Systems and methods for enhanced temperature control in gasifiers

Abstract

There is provided a system for enhancing temperature control in gasifiers comprising a gasifier apparatus and a water injector for delivering water to an internal reactor compartment of the gasifier apparatus. There is also provided a method for enhancing temperature control in gasifiers comprising monitoring temperature of an internal reactor compartment of a gasifier apparatus; and adjustably delivering a quantity of water to the internal reactor compartment, the quantity of water determined by the temperature of the internal reactor compartment. There is further provided a kit for assembling, modifying or retrofitting a gasifier apparatus to permit temperature control by water injection using the disclosed systems and methods.

Description

SYSTEMS AND METHODS FOR ENHANCED TEMPERATURE CONTROL IN GASIFIERSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and benefit from United States Patent Application Serial No. 63 / 652,134 filed on May 27, 2024, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure generally relates to systems and methods for enhanced temperature control in gasifiers, in particular involving water injection to an internal reactor component of a gasifier apparatus.BACKGROUND

[0003] Downdraft gasifiers convert solid fuel into a combustible gas consisting primarily of hydrogen, carbon monoxide, carbon dioxide, methane and nitrogen. When coupled with an internal combustion engine (“ICE”) generator, small downdraft gasifiers are an effective distributed energy solution and can operate on low carbon feedstocks such as biomass and wastes. Using waste as a feedstock offers a distributed energy production and waste management solution.

[0004] Conventional systems are designed for a narrow range of homogenous fuels and cannot operate successfully on fuels that are either outside of this range or highly heterogeneous. Downdraft gasifiers using fuels that are outside of the narrow range of homogeneous fuels or fuels that are highly heterogeneous consistently suffer from reactor temperatures rising above the reactor operating temperature. Existing downdraft gasifier systems and methods control the reactor temperature by reducing the airflow into the reactor, thus reducing exothermic combustion reactions. However, there is a limit to using this method of reducing air flow as restricting the airflow excessively will “choke” the gasifier and reduce the production of gases to below that required by the ICE generator. Further, the limited range of fuels available for conventional gasifiers creates significant challenges for installation of such systems as many locations do not have access to this narrow range of homogenous fuels.

[0005] A need therefore exists for improved systems and methods for utilizing different and mixed types of fuels.SUMMARY

[0006] The present disclosure provides systems for enhancing temperature control in gasifiers, methods for same, and kits for assembling, modifying or retrofitting a gasifier to permit temperature control by water injection. The present disclosure recognizes that there are problems in the current systems and methodologies for effectively utilizing different and / or mixed types of fuels, and provides improved systems and methods.

[0007] In some embodiments, the present disclosure relates to a system for enhanced temperature control in gasifiers, the system comprising: a gasifier apparatus; and a water injector for delivering water to an internal reactor compartment of the gasifier apparatus.

[0008] In some embodiments, the present disclosure also relates to a method for enhanced temperature control in gasifiers, the method comprising: monitoring the temperature of an internal compartment of a gasifier apparatus; and adjustably delivering a quantity of water to the internal reactor compartment, the quantity of water determined by the temperature of the internal reactor compartment.

[0009] In some embodiments, the present disclosure also relates to a kit for assembling, modifying or retrofitting a gasifier apparatus to permit temperature control by water injection, the kit comprising: a water injector assembly for delivering water to an internal reactor compartment of the gasifier; and a metering device for adjustably controlling a quantity of water delivered to the internal reactor compartment.

[0010] Other aspects and embodiments of the disclosure are evident in view of the detailed description provided herein.BRIEF DESCRIPTON OF THE DRAWINGS

[0011] Further advantages, permutations and combinations of the invention will now appear from the above and from the following detailed description of the various particular embodiments of the invention taken together with the accompanying drawings, each of which are intended to be non limiting, in which:

[0012] FIG. 1 is a cross-sectional elevation view of an exemplary temperature control system, according to one embodiment of the present disclosure.

[0013] FIG. 2 is a cross-sectional elevation view of another temperature control system, according to one embodiment of the present disclosure.

[0014] FIG. 3 is a cross-sectional elevation view of an exemplary gasifier apparatus, according to some embodiments.

[0015] FIG. 4 is a graph illustrating temperature differential across different axial locations of a reactor within an exemplary gasifier apparatus employing the temperature control systems and methods according to some embodiments.

[0016] FIG. 5 is a graph illustrating the composition of gas produced by the operation of an exemplary gasifier system according to some embodiments.

