Modular allothermal spouted gasifier system

Abstract

A Spouted gasifier (SG) system includes a submerged jet spouted bed reactor that includes; a plurality of walls that form an interior volume; a material inlet configured- to provide material into the interior volume.; a spouted gas inlet configured to provide fluid into the material in the interior volume to form a fluid-solid mixture; one or more outer surfaces of the plurality of walls configured to perform catalytic combustion, to heat the fluid-solid mixture within the interior volume to form output material; a material outlet configured to provide at least a portion of the output material from the interior volume.

Description

UNITED STATES PATENT APPLICATIONForSPOUTED GASIFIER SYSTEMInventors;John Patrick DecherPeter James DooherAttorney Docket No: 46859.3Prepared by:Lowenstein Sandler LLP500 N Marketplace Dr, Suite 200Centerville, UT 84014(973) 597-2500SPOUTED GASIFIER SYSTEMTECHNICAL FIELD}0001] Embodiments of the present disclosure relate to gasifier systems, and in particular to spouted gasifier systems,BACKGROUND100021 Human civilization uses energy and produces waste. For example, a household may use energy via use of electricity and burning of natural gas and. may produce garbage and sewage waste.BRIEF DESCRIPTION OF THE DR WINGS|0003J The present disclosure is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that different references to "atr” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.10004] FIGS. 1A-P illustrate spouted gasifier (SG) systems, according to certain embodiments.100051 FIGS. 2A-H illustrate submerged jet spouted bed reactors of SGaecordmg to certain embodiments.100061 FIGS. 3A-B illustrate ash collectors of SG systems, according to certain embodiments.

[0007] FIGS. 4A-G illustrate graphs associated with SG systems, according to certain embodiments.|0OO8] FIG. 5 is a block diagram illustrating a computer system, according to certain embodiments.DETAILED DESCRIPTION OF EMBODIMENTS

[0009] Embodiments described herein are related to spouted gasifier systems (e.g.. Modular Allothermal Spouted Gasifier (MASG) systems).|O010] Human civilization uses energy and produces waste. For example, a household may use energy via use of electricity and burning of natural gas and may produce garbage and sewage waste. Fuel may be consumed to produce energy. For example, coal may be burned toproduce electricity. Certain types of fuel and waste conventionally are difficult to consume and are discarded or inefficiently used. Discarding and inefficientl using fuel and waste causes pollution, filling of landfills, noxious fi.i es, etc. Conventionally, consumption of some types of fuel and waste may use large systems that may not be feasible to be located in certain locations, causing those types of fuel and waste to be inefficiently used or discarded or inefficiently transported over long distances;Q0111 The de vices, systems, and methods disclosed herein pro vide SG systems that help solve these and other shortcomings of conventional systems.100121 In some embodiments, a SG system includes a submerged jet spouted bed reactor, The submerged jet spouted bed reactor includes walls that form an interior volume, a material inlet configured to provide material into the interior volume, a spouted gas inlet configured to provide fluid into the material in the interior volume to form a fluid-solid mixture, one or more outer surfaces of the walls configured to perform catalytic combustion to heat the fluid-solid mixture within the interior volume to form output material, and a material outlet configured to provide at least a portion of the output material.from the interior volume, 100131 in some embodiments, the SG system (e,g., spouted-bed reactor) further Includes a draft tube that includes windows and a skirt that is sized with a reactor diameter. The draft tube may be configured to provide stabilization associated with the spouted gas inlet and reduce nozzle-gas demand under pressurized operation (e,g., about 10 bar).|0014J In some embodiments, the SG system further includes a cone- insert and apex nozzle configured to generate a submerged jet using fluid (e.g,, steam and or CO2) at reactor pressure (e.g., about 10 bar absolute).|0015} in some embodiments, the SG system, further includes a dual-path slurry feed comprising an over-bed injector (c.g,, over-bed top-feed) and an under-bed spouting-tube pathway that has in-tube fluid (e,g,, water) flashing and liquid-to-gas (L / G) mass ratio control associated with (e.g., tied to, split tied to) spout-exit temperature and plenum difference in pressure (e.g,, plenum Ap),|O016j In some embodiments, the SG system is a hybrid bed spouted gasifier.f 0017| The present disclosure may relate to spou fed-bed gasification reactors, for example hybrid bed geometries that combine a shallow-angle center cone with a skirt profile and an open-sfoed draft tube incorporating a Venturi throat to improve particle circulation and reduce spouting gas demand,{O01& Conventional spouted bed gasifiers using either flat or conical bases often suffer from dead zones, poor mixing, and high gas requirements. Conventional draft tubes mayimprove solids circulation but arc limited in efficiency without geometric enhancement. There remains a need for a geometry that stabilizes the spout, maximizes entrainment, and ensures uniform solids recycle without excessi e gas consumption,[0O19J In some embodiments, the present disclosure provides a hybrid spouted-bed reactor that includes one or more of the following,|0O2O A central cone element positioned at the base of the bed, having a half-angle of approximately 18 degrees, which guides the upward spouting jet into the draft tube and m inimizes tailback of particles into the nozzle zone,J0021 J A skirt element disposed around the cone, having a slope of approximately 150 degrees relative to the horizontal, increasing bed volume while promoting downward solids movement along the wall into the annular region for stable recycle.|0022 An open-sided draft tube extending vertically through the bed, the draft tube having longitudinal apertures or side slots in its lower section to entrain solids from the annular region into the core gas stream.|0923 J A Venturi throat i neorperated into the draft tube, including one or more of a converging section, a reduced-diameter throat, and / or a diffuser outlet, such that the local static pressure at the slots is reduced, thereby enhancing solids entrainment and increasing the effective entrainment factor (E).|O024] A spouting gas nozzle: aligned with the center cone axis and located beneath the draft tube inlet, supplying steam, CO₂, or a mixture thereof. The nozzle momentum, in combination with Venturi-induced entrainment, generates stable spouting while reducing required spouting gas consumption.}O025|: in some embodiments, gas injected through the nozzle accelerates into the draft tube and passes through the Venturi throat, creating a local low-pressure zone that pulls annular solids inward through the side slots. The cone (e.g., shallow cone, about 18° cone) stabilizes the spout and prevents blockage at the nozzle entrance, while the skirt (e.g,, about 150° skirt) directs particles downward, allowing (e.g., ensuring) continuous annular replenishment. Entrained solids are lifted upward through the draft tube, dispersed in the fountain region, and then cascade down the skirt, establishing a continuous recycle loop with improved energy efficiency,fO026| The present disclosure (e,g„ hybrid bed spouted gasifier of the present disclosure) may have one or more of the following advantages.|O027J Reduced gas consumption due to Venturi-driven entrainment amplification compared to conventional systems.[0028} 'More stable spouting supported by shallow-angle cone geometty compared to conventional systems.[0029} More uniform particle circulation and less dead zones (e.g., minimized dead zones) due to combined cone-skirt configuration compared to conventional systems.[0030} Enhanced carbon conversion efficiency through repeat, exposure of particles to hot spout gas compared to conventional systems.[0031} Less moving parts (e.g., no moving parts) in the hot zone compared to conventional systems, enabling reliable high-temperature and high-pressure operation.[0032} 1n some embodiments a spouted-bed gasification reactor includes one or more of: |0033} a vessel forming (e.g., defining) a reaction chamber:,

[0034] a substantially central cone disposed at the chamber base of the reaction chamber, the substantially central cone having a half-angle of approximately 18 degrees;[0035} a skirt disposed around the substantially central cone, the skirt inclined at approximately 150 degrees relative to the horizontal;[0036} a draft tube extending substantially vertically through the spouted- bed gasification reactor, the draft tube having side apertures and a Venturi throat including a converging section, reduced throat, and diffuser outlet; and / or[0037} a gas injection nozzle disposed beneath the draft tube inlet, where the Venturi throat induces entrainment of solids from the annular region through the apertures to increase the entrainment factor and reduce spouting gas demand,[0038} In some embodiments, a spouted-bed reactor includes a vessel that includes a hybrid bed geometry including a conical base element, a skirted wall region, and a draft tube that has at least one flow-enhancing feature, where gas is introduced beneath the draft tube to establish spouting and solids circulation.[0039} hi some embodiments, the conical base element has a half-angle between about 15° and about 25°[0040} In some embodiments, the skirted wall region is inclined at an angle between about 140° and about 160° relative to the horizontal.[0041 } In some embodiments, the draft tube includes a Venturi throat that has a converging inlet, reduced throat, and diverging outlet.[0042} in some embodiments, the draft tube further includes longitudinal side slots configured to entrain solids from an annular region.[0043} In some embodiments, the gas introduced includes one or more of steam, carbon dioxide, syngas, and or mixtures thereof(0044 In some embodiments, the reactor is configured to operate at a pressure of up to about 20 bar and a temperature of up to about 1,000 °C.[0045} In some embodiments, a method of operating a spouted-bed gasification reactor includes.[0046} introducing a spouting gas through a nozzle of the spouted-bed gasification reactor beneath a draft tube of the spouted-bed gasification reactor positioned above a conical base of the spouted-bed gasification reactor;

[0047] accelerating the gas through a Venturi throat of the draft tube to induce entrainment of solids through side apertures of the draft tube;}O048} lifting entrained solids into a fountain region above the draft tube:,0049J cascading solids downward along a skirted wall of the spouted-bed gasification reactor into an annular region of the spouted-bed gasification reactor; and / or[0050) substantially continuously recycling solids through the annular region into the draft tube.[0051 } In some embodiments, the spouting gas includes steam, CO₂, or a mixture thereof, and the reactor is operated to minimize gas consumption while maintaining threshold circulation (e.g., substantially stable circulation, within, a particular range of circulation values) and a threshold particle conversion, efficiency (e.g., high particle conversion. efficiency).[0052} In some embodiments, the SG system is a single let-down bed refresh system,.[0053} Spouted bed gasifiers operating at elevated pressures are to have periodic removal arid replacement of inert bed material to maintain proper hydrodynamics and prevent accumulation of ash, and char. Conventional solutions rely on lock-hoppers or complex mechanical systems, which introduce moving parts in the hot, pressurized region of the reactor. These approaches increase cost, complexi ty, and risk of mechanical failure. A simplified, reliable bed refresh system is therefore desirable.[0054} In some embodiments, the present disclosure provides a single let-down bed refresh system that withdraws a controlled fraction of inert bed material carrying residual char ('dirty inerts’) from a pressurized spouted bed gasifier and delivers at least a portion of the controlled fraction of inert bed material (e.g., at least a portion of the residual char) to an atmospheric separation device. The single let-down bed refresh system may include a single pressure let¬ down valve, optional purge gas injection, and an atmospheric cyclone separator to achieve continuous or semi-continuous bed refresh without lock-hoppers or moving parts in the hot zone.(0055'1 In some embodiments, dirty inerts (e,g., residual char) are removed from the loop- seal grain leg of the single let-down. bed refresh, system at reactor pressure (about 5-20 bar). The solids flow down ward to a pressure let-down valve of the single let-down bed refresh system that is configured for (e.g., constructed for) erosive service, such as a ceramic-lined knife gate, pinch valve, or choke valve, The pressure let-down valve operates intermittently in timed pulses (e.g., about 0,5-2 seconds every about 5-15 minutes) to meter a fraction of bed mass, corresponding to about 1-5% per hour. As solids pass the pressure let-down valve, the solids undergo depressurization to near-atmospheric pressure. A purge gas stream (carbon dioxide, steam, and / or recycled syngas) is injected downstream of the pressure let-down valve to prevent plugging and to convey the solids into the inlet of an atmospheric cyclone of the single let-down bed refresh system.}0056J The atmospheric cyclone operates at about 1 bar and separates coarse solids (char and inert particles) into the underflow, which is directed to a flotation cell, slurry tank, or storage bin for reuse: The overflow, including (e.g., consisting of) fines and expanded gas, is routed to a fines cleanup stage (secondary cyclone, demister, or cleanup train). Cyclone inlet velocity is targeted in the range of 15-20 meters per second (m / s) during depressurization}0057] Instrumentation may include one or more of: (a) a pressure sensor on the grain leg: (b) a differential pressure sensor across the pressure let-down valve (c) a purge gas flow meter; and / or (d) a level indicator In the cyclone underflow bin,. The configuration scales readily from small laboratory systems (~0.09 m diameter) to pilot (0,2-0, 3 m) and commercial-scale reactors (0.6-1.0 m).(0058} In some embodiments, the SG system may include a single let-down valve (e.g., see FIG. IM).

