherein organic material in the feedstock is converted to synthesis gas.

26. The method of claim 19, wherein inorganic material in the feedstock melts into the molten metal bath, converts into mineral oxides, or any combination thereof.

27. The method of claim 19, further comprising one or more additional processing steps to produce at least one value-added product.

28. The method of claim 27, wherein the at least one value-added product comprises hydrogen, a Fischer-Tropsch fuel or chemical, methanol, ethanol, dimethyl ether, or any combination thereof.

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