[0017] FIGs. 6A and 6B is a set of two graphs illustrating the relationship between temperature and pressure over time in an exemplary gasifier apparatus that uses homogenous fuel (i.e., clean wood chips) (FIG. 6A) or heterogeneous fuel (i.e., construction and demolition waste) (FIG. 6B).

[0018] FIG. 7 is a schematic diagram of an exemplary system for enhanced temperature control in gasifiers, according to some embodiments.

[0019] FIG. 8 is a flowchart showing the steps of a method for enhanced temperature control in gasifiers, according to one embodiment of the present disclosure.DETAILED DESCRIPTION

[0020] 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 disclosure belongs. Although any methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present disclosure, the suitable methods and materials are described below.

[0021] Gasifier systems are used as a form of energy production and can produce electricity when coupled to an ICE generator. They are particularly suited to use in remote locations that do not have access to a power grid. The ability to use (e.g., gasify) a widerange of fuels, including waste fuels, increases the environmental and economic viability of a gasifier system. Specifically, the use of waste fuels in gasifier systems reduces the cost and greenhouse gas emissions of such systems as compared to using conventional or virgin wood fuels. A system or method of enhanced temperature control in gasifiers that allows for use of a range of fuels including waste fuels is desired to improve the sustainability, efficiency, and cost-effectiveness of gasifier systems.

[0022] The embodiments of the present disclosure pertain to systems and methods having improved energy production using waste fuels. Systems and methods of the present disclosure advantageously provide for temperature control of a gasifier apparatus using water injection to increase fuel flexibility of said gasifier apparatus.

[0023] As used herein, the term “conventional or virgin fuels” refers to any relatively homogenous fuel, fuel mixture or set of fuels that can be used as a fuel in a gasifier. In an embodiment, a relatively homogenous fuel comprises about 80% of a single type of fuel, about 90% of a single type of fuel, or about 100% of a single type of fuel. In an embodiment, conventional or virgin fuels provide a relatively low heating value for use (e.g., combustion and gasification) in a conventional gasifier. In an embodiment, conventional or virgin fuels are, or are sourced from, natural resources such as coal, and wood excluding post consumer wood products. In some embodiments, conventional or virgin fuels comprise of or are derived from spruce, willow, ash, maple, spruce, fir, flax, pine, coal, or a combination thereof.

[0024] As used herein, the term “waste fuels” refers to any fuel, fuel mixture or set of fuels that is sourced from waste and that can be used as a substitute for conventional or virgin fuel in a gasifier. In an embodiment, waste fuels provide a relatively high heating value for use (e.g., combustion and gasification) in a conventional gasifier. In an embodiment, the waste fuels herein are substantially heterogeneous. The heterogeneity of waste fuels may relate to the size of the fuels, the shape of the fuels, the composition of the fuels, or any combination thereof. In some embodiments, waste fuels comprise construction, renovation and demolition (CRD) waste, yard waste, municipal solid waste (e.g. paper, plastics, etc.), food waste, agricultural waste, biomass waste, or any combination thereof. In some embodiments, CRD waste comprises engineered wood, wood, shingles, paper, cardboard, gypsum, inerts, polystyrene insulation, or any combination thereof.

[0025] The present disclosure provides a number of advantages over existing technologies. For example, the injection of water may be used to provide improved temperature control of gasifiers over air injection metering, or in combination with air injection metering provide an even more pronounced temperature control of gasifiers. An advantageous aspect of embodiments of the systems and methods herein is the improved ability to use waste fuels in gasifiers, which reduces the risk of using such gasifiers for energy production in locations that may not have access to virgin or conventional fuels. Moreover, the use of waste fuels provides for an environmental benefit by reducing use of conventional or virgin fuels (e.g., wood chips) and providing a practical use for waste that may otherwise be disposed in a landfill. Embodiments of the present disclosure may advantageously be implemented on existing commercial gasifier systems (e.g. by retrofit), thereby offering a waste-to-energy solution for both new and existing systems.

[0026] In an embodiment, the present disclosure relates to a system for enhanced temperature control in gasifiers, the system comprising: a gasifier apparatus; and a water injector for delivering water to an internal reactor compartment of the gasifier apparatus.

[0027] As used herein, the term “enhanced temperature control” is intended to refer to an improved temperature control over conventional gasifiers employing air injection to control temperature. Without being bound by any particular theory, the injection of water may draw heat through either or any combination of: vapourization of liquid water, endothermic steam gasification reactions, or displacement of oxygen by vapour water. In particular, the methods and systems herein advantageously allow for more precise and regulated control of the temperature with a gasifier apparatus, in particular within the internal reactor compartment.