[0059] In some embodiments, (he SG system, may include twin, lock-hoppers (e.g,, see FIG. IN).

[0060] In some embodiments, the SG system is a bed refresh system for a pressurized spouted bed gasifier, that includes::10061] a grain leg for removing inert solids and char particles from a pressurized bed region;

[0062] a pressure let-down valve fluidly connected to the grain leg, configured to discharge solids from the pressurized bed region (e.g., about 5-20 bar) to non-atmospheric pressure, and(0063} an atmospheric cyclone separator downstream of the let-down valve, arranged to receive depressurized Solids and carrier gas, separate coarse solids to an underflow outlet, and discharge fines and gas through an overflow outlet}O064( In same embodiments, the pressure let-down valve is selected from the group consisting of a ceramic-lined knife gate valve, a pinch valve, or an erosion-resistant choke valve.(0065} In some embodiments, the bed refresh system further includes a purge gas injection port positioned downstream of the let-down valve and oriented co-currently with solids flow, configured to introduce one or more of carbon dioxide, steam, and / or recycled syngas at a threshold velocity to prevent plugging and. to convey solids into the cyclone,(0066} In some embodiments, the underflow of the cyclone is connected to one or more of a flotation cell, slurry tank:, and / or other processing vessel for separation, of char fines from inert bed material.|0067} In some embodiments, the overflow of the cyclone is connected to a fines cleanup stage including at least one of: a low-pressure secondary cyclone, a demister, and / or a gas cleanup train,(0068} In some embodiments, the let-down valve is operated intermittently for short timed pulses (about 0,5-2 seconds) at intervals of about 5-15 minutes to achieve a net bed refresh rate of about 1-5% per hour,|0069 } In some embodiments, the cyclone inlet is sized to achieve a gas-solids inlet velocity between about 15-20 m / s during each depressurization pulse,(0070} In some embodiments, the bed refresh system further includes instrumentation including one or more of: a pressure sensor on the grain leg; a differential pressure sensor across the let-down valve; a purge gas flow meter; and / or a level indicator at the cyclone underflow bin.}0071} In some embodiments, the configuration is applied to spouted bed gasifiers having reactor diameters ranging from about 0,09 m to I.0 m, and operating pressures between about 5 and 20 bar.(0072} In some embodiments, a method of refreshing a spouted bed gasifier includes: (0073} withdrawing a fraction of inert bed material from a loop-seal grain leg of the spouted bed gasifier at reactor pressure;

[0074] discharging the withdrawn material through a pressure let-down valve of the spouted bed gasifier to atmospheric pressure;

[0075] injecting a purge: gas stream downstream of the pressure let-down valve to convey the depressurized solids into a cyclone separator of the spouted bed gasifier; aridJ0076] separating coarse inerts from char fines via cyclone underflow and overflow outlets of the spouted bed gasifier, respectively.

[0077] In some embodiments, the SG system further includes a bed refresh loop comprising a standpipe, a loop-seal, a hot classifier, and lock-hoppers configured to return cleaned inert media at a threshold rate to remove material f c g., at a rate sufficient to remove ash, at about 2% bed per about 10 minutes at Alpha scale) w ithout moving parts in a hot zone.J0078] iri some embodiments, the SG system further includes a two-stage membrane separator configured to generate a permeate recycled (e.g., produce a. CO₂-rich permeate recycled) to a spout plenum to stabilize hydrodynamics and to manage dew point at a particular pressure.

[0079] The systems, devices, and methods disclosed herein have advantages over conventional solutions. The present disclosure may be more efficiently use certain types of fuel and waste than conventional systems. This reduces pollution, reduces filling of landfills, reduces noxious fumes, etc. The present disclosure may consume certain types of fuel and waste with smaller systems that are more easily located in different locations. This causes those types of fuel and waste to be more efficiently used and may reduce transportation of types of fuel and waste.FIGS. 1A-P illustrate SG systems 10(1, according to certain embodiments. In some embodiments, SG system 100 of one or more of FIGS. 1A-P may include one or more features, components, functionalities, etc. described in relation to one or more of FIGS. lA-5. For example, SG system 100 of one or more of FIGS. 1A-0 may be a multi-spout, multi- draft-tiibe spouted-bed gas ifier (e.g. „ have one or more of the features, components, functionalities, etc. of FIG. I P).

[0081] SG system 100 may include a submerged j et spouted bed reactor 110 (e.g., reactor vessel) that performs gasification (e.g„, convert carbon to syngas, allothermal conversion). The present disclosure may have significant, advantages over conventional pulverized fuel combustion. For example, the present disclosure may have better control of pollutants (e.g., nitrogen, sulfur oxides) compared to conventional systems.0082| SG system 100 may include a material actuator 120 that provides material to the submerged jet spouted bed reactor 110, a fluid actuator 130 that provides fluid to the submerged jet spouted bed reactor 110, an ash separator 140 (e.g., cyclone that spins the output o f the submerged jet spouted bed reactor 110 to collect ash and provide syngas to berecycled through the catalytic combustion and / or provided to generate energy via fuel cell 152 and / or turbine 154, recirculate ash bed if not converted) that receives the fluid-solid mixture from the submerged jet spouted bed reactor 110 and separates the ash, and / or a fluid separator 150 that receives the fluid (e.g„ receives the fluid-solid mixture) from the submerged jet spouted bed reactor 110 and separates one or more fluids. In some embodiments, a catalytic combustion surrounds at least, a portion of the submerged jet spouted bed reac tor 110 to heat the fluid-solid mixture in the submerged jet spouted bed reactor 110. In some embodiments, an outer surface of the submerged jet spouted bed reactor 11.0 is catalyst coated to cause the annular region to create a radiation field[09831 I® some embodiments, material actuator 120 (e.g,, pump, mixer, etc.) receives fluid 102 and / or solid 104 (e.g., paste slurry of biomass particles of about 80% solid and about 20% moisture, sewage sludge, slurry of biomass particles of about 60% solid and about 40% moisture, sewage sludge slurry or paste) and provides the fluid 102 and oi solid i 04 to the submerged jet spouted bed reactor 110 (e.g., via material inlet of the submerged jet spouted bed reactor 110). The fluid actuator 1.3U provides fluid 102 to the submerged jet spouted bed reactor 1 10 (e.g., via the spouted nozzle). The submerged jet spouted bed reactor 110 generates a fluid-solid mixture 106 and the catalytic combustion combusts fluid 102 on the outer surface of the submerged jet spouted bed reactor 110 to combust at least a portion of the fluid-solid mixture 106. The ash separator 140 receives the fluid-solid mixture 106 from the submerged jet spouted, bed reactor 110 and separates solid 104 (e.g,, ash) from the fluid-solid mixture 106 and provides the solid 104 to the material actuator 120. The fluid separator 150 receives fluid 102 (e.g., from the ash separator 140, from the submerged jet spouted bed reactor 110, etc.) and separates the fluid 102 to provide a first portion to the catalytic combustion, a second portion to the material actuator 120, a third portion to the fuel cell 152 to generate energy, and / or a fourth portion to the turbine 154 to generate energy. The catalytic combustion may provide fluid 102 to the material actuator 120.[0084J The submerged jet spouted bed reactor 110 may have a fluidized bed that suspends solid fuel (e.g., coal, biomass, sewage, etc,:) on upward-blowing jets of fluid (e.g., air, steam, water, etc.) during the gasification (e.g., conversion) process. This may result in turbulent mixing of gas and solids. The turbulent mixing may include a tumbling action (e.g., like a bubbling fluid) that provides more effective chemical reactions and heat transfer than conventional systems. The present disclosure is a gasification (e.g., external combustion) process that may control pollutant emissions without external emission controls (e.g., scrubbers.) The present disclosure may burn fuel at temperatures of 780 to 950 degreesCelsius (’€). This is below the threshold where nitrogen oxides form e,g,, approximately 1,400°C). The mixing action of the fluidized bed of the present disclosure may result in bringing the flue gases into contact with a sulfur-absorbing chemical such as limestone or dolomite. In some embodiments, more than 95% of the sulfur pollutants in coal can be captured inside the boiler by the sorbent. The present disclosure may have a fuel flexibility ~ almost any combustible material, from coal to municipal waste., can be burned - and the capability of meeting emission standards:(e.g.;sulfur dioxide and nitrogen oxide emission standards) without using expensive add-on controls, In some embodiments, carbon dioxide emissions can be controlled by oxy-fuel combustion or by chemical looping combustion (e,g., a form of oxy combustion wherein oxygen is supplied to the fuel via solids contact with metal oxides). In some embodiments, carbon dioxide (e.g., an almost pure stream of carbon dioxide) can then be sequestered or used for enhanced oil recovery (EOR), The present disclosure may be used in a zero-emission power plant (e.g., the present disclosure may be the essential elements in a zero-emission power plant).|0085J The SG system 100 may be a pressurized fluid bed system. This may have an advantage over atmospheric systems, The increased pressure and corresponding air / gas density of the SG system 100 may allow much lower fluidizing velocities (e.g., around 1 meter per second (m / s)) which reduces the risk of erosion for immersed heat transfer tubes. Conventionally, at elevated pressures, the heat released within the combustors increases and deeper beds are needed to accommodate the required heat transfer surface. Since air mass flow m = ρVA;the high air / gas density, p, results in much lower required bed plan area. For the same mass (m), a bubbling bed (pressurized) at 15 bar with a superficial velocity of 1 m / s will require less than one fourth of the bed plan area compared to an atmospheric fluidized bed. Because the gas turbine compressor capability sets the requirement of (he boiler and major components, the present disclosure may have a higher degree of standardization compared to conventional systems. The range of the present disclosure design sizes may be set by the compatible gas turbine sizes. So lid feels can be fed into a device of the present disclosure either by lock hoppers or by a high concentration paste (about 75% to about 80% solids and about 20% to about 25% water or possibly liquid carbon dioxide available from the captured carbon dioxide (CO₂)). The slurry feed is much simpler and requires less maintenance compared to conventional systems.|0086| SG system 100 may include a submerged jet spouted bed reactor 110 that includes a spouted bed. The spouted bed may have major advantages over conventional systems. In the spouted bed, the bulk of the mixing is provided by the injection of fluid (e,g., air, oxygen,CO₂, slurry, steam, water, etc.) through the center of the spouted bed via a nozzle (e.g., instead of the conventional method of fluidization using distributor plates and sparges). Using a spouted bed may decrease residence times for the reactions to go to completion compared to conventional systems, This may allow greater fuel throughput for the same sized reactor or a smaller and less costly reactor for the same energy output. The present disclosure may have significant advantages to applying these ^technologies to coprocessing of coal and biomass, where sufficient fractions of biomass could be used to reduce CO₂ emissions to acceptable levels without sequestration and oxy-fuel combustion.|0087] SG system 100 may include a submerged jet spouted bed reactor 110 that performs spouted: bed gasification. Spouted bed gasification may include a hydrodynamic regime where fluid (e.g., gas) enters a bed of solid particles through a single port or nozzle. The bed of particles may be expanded, suspended, and / or transported, by the upward fluid flow through the port or nozzle. The bed of particles may include particles from one or more of Groups A-D.|6088| Group A may include small particles (30-150 μm) and low density (<1,4 g / cm3),. The fluidization of particles from Group A may be easy, smooth, and homogeneous. This allows for operating with low gas Hows and controlling the growth and speed of the bubbles.|0089] Group B may include particles that have medium diameter (40-500 μm) and density between 1.4 and 4 g / cm³. The fluidization of particles from Group B may be used for high gas flow rates 'I he bubbles from fluidization of particles from Group B may grow a lot and appear al the beginning of fluidization.|0090| Group C may include very small particles (d < 30p ) and fluidisation may be difficult.(0091 ] Group D may include dense and large particles (d > 560 μm), Fluidization is difficult and non-uniform. SG system 100 may be able to better handle particles from Group D than conventional systems (e.g., Group D may be ideal for spouted beds),|0092| At a low velocity rate, a gas may percolate between the particles (e.g., granules) which may generate a pressure drop through the bed of particles. By increasing the velocity, the aerodynamic drag forces may begin to counteract the gravitational force, causing the bed of particles to expand in volume as the particles move away from each other. When the pressure drop ’Caches a critical \aiuc corresponding to the weight of the granules, the fluid phase is able to sustain the bed of particles., and this may be called the fluidized regime. Beyond this, the particles (e.g., solids) may be entrained by the high velocity jet and riseabove the level of the bed surface and subsequently fall outwards to die annulus surrounding the spout.|0093| In some embodiments, the spouted bed of the submerged jet spouted bed reactor 110 of SG system 100 may have a cylindrical geometry and may have performance optimization based on. jet or vessel geometry or particle size and / or shape effects. Spouted beds of the present disclosure have advantages (over conventional systems) such as: (1) flexibility to solids loading; (2) ability to increase characteristic residence time; (3) absence or reduction of dead zones; (4) reduced pressure drop and lower gas flow rate required to attain solids motion relative to minimum fluidization velocity; (5) wide range of operating conditions; and or (6) potential to handle coarse particles or a bed containing a wide size range and morphology of particles.|0094| In some embodiments, the SG system 100 includes a submerged jet spouted bed reactor 110 that has a spouting bed configuration. Analysis of the SG system 100 may utilize the submerged jet configuration; In some embodiments, the submerged jet spouted bed reactor 110 includes a spouted bed in which the bulk of the mixing is provided by the injection of fluid 102 (e.g,, air, oxygen, steam, water, slurry, and / or CO2) through the center of the spouted bed via a nozzle rather than the conventional method of fluidization using distributor plates and sparges. This technique can tailor the necessary residence times for the required reactions to go to completion. This may allow greater fuel throughput for the same sized reactor or a smaller and less costly reactor for the same energy output. There may be significant advantages to applying these technologies to co-processing of coal and biomass, where sufficient fractions of biomass could be used to reduce CO’ emissions to acceptable levels without sequestration and oxy-fuel combustion. In some embodiments, a predictive model may be used to configure spouted bed systems (e.g., SG systems 100) for specific applications and particle size distributions.

[0095] In some embodiments, the spout formation of a submerged jet of a submerged jet spouted bed reactor 110 enables particle recirculation pattern in the spouted bed to be determined for any configuration. In some embodiments, the particle flux and particle entrainment in the spouted bed can be determined.(0096] In some embodiments, the spouted bed systems (e.g., SG systems 100) may be configured for specific applications and particle size distributions including a configuration which has azimuthal symmetry about the spout axis. The boundaries of the spouting region may depend on geometrical factors such as cone angle, reactor aspect ratios, and superficial velocities through the bed.

[0097] In some embodiments, the SG system may include a heating configuration via catalytic combustion (e.g,, within the catalytic combustion.).J0098] The SG system 100 may provide an external heating source to the submerged jet spouted bed reactor 110 (e.g., gasifier reactor) by the use of controlled catalytic combustion on the one or more outside surfaces of the submerged jet spouted bed reactor 110 (e.g,, outside walls of the core reactor tube). The heat may be produced on the outer surface of the submerged jet spouted bed reactor 110, as opposed to the gas phase, which may provide the necessary energy for the endothermic reactions. This may be provided by (e.g., the primary enabling technology may be) the catalytic combustion of syngas to water (H₂O) and CO₂ or a component of the syngas, such as carbon monoxide (CO) to CO₂, if hydrogen production is desired. In some embodiments, the combustion process may use air or oxygen without impacting the parity of the non-combusted product gas from the submerged jet spouted bed reactor! 10 (e.g., a critical design feature may be the ability for the combustion process to use air or oxygen without impacting the purity of the non-combusted product gas from the gasifier).|009‘>| In some embodiments, the SG system 100 includes one cylindrical vessel that is a spouted bed (e.g., submerged jet spouted bed reactor 110) surrounded by an annular combustion chamber (e.g., catalytic combustion). In some embodiments, the SG system. 100 is fabricated as multiple smaller diameter spouted bed systems (e.g., submerged jet spouted bed reactors II 0) in. series that are catalytically coated (e.g., catalytic coating on the outer surfaces of the submerged jet spouted bed reactors 110), Extending the multiple tube concept may be used to scale up or down the total output as needed. Assembling the SG system 100 using multiple small-scale pieces may leverage mass production with considerable cost savings per kilowatt. For the SG spouted bed operating mode, larger diameter reactors can be used at atmospheric or slightly elevated pressures depending on the required residence times. The small, mass-produced units can be aggregated into large, energy-conversion plants. In some embodimen ts, the opera tion of a full power conversion cycle may be broken down into simpler unit processes that can be combined in a variety of ways. In some embodiments, a core grating of a system may be replaced by a spouted bed.In some embodiments, the SG system I 00 includes scale-down without as much heat-loss (e.g,, less heat-loss penalty) compared to conventional systems. The SG system 100 may not have convection and / or diffusion. The SG- system 100 may transfer heat using radiation (e.g., via catalytic combustion). The SG system 100 may be a smaller scale unit which may result in a higher surface area to volume and the generation of heat may beefficiently incorporated: into the portion of the gasifier (e.g., submerged jet spouted bed reactor 110 and Catalytic combustion) that contains the material (e.g., coal / biomass slurry) and minimizes losses to other parts of the SG system 100. This may be performed in the SG system 100 using catalytic combustion on the external surface of the submerged jet spouted bed reactor 110 (e.g., external surface of foe gasifier volume) which, may result in more uniform heating (e.g,, that is directed into the coal slurry volume). The catalytic combustion may heat the walls of the submerged jet spouted bed reactor 110 (eg., gasifier), causing the walls to radiate and take advantage of the black body absorptivity and T4 gradient where the internal coal slurry volume is cooler due to the endothermic gasification reactions occurring. Since the external surface of the submerged jet spouted bed reactor 110 (e.g., gasifier containment vessel) is catalytically coated, this may enable the decoupling of the heat generation from the gasification section and allows a wide variety of fuel to oxidant combinations;[00101) In some embodiments, the mixing in the bed of the submerged jet spouted bed reactor 110 is sufficient to obtain a substantially uniform distribution on radiative intensity within a threshold amount of time (e.g,, 30 seconds).

[0102] In some embodiments, a processing device (e.g,, executing an algorithm) may cause the SG system 100 (e.g., the recycle system) to allow substantially complete conversion. of the biomass feedstock (e.g., solid 104, fluid-solid mixture 106) to syngas (e.g., fluid 102) by sizing the reactor (e.g., submerged jet spouted bed reactor 11) and slurry flow rate (e.g., via material actuator 120 and / or fluid actuator 130). In some embodiments, the SG system 100 may recycle syngas (e.g,, provide fluid 102 output from submerged jet spouted bed reactor 110 to the catalytic combustion) and may supplement the syngas (e.g.. provide additional fluid 102 to the catalytic combustion that did not come from the submerged jet spouted bed reactor 110).

[0103] In some embodiments, the SG system 100 may be a solar fed system. The SG system 100 may irradiate the spout of the submerged jet spouted bed reactor 110 which may provide a substantially uniform temperature distribution within a threshold 'amount of time (e.g., within 30 seconds). An ultraviolet (UV) irradiation component of foe SG system 1 (X) may be replaced by a solar concentrator to provide solar energy. The SG system 100 (e.g., submerged jet spouted bed reactor 110) may be operated with less syngas (e.g,, in the catalytic combustion) for the biomass conversion. In some embodiments, the SG system. 100 may operate in a complete solar mode and may store the solar energy during solar irradiation for operation when there is no solar irradiation.In some embodiments, SG 100 may operate at a threshold pressure (e.g., high pressure operation) using biomass paste feed. Using biomass paste that has about 20% moisture and a pump (e.g,, variable speed Moyno progressing cavity pump), the SG system 100 may operate at pressures of at least 10 bar,JOO 105] The SG system 100 may be used with a wider range of concentrations of biosolids that yield a viable slurry feedstock than conventional spray atomization systems. For biosolids where good slurries cannot be utilized, it may be more beneficial to operate the SG system 100 with the spouted bed configuration (e.g., replacing the reactor core) in 'Which the oxidizing and fluidizing media is FhO and / or CCh.

[0106] A system (e.g., that has spray atomization) may be converted to be a SG system 100 that includes a spouted bed (e.g., submerged jet spouted bed reactor 110). Bubble motion, system instability, mass transfer, and developing greater control of the fluid bed processing of materials from, gasification to combustion and chemical reactions may be used with SG system 100. Computational fluid dynamics (CFD) may be used to predict physical and chemical phenomena during [he fluidized bed ptocesses of SG system 100 CFD may use mathematical models based on mass transport phenomena, energy and momentum conservation, and / or theoretical and empirical correlations. These may use a threshold processing time (e.g,, using complex, and broader models that also require powerful computers), One or more mathematical correlations may be used that describe a fluidized bed process (e.g,, based on the application).|O0107]| A set of equations may be analyzed before starting the problem-solving procedure. These analyses may be consistent with the application at hand and the available data. For combustion and gasification applications, the performance efficiency may be connected to chemical reactions and heat transfer (e.g., where the mixture between gas and solids is the critical component of the mass and energy transfer). A hydrodynamic study of the fluidized bed may be used to improve the process as tills may determine the distribution of the phases and the species involved. Improving the hydrodynamic description may be used to improve understanding of the processes in fluidized beds. In some embodiments, interfacial forces (e.g., drag force) may be considered. The choice of drag models may be used to simulate gas-solids two-phase flows. Since the drag force acts on the particles (e.g., is the only accelerating force acting on particles), the selection of drag models may ma ke a difference in the CFD simulation of the spouted beds of submerged jet spouted bed reactors 110.

[0108] A set of predictive models (e.g., a robust set of phenomenological predictive, models) and design tools may be used to characterize the behavior of a spouted fluid bedsystem in a significantly reduced timeframe. The formulation may treat axi symmetric, incompressible air (gas) flows and may treat a range of particle sizes that include those of most practical interest (e.g., Geldart A, B, C, and D particles). The modeling framework may be Euleriari and the partide dynamics may be determined based on the drag force using models.

[0109] The hydrodynamic behavior of the spouted fluidized bed (e.g.., submerged jet spouted bed reactor 110) may be based on one or more of bed pressure drop, spouting criteria, flow characteristics, how the reactors can be designed to deliver maximum residence time and fuel conversion, etc. In some embodiments, a twin fluid model and / or discrete element (DEM) in a 2D fluidized may be used. The submerged jet spouted bed reactor 110 may be optimized based on the fluidics and combustion. The spouted bed hydrodynamics of the submerged jet spouted bed reactor 110 may be modeled as those of a submerged turbulent jet and may be compared with experiments in the flow visualization system,

[0110] The laboratory flow visualization of the present disclosure (e.g., a proposed SG Spouted bed reactor of the present disclosure) may be used to assess the potential performance uses by using UV fluorescent plastic beads for the bed.material,

[0111] The average recycle time of material in the SG system 100 may meet a threshold recycle time, A hot wire anemometer may be used to measure the airflow velocity without the beads (e.g., to understand what the maximum velocity of the gas may be and to establish a minimum spouting velocity), Monitoring the trace of the black beads may be used to measure the average recycle time of the beads. The average recycle time may be about 11.44 s, The recycle time of the beads may be used to determine how the particles will recycle in an actual set-up. This may be used to improve the efficiency of the gasification of biomass particles, so teejek’ tunc may establish hou ufien the partules of bumwss are rec Jvd hack mm the spout.