[0028] As used herein, the term “gasifier” or “gasifier apparatus”, used interchangeably herein, refers to any vessel, apparatus, facility, machine, or instrument configured for the process of gasification wherein synthesis gas or syngas (i.e., gaseous mixture comprising at least hydrogen and carbon monoxide) and mineral residues are produced through a series of chemical reactions involving air and fuel. In some embodiments, the gasifier apparatus comprises insulation. In some embodiments, the gasifier apparatus comprises insulated sections, non-insulated sections, or a combination thereof. In a particular embodiment, the gasifier apparatus comprises insulation sections and non-insulatedsections. Advantageously, non-insulated sections may increase heat loss and lower the internal temperature of the gasifier apparatus.

[0029] As is known, a gasifier may include several different internal compartments. In an embodiment of the present disclosure, the water is delivered to the internal reactor compartment. As used herein, the “internal reactor compartment” is intended to refer to the internal compartment of the gasifier where combustion and gasification of the fuel occurs.

[0030] In accordance with the present disclosure, the water is injected into the gasifier (e.g. to an internal reactor compartment). In some embodiments, the water may pass through a conduit within and in thermal contact with the internal reactor compartment of the gasifier. The water is delivered to the internal compartment of the gasifier by way of a water injector. While the water may be injected into the internal reactor in liquid form, it may also be injected in the form of steam that has formed within the conduit by absorbing heat from the internal reactor compartment through the wall of the conduit.

[0031] As used herein, the term “water injector” has a broad meaning as encompassing any device, apparatus, component, combination of components, or any combination thereof capable of delivering water to an internal compartment of the gasifier apparatus. In an embodiment, the water injector is a spray-type injector through which pressurized water passes through. In an embodiment, the water injector is a nozzle through which water passes under pressure or not. Other embodiments and configurations are described herein and additional components and / or configurations would be known to the skilled person based on the disclosure herein.

[0032] The systems herein are configured in a manner such that water is capable of being delivered to an internal reactor compartment of the gasifier apparatus during operation of the gasifier. In an embodiment, the water is delivered or injected directly into the internal reactor compartment, without passage through a conduit that extends within the internal reactor compartment. In an embodiment, the water is delivered or injected directly into the internal reactor compartment in the form of liquid water. For example, the water injector or one or more components thereof may pass directly through a wall of the internal reactor compartment with the water being delivered immediately at the interior side of the passage through the wall. In another embodiment, the water passes through a structure or formation that is in thermal communication with the exterior side of the wall of internal reactorcompartment of the gasifier apparatus. This structure or formation may be, for example, an external conduit that wraps around the outside of the internal reactor compartment, the external conduit being in thermal communication with the internal reactor compartment via the wall of the compartment. In another embodiment, the structure or formation may be a lining surrounding the exterior side of the wall of the internal reactor compartment, and in thermal communication with the internal reactor compartment via the wall of the compartment. A skilled person having regard to the present disclosure can determine other structures or formations capable of achieving this ‘heat sink’ effect. In any such embodiment, the water eventually is delivered or injected into the internal reactor compartment in the form of a liquid, a steam, or both a liquid and steam. In other embodiments, the water may pass through a conduit within the internal space or cavity of the internal reactor compartment. In some embodiments, passage of the water through the conduit may permit an additional mode of temperature control by heat exchange with the water within the conduit providing a cooling effect to the internal reactor compartment. This cooling effect may be accompanied by conversion of a portion of the water to steam, but in some embodiments, at least a portion of the water is still delivered to the internal reactor compartment in liquid form.

[0033] As described herein, the systems of the present disclosure may include additional features relating to various aspects of performing the methods herein. For example, the systems may include various devices or components for modulating and controlling the quantity of water delivered to the gasifier apparatus, monitoring equipment, water delivery components, etc. As will be understood by the skilled person, exemplary configurations of the systems are described herein without limitation.

[0034] In certain embodiments, the systems described herein may be used in methods for enhanced temperature control in gasifiers, whereby the methods comprise steps of monitoring the temperature of an internal compartment of a gasifier apparatus; and adjustably delivering a quantity of water to the internal reactor compartment, the quantity of water determined by the temperature of the internal reactor compartment.