[0112] In some embodinients, the SG system 100 (e.g., submerged jet spouted bed reactor 110) may meet threshold radiation transfer properties. The average time that beads lose fluorescence may be measured and the intensity as a function of aperture height of the spectrometer, spatial position of the cylinder, and the aperture diameter of the spectrometer may be used to determine what kinds of visible lights that particles (e.g., beads) emit most under an ultraviolet source light. The fluorescent state decay times may be about 1.2-14 seconds for the dominant wavelengths (c g. about 500-531 nanometers (nm)). For each trial, the position of the UV source light may be about the same. The diameter of the aperture may be about 1.24 millimeters (mm). The dials on the spectrometer may be about 163, 175.5, 188,200.5. and 212. The wavelengths corresponding to the dials niay be about 500, 531.25 nm, 562.5 nm, 593.75 nm, and 625 nm.100113 By measuring the decay spectra of the fluorescent beads, an average time for the beads to lose fluorescence may be about 12-14 seconds. The major wavelength emitted by the glass beads may be at a wavelength, which illustrates the ability of glass beads to emit green visible light (531,25 nm) may be the strongest.100114] The recycle time may have an effect on radiation intensity; Since the spout is being flh-mtnated by the UV light source, the intensity at any potnt away iron?, the spout may be a function of the recycle time, the number of recycles n and the lifetime of the fluorescence states. This effect can be analyzed by die following equations100115] f100116]!x=

[0117] I₀ - intensity of constantly illuminated beads in time period bead passes thru spout

[0118] I₀ ~ intensity in the spout

[0119] Iₓ is the intensity at a distance x from the spout

[0120] τ - (lifetime of excited state)

[0121] λ - characteristic length (40 cm here)

[0122] t_R ~ recycle time for bead thru spout

[0123] Hydrodynamics of the spout bed of the SG system 100 may be determined using the Landau submerged jet. The spouted bed may be analyzed based on the aerodynamics are those of a turbulent submerged jet. Outside the turbulent region, there is a potential flow and the axisymmetric submerged jet may be analyzed in spherical polar coordinates (r and 0) by the use of stream functions ψ, φ defined as follows:

[0124] (7), ψ = (8),

[0125] where ζ = cos θ

[0126] f = (C·D·sin²θ) / (1 - cos θ)(Landau solution) (9)

[0127] where d is a constant (e.g., 1.0) determined from momentum conservation of the jet. In this ease equation 9 may become:{00128] = br(l + f)(10)

[0129] For the conditions in a simulated reactor (e,g., of SG system 100), the jet can be considered a strong jet In turbulent flow, which is confined to a narrow cone of half angle of a. This yields the following expression for the velocities outside of the jet cone (i.e., θ > α). (00130] vf. - “"“(11)

[0131] v_θ = -cor(θ)(12)

[0132] v(magnitude) = b / r · sin(θ)(13)

[0133] ψ = (expression)(14)(00134] The constant b is adjusted to match the flowrate Q₀ from the blower using the following arguments. The radius of the conical spout is related to the distance from the blower orifice, z, by(00135] R - ztana (15)(091.36] Since the momentum, of the fluid exiting the blower is to be conserved, it may be the same through a hemisphere of radius r from the blower orifice for any value of r. Since the momentum flux is proportiotsal to the square of the velocity, the central velocity may decrease as z"1. Since the volumetric flow in the spout (Q) at any z is (velocit )x(cone cross section area), it follows that Q = Bz equals the volumetric flow Q₀ at r = a, we obtain;|00137] - Ba(16)(00138] where a is the linear dimension of the orifice which we take as the diameter.(00139] The increasing flow rate with z is due to entrainment of fluid thru the conical surface. The entrainment flow rate thru a conical section intersected by two planes with z₂ > z₁ is to equal the increase in Q, We have the following:(00140] 2rr(^{r 2 a) ■■■• V’CG (%)"■ fe )< W(00141] This yields;

[0142] (18)K = 1 / (cos α - 1)

[0143] where β is a numerical constant of the order of 1.0,

[0144] The central spout velocity, u, may follow the Landau solution (U₀ is the blower exit velocity).(00145] w ~

[0146] In some embodiments, digital modeling methods may be used. To better understand the dynamics of the spout bed of the SG system 100, a computer model of the reactor may be created using a physics engine (e.g., using a three-dimensional (3D) modeling software). Thismay allow tracking each of the properties of particles individually. Tire model may account for the size and quantity of particles in the reactor (e.g., submerged jet spouted bed reactor 110). Models may be used to simulate spout-fluid beds using smaller and more numerous particles using both DEM and Euler-Lagrange methods.|O0147] To create the model, a particle system may be created within, a rigid chamber and a first plane may be placed beneath the particle system with a blower cen tered in the area of the spout, Turbulence and drag may be added to the spout. To simulate the down drafts near the edge, a second plane with a blower may be placed under the first plane and the direction of ■the new blower may be set. to be downwards. Above the system, a light may be added to simulate the UV bulb present in the physical system. The simulation may not include collisions of the beads, so the beads may not pool at the bottom of the chamber. To simulate the pooling, the sides of the cone at the bottom of the chamber may have a viscosity added, such that the beads would cling to and slowly progress down the side towards the blower.

[0148] The values for the turbulence, drag, viscosity, brightness of the light, and strength of the blowers may be modified such that the paths of the beads visually matched the paths of beads in the physical chamber. The viscosity may be set such that the beads’ recycle time matched the about 11 -second recycle time previously measured. The beads may be set to absorb light from the lamp at a rate proportional to the inverse of the square of the distance of the beads from the lamp and would then emit radiation at a constant rate, with a minimum of zero total irradiation of a bead. The beads may cease to absorb radiation once the beads began to pool, to simulate the shading of beads in the bottom of the reactor, The simulation may be run for about 500 frames at about 24 frames per second. The irradiance of each bead may be averaged over time at each point in the reactor (e.g., submerged jet spouted bed reactor 110). The results may be mapped with a false-heat map. This shows radiation provides uniform temperature distribution throughout the bed (e.g., submerged jet spouted bed reactor 110) (e,g., false heat map of average bead irradiance in the bed after about 60 seconds of irradiance).

[0149] This simulated irradiance may substantially match the observation, The physical bed may run for about 1 minute and images may be captured of the resulting distribution of light from the fluorescent beads. Both the simulated and physical distributions may show a substantially constant distribution of intensity over the entire reactor (e.g., submerged jet spouted, bed reactor 110). This may be because the recycle time of the beads may be similar to the decay time of the fluorescence in the beads, causing the average illumination of thebeads to substantially hit equilibrium throughout the chamber 9e.g., submerged jet spouted bed reactor 110).J00150} The designed laboratory-scale conical spouted bed reactor may be effective for mixing the homogenous plastic beads and investigating the movement characteristics of the plastid: beads under the UV source light. During the experiment, a series of desirable experimen tal data may be measured and calculated. The average recycle time of the beads may be about 11,44 seconds. The beads may be substantially thoroughly mixed in about 30 seconds, which may he an effective residence time for the reactor. Based on this, a 1 -meter diameter reactor could generate about lOlfk s (kilowat) in syngas. The spout aerodynamics may be analyzed in terms of a submerged jet.[001511 To determine the bead flux, an interruptible laser beam may be introduced along a diameter of the reactor chamber (e.g., submerged jet spouted bed reactor 1.10) at different heights. The beam may extinguish each time a particle passes through the beam,[001521 The number of beads pas sing through the collection time (T) may be determined by measuring (he Jutj cycle, Dturne beam nn T), through the following equation:[00153} D = ~r.(20)[001541 Yielding the equation for N[001551 N ~ “^ ( 21)[001561 where t is the time it takes for a bead to pass thru the beam which was about 1 / 240 seconds, and T was about 1 / 4 seconds.[001571 For a bead to break the beam, the beam is to pass through a rectangular strip with the beam as the eenterime 2 bead diameters, which yields an area of 20 cm3, The flux through any horizontal plane is then N. / (T20) since the system is axi-symmetric. The bed flux has the same characteristics as those of a submerged turbulent je t when plotted as a func tion of a / h, where a is the blower nozzle diameter, as is the case for the air velocity. The spout can be constricted a cotie of half angle a.[001581 As there is an increase in height along the cone, the bead current in the spout is obtained by multiplying the flux by ff( / ituna} and the current therefore increases linearly with h, which is due to entrainment of beads in the spout (e.g., each bead passes twice through a horizontal plane),[00150}. Particles of abo ut 1 millimeter may be analyzed. The residence time (R) for 1 (10- micron particles for 80% carbon conversion in the SG tests may be about 6 seconds.Assuming that R is proportional ta the particle diameter (e.g„ average particle diameter ofabout 500 micrometers (pm)), about 60 seconds is used to achieve the same results in the spouted bed SG system 100. Since the particle recycle time was 10 seconds in which the particle was exposed to a uniform radiation environment there may be 6 recycles. Sizing for 2 -minute residence time in the reactor (12 recycles), there maybe ash recycling. The amount, of ash recycling can be dctertnined from analysis oacc the actual single pass carbon. conversion for the specific biosolids is determined. A l-minute residence time may be used for analyses. Process intensificafiah can be. applied by enhancing single pass carbon conversion using concentrated solar illumination through the spout replacing the UV system. There can be advantages to enhancing energy conversion of biomass with solar energy. The submerged jet spouted bed reactor 110 may be a solar spouted bed.100160} One or more components (e.g., submerged jet spouted bed reactor 1 10, cataly tic combustion, etc. ) of the SG system 100 maybe constructed out of Haynes 230 high temperature alloy operating at 1 0 °C. The reactor (e.g., submerged jet spouted bed reactor 110) may be inserted in the SG core and may be operated at a pressure of at least 10 bar. The 1 millimeter hydrotbermally treated biomass particles may be injected into the bed using a Moyno progressing cavity pump. The spout may be created using steam from a steam generator (e.g., fiuid actuator 130). The steam may be injected through a 10-cen.timeter (cm) diameter port (e,g., nozzle, spout inlet). The minimum spouting velocity at 10 bar and for 1 mm particles may be about I nrs.|001611 The spout may be a submerged jet and with a 60-second residence time an the SG system 100 may produce about 400 k xft. A 1 ~m:!SG system 100 may produce about 1.5 MW:.:.:.100162} in some embodiments, a submerged je t spouted bed reactor 110 of SG system 100 may replace coal slurry with biomass slurry (e.g., liquid bioslurry injection).100163} In some embodiments, the submerged jet spouted bed reactor 110 of SG system 100 may be a 10 cm diameter single tube unit (e.g., that has a biomass slurry feed intake).|001 4} In some embodiments, SG system 100 is a tunable catalytic gasifier that may 'be used for gasifying coal, biomass, and / or other foel sources. The submerged jet spouted bed reactor 110 (e.g., gasifier reactor) may be heated by a catalytic combustion (e.g., catalytic tube or other jacket) that generates heat by catalytically combusting syngas (e.g., syngas produced by the SG system 100), The SG system 100 may be a chemical reactor that performs gasification processes.}O01 5| With the financial and environmental costs associated with extracting and refining fuels, there is an increased urgency to find sources of alternative energy and / or alternativeways of processing feels (e.g., coal, biomass, and other naturafly-occunriug fuels). Some fuels may be in solid form that is difficult to utilize by conventioaal systems. The SG system.100 may be able to convert such fuels into useful form.[001661 In some embodiments, fuel is provided to a submerged jet spouted bed reactor 110 (e.g., reactor chamber) heated by radiative heat (e.g,, by the catalytic combustion). The fuel may be heated in the submerged jet: spouted bed reactor 110 (e.g., reactor chamber) so as to gasify at least a portion of the fuel to a syngas that may include one or more of hydrogen, carbon monoxide, carbon dsoxtde, methane, or any combination thereof.[001.67J FIG, t A illustrates a SG system 100, according to certain embodiments. In some embodiments, material actuator 120 mg,, pump) receives fluid 102 (e,g.., CO2, H2O, etc.) and solid 104 (e.g., coal, biomass, sewage, etc.) and provides the fluid 102 and solid 104 (e.g., as a fluid-solid mixture 106) to the: submerged jet spouted bed reactor 110. Fluid actuator (e.g,, pump, blower, etc.) may provide fluid 102 into the submerged jet spouted bed reactor I I 0). The catalytic combustion mat' provide heat to the submerged jet spouted bed reactor 11.0 which may pro\ ide fluid-solid mixture 106 (e.g., Ha, CO, HeO, ash, etc.) to an ash separator 140, The ash separator.140 may provide solid 104 (e.g,, ash) to the material actuator 120 (e.g., to be recycled). The ash separator 140 may provide fluid 102 to the fluid separator 150. The fluid separator 150 may provide fluid: 102 (e.g,, HjO,ete.) to the material actuator 120 (e.g:., to be recycled), fluid 102 (e.g., C0, etc.) to the catalytic combustion, fluid 102 (e.g.. Ha) to a fuel cell 152 (e.g., solid oxide fuel cell (SOFC)), and fluid 102 (e,g., CO) to a turbine I54 (e.g., internal combustion engine), Fluid 102 (e.g,, syngas) may be provided to the catalytic combustion to combust and provide heat to the submerged jet spouted bed reactor I I.0, Fluid 102 (e.g., COa) may be provided from the catalytic combustion to the material actuator 120 (e.g., to be recycled).[00168) FIG. 1 B illustrates a SG system 100, according to certain embodiments. Material actuator 120 (e.g., slurry prep) may receive solid 104 and / or fluid-solid mixture 106 (e.g., biosluny intake) and fluid (e.g., H> O in and / or H2O recycle). The material actuator 1 0 may provide the fluid-solid mixture 106 (e,g., slurry) to the submerged jet spouted bed reactor 110, The submerged jet spouted bed reactor 110 may provide a fluid-solid mixture 106 (e.g.. Hr, CO, H;’O, ash, etc.) to ash separator 140 which may provide fluid 102 (e.g., Ha, CO, FfcO) to fifed separator 150. Fluid separator 150 may provide fluid lf)2 (e g... HA) recycle) to the material actuator 120. Fluid separator.150 may provide a first portion (e.g., about 25%) of fluid 102 (e.g,, Hi, CO (syngas)) to the catalytic combustion chamber 160 and a second portion (e.g,, about 75%) of the fluid 102 (e.g., syngas) to fuel cell 152 (e.g., SOFC) and toturbine 154. Catalytic combustion chamber I 60 may receive fluid 102 (e.g., fluid in and 25% syngas from fluid separator 150) to combust and heat the submerged jet spouted bed reactor 110.J0O169j FIG. 1C illustrates a SG system 1 0, according to certain embodiments. Submerged jet spouted bed reactor 11.0 (e.g„ gasifier, cataiytieally-heated gasifier) may receive a mixture of fluid 102 (e.g,, CO₂, HzO, etc.) and solid 104 (e.g., coal) (e.g., receive fluid-solid mixture 106 via an inlet): and may receive: a fluid 102 (e.g., via a spout nozzle). At least a portion of the fluid-solid mixture 106 (e.g., coal) may be gasified and may react to form a fluid-solid mixture 106 (e.g., syngas that contains ash, hydrogen* water, and carbon monoxide). The submerged jet spouted bed reactor 110 may provide a fluid-solid mixture 106 (e.g., Hz, CO, HO, ash, etc.) to ash separator 140.[001701 Ash separator 140 may separate solid 104 (e.g., ash) from the fluid-solid mixture 106 (e.g;, ash separator 140 removes ash from the syngas). The ash separator may provide fluid 102 fem the fluid-solid mixture 106 to a fluid separator 150 which may separate a first type ol fluid H C (e.g. H.-O. water is removed from the syngas to leave behind hydrogen and carbon monoxide). The fluid separator 1 0 may provide one or more second types of fl uid, (e.g.. He, CO) to fuel cell 152 and turbine 154 (e.g., hydrogen, and carbon monoxide may be introduced to a fuel cell or to a turbine where they are used to produce energy). The fuel cell 152 may produce electricity from the hydrogen and the carbon monoxide.[00171| The fluid separator 150 may provide about 50% CO to a CO splitter 156 (e.g,, some of the syngas may be introduced to the carbon monoxide splitter 156) which may provide COi to the catalytic combustion chamber 160 (e.g,, carbon monoxide is combined with oxygen and then fed to a catalytic combustion chamber 160), The catalytic combustion chatober 160 may receive the COz from the fluid separator 150 and may receive Oz. The catalytic combustion chamber 160 may combust the input fluid 102 and may heat the submerged jet spou ted bed reactor 110 (e.g., the carbon monoxide and oxygen may then be reacted in the catalytic combustion chamber to provide heat to the submerged jet spouted bed reactor 110). In some embodiments, the catalytic combustion chamber 160 may include a platinum-based catalyst (e.g., on the outer surface of the submerged jet spouted bed reactor 110) that reacts with the carbon monoxide and oxygen to evolve heat, such as is done in a catalytic converter. Such a converter may convert carbon monoxide and oxygen to carbon dioxide.[00172| In some embodiments, flic reactions driving coal and biomass steam gasification are listed below;(00173] Steam Refonni n g R cuction(00174] C-!-H.-O~*€C> f-H ■ All -+131.3 kJ / mol(00175] Boudotiard Reaction|00170] CKXh-»2CO AH- + 172,5 kJ7mol(00177] Char Oxidation(00178] C+%Ch (from biomass puct«te)™*CO(00179] AH- 110.3 kJ / ol(00 80] Reverse Water Gas Shift Reaction.(00181] HJ+CO^CO+HJO AH==+41.2 fcj / olJ00182] In addition to the aforementioned reactions, pyrolysis, decomposition, and other reactions may also be occurring to cleave and condense the coal and / or biomass lattice structure, and to react the oxygenated minerals to release Os.(00183] In some embodiments, the particles of solid 104- and / or fluid-solid mixture 106 is at least partially charred and / or undergoes hydrothermal treatment to fonn a stay and'or a paste.(00184] In some embodiments, fluid 102 (e., syngas and / or air) enters a tubular catalytic combustion chamber 160 (e,g., catalytically coated tube) that is a tubular catalytic combustion chamber 160 suirormds a submerged jet spouted bed reactor 110 (e.g., catalytically heated tube reactor) that is a tubular reactor vessel. The catalytic combustion chamber 160 (e.g., catalytic combustor) may function as a heater jacket around the submerged jet spouted bed reactor 111) (e.g,, reactor tube). Syngas generated (e.g., evolved) from the submerged jet spouted bed reactor 110 (e.g., reactor) may be recycled back (o the catalytic combustion chamber 160 (e.g., catalytic combustm:). The amount of reac tor product syngas (e.g., from the submerged jet spouted bed reactor 110) recycled to the catalytic combustor (e.g., catalytic combustion chamber 160) may be from about 1% to about 99% of the reactor product syngas (by volume or by weight), or from about 10% to about 80% of the reactor product syngas (by volume or by weight), or even about 50% of die reactor product syngas (by volume or by weight), Syngas may also, in some embodiments, be used as the atomizing fluid in the SG system 1 0 (e.g., fluid-solid mixture 106 to be provided to submerged jet spouted bed reactor 110). In some embodiments, submerged jet spouted bed reactor 110 may be heated by one or more of catalytic combustion chamber 160, a radiant heater, an electric heater / element, solar radiation, traditional combustion (e.g., burning fossil fuel) and / or micro ave radiation to impart heat to the interior of die submerged jet spouted bed reactor 110,(09 85] In some embodiments, catalytic combustion may affect best generation at the surface of a substrate (here, a metal surface).. Heat may be produced and released at the substrate surface, which is located within the momentum boundary' layer of fluid flow. In some embodiments, heat generation in die catalytic combustion, chamber 160 may be by homogeneous combustion, which process gives rise to heat generation outside the momentum boundary layer. The catalytic combustion approach can thus deliver heat direcdy at the substrate surface. Because heat conduction is much slower through the gas including the momentum boundary layer than the metal substrate, using catalytic combustion can increase heat transfer by a significant amount, even as much as by a factor of I (100f|001S6 FIGS. 1D-L illustrates SG systems 100, according to certain embodiments, In some embodiments, SG system 100 has an enhanced reactor configuration (e.g., of submerged jet spouted bed reactor 110) for integrated SG system 100 design.(00187] In some embodiments, the reactor design (e.g., of submerged jet spouted bed reactor 110) of d e SG system TOO is enhanced to optimize slurry injection (e.g., via material actuator 120), steam flashing (e.g., of fluid 102). and solids circulation (e.g., solid 104 fto ash separator 140) for improved thermal and conversion efficiency, The reactor (e.g., submerged jet spouted bed reactor 1.10) may include a spouted bed (e.g., about 22 cm high) filled, with solids (e.g., approximately 6 kg of sand in the 20 cm diameter prototype). To manage bed material levels, a weight-loss feeder may monitor and control the sand drain rate (e.g., typically at 0.5 kg every 10 minutes). After use, sand is processed through a cyclone separator to remove ash and char, and then recycled into an agitated slurry feed tank.(001881 The slurry (e.g., including about 70% solids content of either coal particles or biomass energy particles (BEP)) may be injected through a spouting tube 170 (e.g., a Baynes 2. hi alloy tube with about 3 cm diameter using a Moyno progressing cavity' pump at about 15 bar). The spouting tube 170 may not only support the fluidization process but also may provide the necessary steam derived from the slurry water itself The SG system 100 may operate at a reactor pressure of approximately 10 bar.(00189] In some embodiments, parameters derived from the SG system 100 may include approximately:(00190] Coal / BEP injection rate: 0.00556 kilograms / second (kg / s):(00191] Saud injection rate: 04)0083 kgfe;(00192] Total solids feed rate: 0,00639 kg / s;(00193] Total slurry injection rate: 0.00913 kg / s;(00194 ] Water injection rate: 0.00274 kg / s:

[0195] Steam generate© (at 10 bar and U 00®C): 0.0 438 m-Vs (4.38 L / s);|00.196| Injection tube cross-sectional area: 7.07 * IO“4rn2; and / or|00197| Resulting steam velocity: 6.2 m / s.

[0198] In some embodiments, to have substantially full steam flashing (c.g.ffoil steam flashing) of the slurry before entering the bed (e.g., submerged jet spouted bed reactor 110), the bottom plate of the bed may be eievated about 25-30 centimeters (cm) above the injection point to provide proper momentum buildup and thermal exposure.(00199) In some embodiments, the integrated approach of SG system 100 allows effective particle spouting, optimizes reactor residence times, and enhances energy conversion efficiency (e.g., when handling challenging biomass slurries or coal / BEP mixtures). The use of spouting tube 170 (e.g., Haynes 230) and high-pressure operation may provide darability and performance"under extreme thermal loads. The SG system 100 maybe illustrated by one or more of FIGS. I D-F.

[0200] Referring to FIG. I D, SG system 100 may include a catalytic combustion chamber 160 that includes a mac tar 110 (e.g., submerged je t spouted bed reaetor). The reactor 110 may receive fluid 1 <) ’ x ia fluid actuator 130 and may receive solid 104, fluid 102, and / or fluid-solid mixture 106 via spouting tube I 70 (e..g., from valve 132. The reaetor 110 may include a spouted bed (e.g., at about 10 bar) and an elevated bed. The spouting tube 170 may provide material into the reaetor 110 between spouted bed 112 and elevated bed 114.