[0035] The methods herein involve a step of monitoring the temperature of an internal compartment of a gasifier apparatus. In an embodiment, the internal compartment is an internal reactor compartment. In an embodiment, the internal compartment is not the internal reactor compartment, but the monitored temperature provides information relevant to the temperature in the internal reactor compartment. The monitoring of the temperature may beany suitable device or component. In an embodiment, the monitoring of the temperature is by a thermocouple or other temperature gauge. In an embodiment, the temperature may be manually monitored and the quantity of water delivered to the gasifier manually adjusted. In others embodiments, one or more points of automation may be used. In an embodiment, the temperature is automatically monitored and through an automated process the quantity of water delivered to the gasifier is adjusted.

[0036] The methods herein involve a step of adjustably delivering a quantity of water to the internal reactor compartment based on the temperature of the internal compartment. The quantity of water delivered may be adjusted by any suitable means. In an embodiment, the system of the present disclosure may include adjustable values that control the flow rate of the water out of the water injector. In an embodiment, the system of the present disclosure may include pressure controls and devices to adjust the amount of pressure applied to the water and thereby impact the rate of flow of the water. In an embodiment, the water injector itself may be configurable to control the rate of delivery of water to the gasifier. Other modes are described herein and are non-limiting.

[0037] In certain embodiments, the systems and methods of the present disclosure may be the result of newly constructed gasifier apparatuses. In certain embodiments, the systems and methods of the present disclosure may be the result of retrofitting an existing gasifier apparatus to allow for water injection.

[0038] Accordingly, in certain embodiments, the present disclosure relates to a kit for assembling, modifying or retrofitting a gasifier apparatus to permit temperature control by water injection, the kit comprising: a water injector assembly for delivering water to an internal reactor compartment of the gasifier; and a metering device for adjustably controlling a quantity of water delivered to the internal reactor compartment. As used herein, the term “metering device” is intended to refer to any single component or combination of components that is capable of modulating and / or controlling the quantity of water delivered to the gasifier apparatus, such as for example and without limitation valves, pressurization devices, adjustable flow rate injectors, etc.

[0039] Reference will now be made in detail to exemplary embodiments of the disclosure, wherein numerals refer to like components, examples of which are illustrated in the accompanying drawings that further show exemplary embodiments, without limitation.

[0040] FIG. 1 illustrates an exemplary temperature control system 100 of the present disclosure comprising a gasifier apparatus 105 and a water injector 110. The water injector 110 injects water 115 directly to an internal reactor compartment 120 of the gasifier apparatus 105. By “directly to”, it is intended to mean that the water is provided to the interior space or cavity of internal reactor component. In some embodiments, the water injector 110 comprises a conduit 125 passing through an exterior wall 130 of the gasifier apparatus 105 and a water injection nozzle 135 on the interior side of the exterior wall 130 for injecting the water 115 directly to the internal reactor compartment 120.

[0041] In some embodiments, a heat transfer portion 127 of the conduit 125 extends for a length in contact with the exterior wall 130 and / or within the internal reactor compartment 120 to conduct heat from the internal reactor compartment 120 into the water 115 within the heat transfer portion 127 of the conduit 125. The heat transfer portion 127 of the conduit 125 is between a first end 125A of the conduit 125 and a second end 125B of the conduit 125. In some embodiments, the heat transfer portion 127 of the conduit 125 comprises a portion of the length between the first end 125A and the second end 125B. In some embodiments, the heat transfer portion 127 of the conduit 125 comprises the entire length between the first end 125A and the second end 125B.

[0042] The water injection nozzle 135 may be positioned in any location within the interior side of the exterior wall 130. In some embodiments, the position of the water injection nozzle 135 is configured to accommodate a certain length of the heat transfer portion 127 of the conduit 125. In some embodiments, the water injector 110 comprises a plurality of conduits 125, a plurality of water nozzles 135, or a combination thereof. In some embodiment, the conduit 125 extends no further into the internal reactor compartment 120 than to the interior side of the exterior wall 130. In some embodiments, there is no conduit 125, but rather merely a water injection nozzle 135 spanning the exterior wall 130.

[0043] FIG. 2 illustrates another embodiment of the exemplary temperature control system 100 shown in FIG. 1 . In some embodiments, the water injector 110 injects water 115 into an air passage system 140 to deliver the water 115 to the internal reactor compartment 120. In some embodiments, the air passage system 140 comprises an air inlet plenum 145 positioned exterior to the gasifier apparatus 105 for receiving the water 115 from the water injector 110, an air nozzle 155 positioned within the internal reactor compartment 120, and an air conduit 150 connecting the air inlet plenum 145 to the air nozzle 155. In someembodiments, the air nozzle 155 and the water injection nozzle 135 may be a single component or separate components. In some embodiments, the air passage system 140 is configured to deliver air, water, or a combination thereof to the internal reactor compartment 120. In some embodiments, the air passage system 140 comprises a plurality of air conduits 150, a plurality of air inlet plenums 145, a plurality of air nozzles 155, or a combination thereof.