[0021] Referring to FIG. I E, SG system 100 may be an indirectly-heated spouting bed coal gasifier associated with spouting fluid. Material 22O(e.g,, coal-water slurry plus clean sand) and / or fluid 102 (e.g., product gas) may be provided to the interior volume 2.12. A spouting tube 170 may be provided to the interior volume 212 (e.g., material may enter the interior volume 212 via spouting tube 170). The reactor 1 10 may be an indirectly heated spouting bed coal gasifier. The interior volume may include a bed of material 1 0 (e.g., bed) and fluid 162 e,g.,:injected steam). The SG system 100 may include a drain 174.

[0202] Referring to FIG. IF, SG system.100 may include a reactor 110 and may provide syngas recycle to catalytic wall heating. The SG system 100 may include a spouting tube 170 (e.g., central spouting tube) that receives fluid 102 (e.g., steam). SG system 100 may include walls 210 (e.g., spouted tub) that may receive fluid 102 (e.g., steam) and material 202 (e.g., oxc’lvd feed) The SG ssstem 100 may include mateual 202 G g spouted h<-d) may tct eno fluid 102 < g. i ecycled syngas) and may provide fluid 102 (e,g., syngas) via fluid outlet 208. Theicactor may perforin annular catalytic combustion 176.(00203] 'The SG system lot) may introduce syngas recycle loop to support catalytic wall heating in the annular zone surrounding the main spouted bed reactor. A metered portion of hot syngas (e.g,, about 7- 10% of total output) is recycled after coarse char and / or ash separation. This stream is redirected into an annular heating jacket or passage along the inside wall of the reactor. The annulus may contain: a cataly tic material (e.g„ Rh / A12O3?Pt / CeZrQx) supported on high-temperature alloy fmsswhich combust the syngas upon contact with air or oxygen,(00204] This catalytic heating provides radiant energy to (he reactor interior and may enable al.lotherm.al operation ( e.g... folly allotbennal operation.) without external heaters.(09205] The SG system 100 may cause about 7-10% of cleaned syngas to be recycled for catalyst combustion, SG system 100 may cause char and merits to be removed prior to recycle using cyclone separator. SG systems 100 may provide recycle line feeds into the annular catalytic chamber surrounding the reactor. Combustion heat may radiate inward through high-emissivity reactor Wall This may enable high-temperature allothermal operation (e.g., about 1000- 1 100% i. This may be compatible with modular single-jet or multi-jet configurations This may allow flexible use of oxygen, or air as combustion agent in annulus, (09206] In some embodiments, water and / or coal ratio analysis may be used for stable spouting. The analysis may be used to determine minimum required water-to-coal ratio (W / C) to cnsiirc stable spouting in the gasifier system (c.g,, I -meter diameter gasifier system) using: an imderbed spouting tube (e.g,, single 3.5 cm undefoed spouting tube) and about 60% solids overbed slurry feed,(00207] In some examples, the calculations and results may include:(09298] Gasifier diameter: 1.0 m(09209] Spout expansion diameter: 0,20 m(09210] Mim um spouting velocity (superficial); 0,6 in / 10921.1] Spout cross-seettonal area: 0.0314 tfo(00212] Minimum steam flow required: 0,0188 tfo / s(00213] Steam density at ICKX)®C, 10 bar: -1.27 kg / hfJ00214] Required steam mass flow: —86 kg / hr(00215] Water needed for flashing (90-95% efficiency)': - 1 kg / h.c(09216] Water-to-coal ratio required: -0.15 (15%)(09217] Water in 60% slurry: 400 kg / hr (W / O 0.67)(00218] Available water may be sufficient for steam spouting.

[0219] In some examples, die underfeed spouting tube (e.g., single 3.5 cm underfeed spouting tube) may sustain a stable spout with just about 91.kg / hr of water flashing to s team.. Since the about 60% slurry provides about 400 kg / hr of water, only about 23% of this water is to be vaporized in the spouting tube. The rest can flash or evaporate in the bed. The SG system 100 may provide robust and stable spouting performance.

[0220] In some embodiments, syngas recycle may recycle fraction for steam generation: and endothermic support. This analysis estimates the required frae ion of cleaned syngas to be recycled in the I -meter gasifier system with a single 3 5 cm tinderbed jet and ofrx, sohds overbed shiny feed. The recycled syngas supports both steam generation to maintain spouting and the heat needed to sustain endothermic gasificationreacrions,

[0221] In some examples, ike recycle to flash. water in. spouting tube may include;

[0222] Water to flash; 1 JcgZhr1002231 Enthalpy required (25%’ to 1000%); --295O kJ / kg100224] Total energy for flashing: -74 aS kf 00225] Syngas eueray output • 2%<l kW

[9226] Required syngas recycle for flashing: -2.9%

[0227] In some examples, the recycle for endothermic gasification support may include:

[0228] Typical endothennic heat requ irement for steam gasi fication: -350-400 kJ / mol carbon

[0229] Based on carbon input rate (600 kg / hr): - 165-180 kW

[0230] Required syngas recycle to annular catalytic wall heater: ~7% of output

[0231] T otal required syngas recyc le (flashing 4- gasification): -10%

[0232] In some embodiments, a total of approximately 10% of the cleaned syngas may be recycled:

[0233] about 2, % to flash water in the underbed spouting tube

[0234] about 7% to support endothermic gasification via the annular catalytic heating system

[0235] This may allow allothennal operation (e.g.,, foil altathermal operation) without compromising overall System: efficiency.

[0236] In some embodiments, the SG system 100 may be designed for about 10% syngas recycle to wall hearing annulus. The SG system 1 fXl may enable recycling: about 10%> of cleaned syngas from the reactor output and injecting it into the annular space surrounding the gasifier core for catalytic combustion-based: wall heating. The goal is to provide sufficient heat for:00237} Flashing water in the underbed spouting tube ('"2.9%)|0023S) Supporting endothermic gasification. (--7 )|00239| In some embodiments, the SG system 100 may include a high-temperature metered split line from the main syngas outlet, a particulate- tree cyclone line for clean syngas routing, a control valve, and / or an injection nianifold evenly distributed around the annulus. Oxygen or air may be mixed with die recycled syngas at the annular inlet to initiate catalytic combustion along: the internal wall coating,(002401 T his allothermal strategy may maintain high radiative wall temperature (e.g., about 1000- 1100°C) and enables effective gasification with limited external heat requirements. (00241] seme embodiments, SG system 100 may have one or more of the following features:(00242] 10% syngas diverted before power generation or compression(00243] Recycle line equipped with ej clone and filter to remove particulates1002441 Automated control valve regulates flow into annular chamber1002451 Oxygen injection atmanifold ensures catalytic combustion at wall(002401 Radiant heat transfer sustains bed temperature and flash tube heating(002471 Pressure-rated annulus surrounds reactor with inlet mixing ports(O0248| Fully integrated with single-jet or multi-jet gasifier architectures|O0249] Referring to FlG. 1G, SG system 100: may be a dual-feed spouted bed gasifier. The SG system 100 includes a reactor 110 that: may be a spouted bed gasifier that may have a first material inlet 202 (e.g., overbed spray nozzle), a second material inlet 202 (e.g., for insulation), a port for fluid 102 (e.g., syngas port), a material outlet 204 (e.g., to provide ash and / or char), etc. SG system 100 may include a sight glass 178, and / or an underbed shirty feed 179.(0G2501 Iti some embodiments, the SG system 100 is enhanced to include a dual-fee slurry injection approach, allowing material 220 (e.g., slurry) to be injected both from the bottom spout and from the top overbed inlet (e.g., material inlets 202 of FIG. 1 G). This dual-feed configuration may enable dynamic adjustment based on the viscosity and composition of the feedstock. A control system (e.g., Al control System) may manage the feed routing in substantial real-time (e. m: real-time) to optimize atomization and reaction efficiency. (00251] The reactor 110 (e.g., spouted bed reactor) may be constructed as a flat-bottom configuration, where an elevated bed plate supports the inert bed material (e.g., sand or alumina). Under tire plate, spouting tubes may be heated via catalytic wall combustion. Wateror shirty injected through the spouting tabes may flash to steam (e.g., fluid 102), initiating the spouting behavior without external steam injection.|00252] In the top-feed configuration, the material 220 (e.g., shiny) is injected from above to allow for substantially uniform (c.g., uniform) particle distribution and improved atomization over the bed. In the top-teed configuration., only water may be passed through the spouting tubes to maintain bed fluidization.{00253] In some embodiments, to maintain bed integrity, about 7% of the inert bed mass may be periodically drained about every 10 minutes through a valve (e,g., computer-controlled valve); This partially used material may be sent to a hot cyclone separator, where ash and char are removed. Clean inerts: may then be returned to the slurry mixing tank and reinjected into tire reactor 110,{002541 The catalytic heating system on the outer walls of the reactor 110 may utilize a platinum-coated surface. About?0‘J <> of the fluid 102 (e.g., gas) produced may be recycled to this annular heating zone, along with controlled air flow, to sustain a substantially uniform internal ietnpcmtui\- (c g, of about IdtKCC){00255] Following mitral gas cleanup using a high-temperature cyclone separator, the fluid 102 (e.g., gas) may either be:|00256| I) routed directly io an engine or turbine for electricity generation; or|00257| 2) sent through a water-gas shift reactor to convert CO into H2 and CO2, where foe CO2 may then be removed using chemical absorption or membrane separation (e.g., yielding nearly pure hydrogen which may be stored or used in fuel cells).{00258] hi some embodiments, the SG system 100 is integrated with a modular hydrothermal treatment (HTT) reactor for pre-processing biomass or waste sludge into slurry which may allow a folly closed-loop biomass-to-energy system. Waste heat from the gasifier and power modules may be reused to operate the HTT reactor, maximizing thermal efficiency.{00259] The SG system 100 may support fuels ranging from biomass to coal slurries and other energy-dense feedstocks, Improvements may include.' the dual-feed slurry system; Catalytic wall heating; elevated fiat bed plate with Steam generating injection tubes; AI- coutrolfcd inert recycling and feeding; and syngas purification with hydrogen production capability.{00260] These features may result in SG system 100 being a compact, modular, highly efficient gasification system adaptable for di verse feedstocks and distributed deployment.(0026! ] FIG, 1 H illustrates a SG system 100 that includes a reactor 10 and may be a dual¬ cyclone system (e.g., syngas cleanup and inert recycle) that may include a syngas cleanup cyclone 182 and an inert recycle cyclone 184. The SG system 100 may include a valve 172 (e.g., metered valve) that may provide material from reactor 110 to the inert recycle cyclone 184. The reactor 110 may provide fluid 102 (e<g., syngas) to the syngas cleanup cyclone 1 2.