[0044] In some embodiments, a heat transfer portion 152 of the air conduit 150 extends for a length within the internal reactor compartment 120 to conduct heat from the internal reactor compartment 120 into the water 115 within the heat transfer portion 152 of the air conduit 150. The heat transfer portion 152 of the air conduit 150 is between a first end 150A of the air conduit 150 and a second end 150B of the air conduit 150. In some embodiments, the heat transfer portion 152 of the air conduit 125 comprises a portion of the length between the first end 150A and the second end 150B. In some embodiments, the heat transfer portion 152 of the air conduit 150 comprises the entire length between the first end 150A and the second end 150B.

[0045] In some embodiments, the heat transfer portion 152 of the air conduit 150 and the heat transfer portion 127 of the conduit 125 may be a single component or separate components. In some embodiments, the air conduit 150 and / or the conduit 125 comprises any material that is suitable for heat conduction including copper, silver, steel, brass, aluminum, bronze, iron, or a combination thereof. In some embodiments, the air conduit 150 and / or the conduit 125 is straight, curved, angled, or a combination thereof. In some embodiments, the air conduit 150 and / or the conduit 125 is configured for a shape so as to maximize the surface area and temperature control properties for a particular length of the heat transfer portions (152, 127).

[0046] In some embodiments, the system 100 further comprises a metering device 160 positioned upstream of the water injector 110, for adjustably controlling the flow of water 115 to the internal reactor compartment 120 of the gasifier apparatus 105. In some embodiments, the metering device 160 adjustably controls the flow of water 115 by maintaining a consistent flowing stream, providing the water 115 in intervals, stopping the flow, or a combination thereof. In some embodiments, the metering device 160 comprises a pump, a flow meter, a control valve, or any combination thereof. In a particular embodiment, the metering device 160 comprises a low flow pump, a mass flow controller, a proportionalvalve, or a combination thereof. In some embodiments, the system 100 comprises a plurality of metering devices 160 positioned upstream of the water injector 110.

[0047] In some embodiments, the system 100 further comprises one or more sensors (not shown) positioned to monitor temperature, pressure, or a combination thereof within the internal reactor compartment 120 of the gasifier apparatus 105. In some embodiments, the one or more sensors monitor at least temperature. In some embodiments, the one or more sensors are distributed throughout the internal reactor compartment 120 so as monitor the differential of temperature, pressure, or a combination thereof between different locations within the internal reactor compartment 120. In some embodiments, the one or more sensors comprise negative temperature coefficient thermistors, resistance temperature detectors, thermocouples, semiconductor-based sensors, aneroid barometer pressure sensors, manometer pressure sensors, bourdon tube pressure sensors, vacuum pressure sensors, sealed pressure sensors, piezoelectric pressure sensors, strain gauge pressure sensors, or a combination thereof. In a particular embodiment, the one or more sensors comprise thermocouples.

[0048] In some embodiments, the system 100 further comprises one or more sensors (not shown) positioned to monitor pressure within the internal reactor compartment 120 of the gasifier apparatus 105. In some embodiments, the one or more sensors are distributed throughout the internal reactor compartment 120 so as monitor the pressure differential between different locations within the internal reactor compartment 120.

[0049] In some embodiments, during operation of the system 100, the temperature of the internal reactor compartment 120 of the gasifier apparatus 105 is monitored and the water 115 is injected to the internal reactor compartment 120 of the gasifier apparatus 105 using automated and / or programmable logic control. In some embodiments, the air is injected to the internal reactor compartment 120 using automated and / or programmable logic control. In some embodiments, the metering device 160 adjustably controls the flow of water 115 using automated and / or programmable logic control in response to changes in the temperature of the internal reactor compartment 120. In some embodiments, the water 115 is injected to the internal reactor compartment 120 using automated and / or programmable logic control when the temperature of the internal reactor compartment 120 exceeds a predetermined threshold temperature.

[0050] In some embodiments, the internal reactor compartment 120 of the gasifier apparatus 105 comprises a combustion zone of the gasifier apparatus 105. In some embodiments, the gasifier apparatus 105 comprises an updraft or counter current gasifier, a downdraft or co-current gasifier, a cross-draft gasifier, a fluidized bed gasifier, a moving bed gasifier, or a combination thereof. In some embodiments, the gasifier apparatus 105 is a downdraft gasifier. In some embodiments, the system 100 is configured to be entirely contained within a shipping container.

[0051] FIG. 3 illustrates an exemplary gasifier apparatus 200 for advantageously using waste fuels for energy production. In some embodiments, the gasifier apparatus 200 comprises a screw feeder, one or more sensors, one or more air nozzles, an ignitor, a char basket, or a combination thereof. In some embodiments, the gasifier apparatus 200 contains a gasification zone. In some embodiments, waste fuel is fed into the gasifier apparatus 200 by the screw feeder. In some embodiments, the waste fuel is provided into the gasification zone by gravity wherein the ignitor burns the waste fuel with air provided from the one or more air nozzles. In some embodiments, the gasification zone is positioned below the one or more air nozzles so as to advantageously reduce heat produced from the gasification zone and control the temperature of the gasifier apparatus 200.

[0052] FIG. 4 illustrates the temperature differential of the exemplary gasifier apparatus 200 shown in FIG. 3 over 1 hour of operation.

[0053] FIG. 5 illustrates the product gas composition of the exemplary gasifier apparatus 200 shown in FIG. 3 over 3 hours of operation. It is notable that the main constituents of the product gas are carbon monoxide and hydrogen, followed by carbon dioxide and methane. In some embodiments, the product gas composition may comprise nitrogen oxide, nitrogen dioxide, dinitrogen monoxide, carbon dioxide, carbon monoxide, methane, ethane, ethylene, acetylene, propylene, butane, formaldehyde, acetadyhyde, and NMHC. In some embodiments, the product gas is converted into syngas. In some embodiments, syngas comprises carbon monoxide, hydrogen, carbon dioxide, methane, or a combination thereof.

[0054] FIGs. 6A and 6B illustrate the changes in pressure drop and temperature over 2.5 hours using virgin or conventional fuel (i.e., clean wood chips) versus waste fuel (i.e., construction and demolition waste) in conventional gasifier systems. It is notable that theclean wood chips provide more consistent and stable data points than the waste fuel. In some embodiments, waste fuel such as CRD waste may undergo densification. Advantageously, densification may increase the suitability of CRD waste in gasification through improvements in bulk properties and reduction in fuel heterogeneity.

[0055] FIG. 7 illustrates an exemplary workflow (300) of exemplary systems for advantageously using waste fuels for energy production. In some embodiments, the gasifier apparatus comprises a small scale (10 kg / hr) downdraft air blown gasifier. In some embodiments, a final step of emission control comprises a cyclone, a packed bed trickle filter, or a combination thereof. In some embodiments, the syngas is further cleaned using a cyclone and packed bed trickle filter. In some embodiments, fuel is characterized through proximate and ultimate analysis, heating value, ash elemental analysis, particle size distribution, or a combination thereof.

[0056] FIG. 8 illustrates the steps of an exemplary method 400 of the present disclosure for enhanced temperature control in gasifiers. In some embodiments, the method 400 comprises the step of monitoring 410 the temperature of an internal compartment of a gasifier apparatus; and the step of adjustably delivering 420 a quantity of water to the internal reactor compartment, the quantity of water determined by the temperature of the internal reactor compartment.

[0057] In some embodiments, the step of monitoring 410 the temperature of the internal reactor compartment is by one or more sensors. In some embodiments, the one or more sensors comprises temperature sensors, pressure sensors, or a combination thereof.

[0058] In some embodiments, the step of monitoring 410 the temperature of the internal reactor compartment is by automation and / or programmable logic control. In some embodiments, the automation and / or programmable logic control adjustably controls the injection of water into the internal compartment of the gasifier apparatus.

[0059] In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment increases the quantity of water when the temperature of the internal reactor compartment rises above one or more predetermined temperature thresholds. In some embodiments, the one or more predetermined threshold temperatures is about 1 ,100°C, about 1 ,050°C, about 1 ,000°C, about 950°C, about 900°C, about 850°C, about 800°C, about 750°C, about 700°C, or about 650°C. In someembodiments, the one or more predetermined threshold temperatures is about 1 ,000°C. In some embodiments, the one or more predetermined threshold temperatures is about 950°C. In some embodiments, the one or more predetermined threshold temperatures is about 900°C.