[0262] In some embodiments, SG system 100 may include dual hot atmospheric cyclones for syngas and bed inert cleanup (e.g., dual hot atmospheric cyclone configuration for syngas and inert cleanup). The SG system 100 may use two separate hot atmospheric separators for efficient and maintainable cleanup,

[0263] The first cyclone system (e.g,, inert recycle cyclone 184) may handle bed drain material (e.g,, inert sand and / or ash), operating independently and recycling cleaned inerts back through the slurry feed system.|0()264| The second cyclone system (e.g., syngas cleanup cyclone 182) may handle high- temperature syngas after pressure reduction, removing char and fine ash at atmospheric pressure prior to cooling or end.~iise.|O0265] The separation may allow optimal flow control, may avoid tar condensation, may simplify maintenance and may reduce cost.[O0266| The inert recycle cyclone 184 may receive used material from the reactor 110 and may provide clean material, (e.g., clean an / or inert slurry). The syngas cleanup cyclone 182 may receive syngas (e.g., via a pressure reducing valve (PRV) from the reactor 110) and may separate the syngas into cleaned syngas and other material,

[0267] In some embodiments, SG system 100 may provide syngas cleanup for gas-powered generator, A cleanup system may use syngas from a reactor 110 (e.g,, spouted bed gasifier) in a gas-powered generator engine.[002681 A valve (e.g., PRV) and hot cyclone may be used for initial pressure drop and ash removal. A heat exchanger may cool syngas below 100 degrees Celsius. Tar scrubber (e.g., wet or dry) may remove condensable hydrocarbons. Fine filtration (e.g,, less than 1 mg / Nml) may eliminate engine-damaging particles. Optional ZnO bed may.remove HS and protect engine internals. Moisture removal and pressurization may occur before combustion. This setup may enable safe and efficient engine operation while maintaining generator life and reducing fouling and cortosipn.[002691 In some embodiments, the SG system.100 may provide one or more of a pressurized spouted-bed design, dual-path slurry teed rationale, bed refresh loop, membrane CCh recycle.and / or the verified cone and / or draft-tube spouting. The SG system 10Q may or may not inchide reactor length and bead curves.J00270| In some embodiments, the SG system 100 includes a pressurized allothermal spouted-bed core (e,g., at about 10 bar). The reactor chamber may be maintained at about 10 bar absolute during startup, steady state, and turndown. The apex spouting nozzle may be supplied with steam and / or COi at compatible pressure to preserve chamber pressurization and / or spout stability. The SG system 10(1 may align with the hydrogen-foward loop and membrane pressure windows. This may provide stable liydrodyuamics, consistent resideace time, and / or compatibility with downstream membranes.(00271 ] In some embodiments, the SG system 1 GO includes a draft-tube geometry’ and / or windows (e.g., dimensions may scale with diameter). The SG system 100 may include a draft tube that may have side windows and a conical skirt may be disposed coaxially in a conical lower section Window spacing and open area scale with reactor diameter to stabilize the spout and / or fountain and may reduce nozzle^gas demand while maintaining solids recirculation without wall impingemern. in some embodiments, the lower parasitics and a wider steady-spouting envelope without: changing global energy balances,(00272] In some embodiments, the SG system 100 includes a cone insert and / or apex, nozzle. The cone insert with return skirt may direct solids into die annulus. A steam-oilly or steam and / or COs apex nozzle may form a submerged jet. The geometry may limi t eokl-wall tar deposition while supporting! steady entrainment. In some embodiments, a steam and / or CCb apex nozzle through the cone generates a submerged jet that forms the spout. The geometry may minimize tar deposition on cold surfaces and provide steady entrainment. This may allow cleaner operation (e.g., less coking) and stable spouting at lower steam rates, (00273] in some embodiments, the SG system 100 includes a dual-path slurry feeding (e g., over- bed (lop) plus under-bed (mbe, spouting tube)). This allows splitting feed between over¬ bed top-feed and under-bed spouting-tube paths improves atomization, startup reliability, and fouling resistance, provided the under-bed fraction is constrained by anti-quench liqnid-to- gas (L / G) limits and closed-loop checks on spout-exit temperature and plenum Ap.(00274) The over-bed (e.g., slurry feed) top-feed may inject Slutty into the fountain above the draft tube for rapid atomization and low injector fouling (e.g., see FIG. IG). A top-feed injector may deliver slurry into the fountain region above the draft tube. High shear may promote rapid droplet heat-up and vaporization with minimal injector fouling (e.g., about 3 cm bore with purge sleeve at Alpha scale).!< K)275] The under-bed spouting tubes may inj ec t steam and / or COi ben eath an elevated bed plate (e.g„ with ih-tu.be water flash). One or more under-bed spouting tubes inject steam and / or COa beneath an elevated bed plate. A controlled fraction of slutty may be metered through the tubes such that slurry water flashes to steam in-tube (e.g., adding momentum and mixing), initiating or reinforcing spouting. To avoid quench, the liq id-to-gas (L / G) mass ratio per tube may be constrained (e g., <0.05-4).15) and the feed split may be closed-loop tied to spent-exit temperature and pieman Ap. Typical control may keep L / G per tube at about...f) 05-0.15 and may reduce the under-bed fraction if spout-exit temperature falls or plenum Ap spikes. This may allow better atomization and startup* lower fouling risk* and / or robust turndown without violating pressure and / or energy constraints.[O0276| hi some embodiments, the SG system 100 includes a bed refresh, ash handling, and / or return. A hot-solids loop removes ash while maintaining inert inventory (e.g., standpipe -* iobp-seal — * hot classifier — » lock-hoppers — * sand return). An alpha-scale setting may remove approximafeiy 2% of bed inventory' about every 10 minutes without moving parts in the hot zone Fhe larger tubes may preserve a similar turnover on a mass¬ fraction basis. This may prox ide stable particle size distribution, steady filter Ap, and predictable O EX.[O0277J In some embodiments, the SG system 100 includes a membrane CQa Separation & 'Recycle (pressurized integration). A two-stage membrane unit may split COa from an H?- emiched stream, A blower recycles a portion of COJ may permeate to the spout plenum to stabilize spouting, tune residence time, and manage dew point at pressure (e.g,, without relaxing the about 10 bar envelope). This may provide hydrodynamic stability with H2-forward benefits wh ich may be consistent with earlier mass and / or energy balances, [O0278j In some embodiments, the SG system 100 includes a physics and, encrgy~balancc consistency. The SG system 100 may provide hydrodynamic and / or heat-transfer optimizations. The enhancements may adjust hydrodynamics and parasitics without changing validated mass and / or energy balances or the hydrogen-forward processing sequence (e.g,, cleanup -* reformer HT-W S membranes). The SG system 100 may not alter overall wasie-to-energy con version assumptions for Alpha to SG scaling, at most tins may reduce •parasitics and increase stability margins, improving real-world performance headroom.[002791 In some embodiments, the SG system 100 includes a draft tube with windows and skirt sized with reactor diameter to stabilize the spout and reduce nozzle-gas demand under pressurized operation. In some embodiments, the SG system 100 includes a cone insert and apex nozzle configured to generate a submerged jet using steam anchor CO* at a reactorpressure of about 1ft bar absolute. In some embodiments, the SG system J 00 mcludes dual¬ path slurry feed' including an over-bed injector and an. under-bed spouting-tube pathway with in-tube water flashing and liquid-to-gas mass-ratio control tied to spout-exi t temperature and plenum Ap.

[0280] In some embodiments, the SG system 100 includes bed refresh loop including standpipe, loop-seal, hot classifier, and Ipck-hc-ppers returning cleaned inert media at a rate sufficient to remove ash without moving parts in the hot zone. In some embodiments. the SG system 100 includes a two-stage membrane separator producing a CCh-rich permeate recycled to a spout plenum to stabilize hydrodynamics and manage dew point,

[0281] Referring to FIG. II, in some embodiments,, the SG system 100 includes a cone and / or draft-tube spouting (e.g., hybrid bed with a sloping skirt and center cone). Iri some embodiments, the spouting nozzle 189 may include about 8-10 mm inside diameter (ID). In. some embodiments, the draft tube 186 has about 25-30 m inside diameter and may be about 50-60 mm tall with a welded conical skirt 188 (e.g., that is about 150 degrees) disposed on a bed support and / or floor 187. FIG. II may be referred to as an alpha spouting system (e.g., cone apex nozzle into draft tube 186 (windowed draft tube), welded skirt 188), In some embodiments, the SG system 100 includes an alpha spouting system (e.g., that is about 9 cm). The SG system 100 may include a cone apex, nozzle 189 into a draft tube 186 (e.g., windowed draft tube), and / or welded conical skirt 188 (e.g., to be used with a reactor 110 at about 10 bar).(002821 In the conical spouted bed with a draft tube, the center cone ma.y be used even when the nozzle jet is inj ected into the bottom of the draft tube. The cone supports par ticle circulation, entrainment, and heal transfer in the following ways.

[0283] The cone may guide flow into the draft tube. The center cone may raise the draft tube above the bed floor and may funnel particles toward the nozzle jet. This may allow solids to be substantially continuously fed into the spout entrance, avoiding stagnati n or dead zones.

[0284] The cone may promote entrainment. As gas accelerates through the draft tube, surrounding particles are entrained through the open sides. The sloping cone surface directs particles radially inward, increasing their chance of being swept into the spout and boosting the entrainment factor (E).

[0285] The cone may provide recirculation path control. Particles lifted through the draft tube exit in to the freeboard, then tall back down along the annular region. The about 36° conesurface guides them back toward the spout base, closing the spout-annulus recycle loop, and ensuring steady circulation,J00286] The cone may provide a radiation view factor. The cone surface may be directly exposed to wall radiation in radiatively heated systems. As particles slide over the cone, the particles may receive radiant energy before being recaptured into the spout, improving heating rates and gasification efficiency.(00287) The center cone may be used for stable spouting, particle recirculation, entrainment enhancement, and heat transfer. Even with nozzle injection into the draft tube, the cone geometry' remains a key design element(00288) In some embodiments, SG system 100 (e.g,, spouting gasifier system) may have the bottom bed plate in an elevated posi tion for either water for water coal or biomass water slurries are heated by the catalytic wall heating thereby flashing all water steam and effecting spouting and biomass and or coal feed and also recycling (e.g., about 7 percent) of inert bed material for char and / or ash removal and re-insertions clean inserts into bed. In some embodiments, slurry is fed over the bed and water is sent through spouted heating tubes as well as the case where slurry is fed through the heated spouting tubes.(00289] In some embodiments, submerged jet spouted bed advantage may be optimized for radiati ve heating and efficient recirculation. The submerged jet may create a strong conical spout from the bed base upward. This may allow frill particle exposure to radiant heat from all wall surfaces. In some embodiments, this may eliminate need for draft tube preserving radiation access and simplifying design, This supports high solids slurry' feed with minimal clogging risk. This promotes efficient annular recycle and high carbon conversion in compact vessels. This may be used for 10 cm to 1 m diameter radiative allothermal gasifiers.(00290] In some embodiments, responsive to about 60 percent of slurry having threshold properties (e.g., good: flow properties), it can be fed through the underbed spouting tube (underbed.feed) as well as with the same efficiency if the overbed feed where slurry is fed through the top of reactor onto bed and water flashing to steam fed through the spouting tube separately.(00291) In seme embodiments, SG System 100 may have a hot cyclone bed drain (e.g., char and / or inert separation for about 10-minute recycle). A dedicated hot cyelone bed drain may separate light char from heavier inerts so that ebar can be dry-transferred to a slurry tank for recycle while replenishing clean inerts back into the bed (e.g.. about every' 10 minutes). (00292] In some embodiments, SG system 100 may have cyclones separate by aerodynamic cat (rhe p * dpA2), not pure density. In some embodiments, SG system ICO may have light.porous char (low density, if regular shape) reports to overflow; dense inerts go to underflow. In some embodiments, SG system 100 may have target cut size (d50) that may discriminate between char and inerts (e.g., about 100-300 microns). In some embodiments, SG system 100 may have at about 10 bar, higher gas density increases d50 and compensate with smaller cyclone diameter or higher inlet velocity,|O0293] In some embodiments, SG system: 100 may have dedicated hot bed-drain classifier, separate from syngas cleanup cyclone. In some embodiments, SG system 100 may have inlet velocity of about 15—22 m / s and / or smaller cyclone diameter to lower cut size. In some embodiments, SG system 100 may have overflow (vortex finder) (e,g;., with char-rich fraction, cool and / or condition, slurry tank, etc,), In some embodiments, SG system 100 may have underflow (dipleg), such as inert-rich fraction (e.g,, metered retain to bed). In some embodiments, SG system 100 may have optional polish (e.g,, add short elutriator to dipleg or secondary “peeler'’ cyclone to overflow),100294] In some embodiments, SG system 100 may have drain about 5-10% of bed inventory about cwry 10 minutes (about 7% typical). la some embodiments, SG system 100 may use 1oss«in*wvi ht feeder on inert return for steady bed mass, In some embodiments. SG system 100 may recycle char from overflow to slurry tank in synchronization (e.g., coordination, sync, etc,) with inert replenishment.J 0295] In some embodiments, SG system 100 may have a screw cooler or nitrogen sweep installed on char overflow leg before slurry tank In some embodiments, SG system 100 may use silicon: carbide or basalt liners in cyclone inlet and / or bend for erosion resistance, In some embodiments, SG system 100 may have the dipleg sealed (J-valve and / or trickle valve) to prevent gas bypass. In some embodiments, the "central acceleration” may not be a major separation force. In some embodiments, SG system 100 may have effective char and / or inert split comes from balancing drag and centrifugal forces, timed via cyclone geometry and inlet velocity to achieve the desired cut size.|O0296] Referring to FIG I J, SG system 100 may have a bed drain of hot cyclone 190 with char overflow and inert return. Hot cyclone 1 0 may receive gas and solids via material inlet 202. The hot cyclone 190 may have a material outlet 204 (e.g., inert return) to bed return 194 and a material outlet 204 (e.g., char overflow) to slurry tank: 192.(00297] Referring to FIG. IK, hot cyclone may receive gas and solids via material inlet 202. The hot cyclone 190 may have a material outlet 204 (e.g., underflow return, io bed) and a material outlet 204 (e.g,, overflow) to slurry tank 192.(0 298] In some embodiments, SG system 100 has clean inerts going to shitry tank 192 as well as char and ash. In some embodiments, the bed drain of hot cycle 190 may have a substantially full parge. Both the cyclone overflow (e.g., ehar plus fines) and the cyclone underflow (e.g., coarse inerts) may be routed to the slurry tank 192 every parge cycle. Fresh, clean inerts may be metered into the bed at the same mass rate as the total purge to maintain bed mass and composition.(00299] In some embodiments, SG system 100 has both overflow and underflow to slurry tank: for combined char and inert recycle; In some embodiments, SG system 100 has fresh inert make-up substantially equal to purge rate maintains bed inventory. In some embodiments, SG system 100 has bed turnover (e,g., about 42% / h at about 7% every about 10 min purge) that allows dean bed media. In some embodiments, SG system 100 has loss-in-weight feeder that controls inert addition to maintain steady bed height and pressure drop. In some embodiments, SG system 100 has a screw cooler or Nn quench for underflow before slurry tank to manage tcnipcrature.