[0060] In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment maintains the temperature of the internal reactor compartment within an optimal temperature range. In some embodiments, the optimal temperature range is between about 600°C to about 1 ,200°C. In some embodiments, the optimal temperature range is between about 700°C to about 1 ,100°C. In some embodiments, the optimal temperature range is between about 800°C to about 1 ,000°C. In some embodiments, the optimal temperature range is between about 850°C to about 950°C.

[0061] In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment comprises directly injecting water to the internal reactor compartment. In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment comprises delivering the water to an air passage system for delivery into the internal reactor compartment. In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment comprises passing water through a length of conduit within the internal reactor compartment prior to the water being injected into the internal reactor compartment. In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment comprises passing water through a length of conduit concurrently with a passing of air through the length of conduit from an air passage system.

[0062] In some embodiments, a heat transfer portion of the conduit is formed and temperature control of the gasifier apparatus is provided by way of heat conduction to water within the heat transfer portion. In some embodiments, the temperature control of the internal reactor compartment comprises latent heat of vaporization of the water, endothermic steam gasification reactions, or any combination thereof.

[0063] In some embodiments, the step of adjustably delivering 420 the quantity of water to the internal reactor compartment comprises a metering device for adjustably controlling the flow of water to the water injector. In some embodiments, the metering deviceadjustably controls the flow of water to the water injector using automation and / or programmable logic control.

[0064] In some embodiments, the method increases fuel flexibility of the gasifier. In some embodiments, the fuel flexibility is increased by allowing fuels with a variety of heating values to be used within the gasifier apparatus. In some embodiments, the fuel flexibility is increased by allowing waste fuels to be used within the gasifier apparatus. In some embodiments, the fuel flexibility is increased by allowing CRD waste to be used within the gasifier apparatus. In some embodiments, the gasifier apparatus is a downdraft gasifier.

[0065] In some embodiments, the present disclosure also relates to a kit for assembling, modifying or retrofitting a gasifier apparatus to permit temperature control by water injection, the kit comprising: a water injector assembly for delivering water to an internal reactor compartment of the gasifier; and a metering device for adjustably controlling a quantity of water delivered to the internal reactor compartment.

[0066] In some embodiments, the water injector comprises a water injection nozzle configured for interconnecting a water delivery conduit to an air inlet plenum. In some embodiments, the water injector comprises a conduit and a water injection nozzle. In some embodiments, the gasifier apparatus is a downdraft gasifier.

[0067] In the present disclosure, all terms referred to in singular form are meant to encompass plural forms of the same. Likewise, all terms referred to in plural form are meant to encompass singular forms of the same. 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 this disclosure pertains.

[0068] As used herein, the term “about” refers to an approximately + / -10 % variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

[0069] It should be understood that the compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of or "consist of the various components and steps. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.

[0070] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0071] Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the disclosure covers all combinations of all those embodiments. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be referenced herein, the definitions that are consistent with this specification should be adopted.

[0072] Many obvious variations of the embodiments set out herein will suggest themselves to those skilled in the art in light of the present disclosure. Such obvious variations are within the full intended scope of the appended claims.

Claims

CLAIMS:1 . A system for enhanced temperature control in gasifiers, the system comprising:- a gasifier apparatus; and- a water injector for delivering water to an internal reactor compartment of the gasifier apparatus.

2. The system of claim 1 , wherein the water injector injects water directly to the internal reactor compartment.

3. The system of claim 2, wherein the water injector comprises a conduit passing through an exterior wall of the gasifier apparatus and a water injection nozzle on the interior side of the exterior wall for injecting the water directly to the internal reactor compartment.

4. The system of claim 3, wherein a heat transfer portion of the conduit extends for a length in contact with the exterior wall and / or within the internal reactor compartment to conduct heat from the reactor into the water within the heat transfer portion of the conduit.

5. The system of claim 1 , wherein the water injector injects water into an air passage system to deliver the water to the internal reactor compartment.

6. The system of claim 5, wherein the air passage system comprises an air inlet plenum positioned exterior to the gasifier apparatus for receiving the water from the water injector, an air nozzle positioned within the internal reactor compartment, and an air conduit connecting the air inlet plenum to the air nozzle.

7. The system of claim 6, wherein a heat transfer portion of the air conduit extends for a length within the internal reactor compartment to conduct heat from the internal reactor compartment into the water within the heat transfer portion of the air conduit.

8. The system of any one of claims 1 to 7, further comprising a metering device positioned upstream of the water injector, for adjustably controlling the flow of water to the internal reactor compartment of the gasifier apparatus.

9. The system of claim 8, wherein the metering device comprises a pump, a flow meter, a control valve, or any combination thereof.

10. The system of any one of claims 1 to 9, further comprising one or more sensors positioned to monitor temperature within the internal reactor compartment of the gasifier apparatus.

11. The system of claim 10, wherein during operation the temperature of the internal reactor compartment of the gasifier apparatus is monitored and the water is injected to the internal reactor compartment of the gasifier apparatus using automated and / or programmable logic control.

12. The system of any one of claims 1 to 11 , wherein the internal reactor compartment of the gasifier apparatus comprises a combustion zone of the gasifier apparatus.

13. The system of any one of claims 1 to 12, wherein the gasifier apparatus is a downdraft gasifier.

14. A method for enhanced temperature control in gasifiers, the method comprising:- monitoring temperature of an internal reactor compartment of a gasifier apparatus; and- adjustably delivering a quantity of water to the internal reactor compartment, the quantity of water determined by the temperature of the internal reactor compartment.

15. The method of claim 14, wherein the step of monitoring the temperature of the internal reactor compartment is by one or more sensors.

16. The method of claim 14 or 15, wherein the step of monitoring the temperature of the internal reactor compartment is by automation and / or programmable logic control.

17. The method of any one of claims 14 to 16, wherein the step of adjustably delivering the quantity of water to the internal reactor compartment increases the quantity of water when the temperature of the internal reactor compartment rises above one or more predetermined temperature thresholds.

18. The method of any one of claims 14 to 17, wherein the step of adjustably delivering the quantity of water to the internal reactor compartment maintains the temperature of the internal reactor compartment within an optimal temperature range.

19. The method of any one of claims 14 to 18, wherein the step of adjustably delivering the quantity of water to the internal reactor compartment comprises directly injecting water to the internal reactor compartment.

20. The method of any one of claims 14 to 18, wherein the step of adjustably delivering the quantity of water to the internal reactor compartment comprises delivering the water to an air passage system for delivery into the internal reactor compartment.

21. The method of any one of claims 14 to 20, wherein the step of adjustably delivering the quantity of water to the internal reactor compartment comprises passing water through a length of conduit within the internal reactor compartment prior to the water being injected into the internal reactor compartment.

22. The method of claim 21, wherein a heat transfer portion of the conduit is formed and temperature control of the gasifier apparatus is provided by way of heat conduction of water within the heat transfer portion.

23. The method of any one of claims 14 to 22, wherein the temperature control of the internal reactor compartment comprises vaporization of the water, steam gasification with the water, or any combination thereof.

24. The method of any one of claims 14 to 23, wherein the step of adjustably delivering the quantity of water to the internal reactor compartment comprises a metering device for adjustably controlling the flow of water to the water injector.

25. The method of any one of claims 14 to 24, which increases fuel flexibility of the gasifier.

26. The method of claim 25 wherein the fuel flexibility is increased by allowing fuels with a variety of heating values to be used within the gasifier apparatus.

27. The method of any one of claims 14 to 26, wherein the gasifier apparatus is a downdraft gasifier.

28. A kit for assembling, modifying or retrofitting a gasifier apparatus to permit temperature control by water injection, the kit comprising:- a water injector assembly for delivering water to an internal reactor compartment of the gasifier apparatus; and- a metering device for adjustably controlling a quantity of water delivered to the internal reactor compartment.

29. The kit of claim 28, wherein the water injector comprises a water injection nozzle configured for interconnecting a water delivery conduit to an air inlet plenum.

30. The kit of claim 28, wherein the water injector comprises a conduit and a water injection nozzle.

31. The kit of any one of claims 28 to 30, wherein the gasifier apparatus is a downdraft gasifier.

32. The system of any one of claims 1 to 13, wherein at least a portion of the water that is delivered to the internal reactor compartment is in the form of liquid water.

33. The system of any one of claims 1 to 13, wherein substantially all of the water that is delivered to the internal reactor compartment is in the form of liquid water.

32. The method of any one of claims 14 to 27, wherein the step of adjustably delivering a quantity of water to the internal reactor compartment comprising delivering at least a portion of the quantity of water in the form of liquid water.

33. The method of any one of claims 14 to 27, wherein the step of adjustably delivering a quantity of water to the internal reactor compartment comprising delivering substantially all of the quantity of water in the form of liquid water.

Images