[0300] In some embodiments, higher inert loading in slurry increases viscosity and pump and / or nozzle wear. In some embodiments, cyclone cut size may direct course inerts to underflow to avoid clogging slurry lines. In: some embodiments, thermal loss from purged hot solids may use preheating of fresh inerts. In some embodiments, option for partial purge may send a percentage of underflow to slurry and remainder to bed.

[0301] In some embodiments, the SG system 100 may be used for hydrogen production (e,g., for dowmstream systems and suppliers). Flow may include one or more of the following Operations:(00302] Gas cooling andknockout "(e.g.. condense and / or remove water after WGS);

[0303] Water-gas shift (HTS+-LTS) ic g., consort CO to H2 using steam):

[0304] Syngas cooling and hot filtration (e.g., drop temperature to WGS inlet, remove fines);

[0305] Hot cyclone and / or syngas cleanup;

[0306] CO2 removal (selex l andfor amine) (e,g., bulk CO2 separation which may be physical and or chemical);

[0307] Hydrogen purification (pressure swing adsorption (PSA)) (e.g., which may achieve >~99.9% H2 purity); and / or

[0308] H2 compression and storage ( e.g deliver H2 at pressure for use).

[0309] Referring to FIG. IK, in some embodiments, hot cyclone bed drain may include recycle (e.g., baseline purge stamped, overflow to stay, underflow to bed). The baseline(e.g.:, steady-state) may have a partial purge of about 2% of bed mass every I minutes. Full purge may be reserved for startup and / or upset. The SG system 100 may include overflow (char + fines) to slurry tank 192 (e.g., recycle to feed), underflow (e.g., coarse inserts) to return to bed (e.g., via material outlet 204), and an optional partial purge to send a portion of underflow to slurry to control fouling,

[0310] Referring to FIG. It, in some ^embodiments hot cyclone bed drain includes a substantially lull purge (e.g., baseline purge stamped, both overflow and underflow to slurry tank: with fresh inert make-up). The baseline (e.g., steady state) may have a partial purge equal to about 2% of bed mass about every 10 minutes (e.g., use full purge during startup and / or commissioning or foulant spikes).

[0311] The full purge flow summary may include overflow (char plus fines) to slurry tank 192, underflow (coarse- inerts) to slurry tank 192, fresh inerts added, to bed via loss-in-weight feeder at purge mass rate,[003121 In some embodiments:, SG system IM may include a hot cyclone bed drain. A full purge may he used foi snnphc rt and rubus(nc‘>3 during start-up. commwsn-mtig,,md fouling events, but may switch to partial purge for stead-state to reduce operating cost and heat loss.[003131 The startup and / or commissioning phase may include::[003141 Fait purge mode - both overflow and underflow to slurry tank;[003151 Purge rate: -7% bed mass every 1 (I minutes (>> 42% / hour turnover);

[0316] Ensures very clean bed media and rapid removal of fines / ash; and / or

[0317] Fresh inert make-up rate ~ total purge rate,

[0318] The steady-state ope rati on ma v inc lude;

[0319] Partial purge mode - 30 -o<) ol underflow sent to slurry tank; remainder returned to bed;[003201 Example purge rate: 2-3% bed mass every ID minutes (» 12-18% / hour turnover):[003211 Reduces inert make-tip demand, slurry viscosity, and pump / nozzle wear; and

[0322] Fresh inert make-up rate ~ purge rate to slurry,

[0323] In some embodiments, SG system: 101) may include loss -in- weight feeder for fresh inerts to maintain steady bed inventory, screw cooler or Nn quench on underflow’ to manage temperature before slurry tank, cyclone cut size tuned so char preferentially reports to overflow, coarse inerts to underflow, and / or maintain optional switch-over valves to toggle between full purge and partial purge modes. In some embodiments, full purge may be operationally simplest. Partial purge during steady-state may offer lower OPEX and reduced heat loss while still maintaiiung bed cleanliness. Switch between modes may be used.(00324] la some embodiments, the reactor 1.10 may be a spouted gasifier (SG).(O032S] In some embodiments, system 100 includes one or more of the following subsystems:(00326] Waste reccivitig / screcn (e.g„ removes oversize and metals to protect grinders before downstream equipment);(00327] Shredder 4 wet-mill (e,g., reduces feed particle size to <1 mm for uniform stay and efficient HTT performance);1003281 Hl T mini-reactor (e.g., hydrothermal treatment to pre-condition waste slurry, lower viscosity, sterilize feedstock);(00329] Slurry pumps (e.g,, positive displacement Moyn pumps to reliably move viscous slurry without clogging);(00330] Reactor shell + liner (e.g,, ASME code shell with HAYNES® 230 liner for high-T radiant transfer);|O0331] Cone insert t e g,, 36° cone stabilizes solids recirculation, improves wall-particle heat transfer);100332] Spout tube (e.g., central tube delivering COnrsteam jet. through cone, creates fountain spout);(00333] Top-feed injection tube (e.g,, 3 cm ID bore for uncloggable slurry injection into fountain; purge sleeve for OP);(00334] Catalytic combustor annulus (e.g,, external allothennal combustor burning slipstream syngas to provide radiant heat);(00335] Electric preheaters (e.g,, for cold startup, provides 3-5 kW radiant heating before annulus ignition);(00336] Cyclone (e.g., separates coarse ash and particulates before candle filters);|00337] SIG candle filters (e.g., 2) (e.g,, captures fine particulates down to <1 j g / Nxg3with, pulse cleaning);(00338] Ni tar reformer (e.g,, catalytic reactor cracking ter Hn / CO for S0FC-gradc fuel; (00339] ZnO guard bed (e.g,, removes RnS, HC1 to ppb levels protecting power block catalysts);(00340] HT-WGS mini-reactor (e.g., high-temperatare shift reaction to increase Hn yield) (003 11 Mt-mbia - skid (hcmjri (c g. mr.igc membrane separation Hn retenrate to power, COn permeate to spout);(00342] COn recycle blower (e.g,, returns COn permeate to spout manifold, controls dewpoint)(0 3431 Bed refresh loop (e.g,, standpipe + loop-seal — hot classifier —♦ lock-hoppers —» sand return. Removes ash without moving parts in. hot zone);(00344| Controls & Al (e.g., PLCZSCADA, QA analyzers, Al digital twin for optimization & predictive maintenance); anchor(00345| Power Block Options (e.g., SOFC (5 kW), Hn engine (5~l 0 kWe, Mieroturbine (30-65 kWe), PBM FC (5 'kWe);Provides flexibility in technology choice).(003461 FIG, I illustrates a SG system 10(1, according io certain. embodiments. In some embodiments, the SG system 100 may inc hide a single let-down valve (e,g., atmospheric cyclone* single let-down bed refresh system with purge assist and atmospheric cyclone). The SG system 100 may have a spouted bed, loop-seal grain leg, pressure let-down valve, cyclone, vent and / or cleanup, and / or slurry tank.(00347) The spouted bed 112 e.g., at about 10 bar) may provide flow to the loop-seal grain leg 105 (c g. HP solids) which provides flow to the pressure let-down valve 196 (which also receives purge gas of CG2 and or steam). Flow may be provided from the pressure let-down valve 196 to the cyclone Iq0 te.g., al about 1 bar) 'which may provide underflow (e.g., solids to flotation and / or slurry tank. The cyclone 190 may also provide overflow (e.g,, lines and / or gas) to vent and / or cleanup. This may be used for small continuous bleeds (e.g,, about 2% every about 10 minutes equivalent). This may keep valve Cv small and may use abrasion- resistant trim. This may add cc d-lcg instrumentation of pressure, temperature, andfor change of pressure across valve (e.g., solid flux estimate).(00348) FIG. IN illustrates a SG system 100, according to certain embodiments. In some embodiments, the SG system 100 may include twin lock-hoppers (e.g., flotation cell that may be atmospheric). The SG system 100 may have a spouted bed, loop-seal grain leg, a lock: hopper A, a lock hoppe; B a vent gas, a depressurization valve, a flotation bed, and / or a storage bed.(O0349| The spouted bed 112 te.g., at about 10 bar) may provide flow to the loop-seal grain leg 195 (e.g,, HP solids) which provides flow to the lock hopper A 198A.(e»g., fill at high pressure (HP) and the lock hopper B 198B (e.g., dump at low pressure (LP). Flow may go from the lock hoper A I98A to depressurize valve 199 and from the depressurize valve 199 to the vent gas (e.g., LP cyclone and / or cleanup). Flow may go from the lock hopper B to flotation bed (e.g,, about 1 bar). A first portion (e.g,, char) of flow may go from the flotation bed to slurry and / or recycle. A Second portion (e.g., inerts) of flow may go from the flotation bed to storage for bed. This may be used for intermediate about 2% bed refresh about every 19 minutes without disturbing bed pressure. This may provide positive solids accouftting foreasier mass balance of? char vs. inerts. This may add isolation valves, level probes, and / or quick-clamp wear liners.00350 FIG. 10 illustrates a SG system 100, according to certain embodiments. SG system 100 may include a hybrid bed 112, a skirt 188, and / or a substantially center cone 113 that may be at about 36 degrees from horizontal.

[0351] FIG. IP illustrates a SG system 100, according to certain embodiments. The SG system 100 may be a multi-spout, multi-draft-tube spouted-bed gasifier. FIG. IP ay i llustrate relati ve posi tioning of the under-bed spouting tubes and the vertically orien ted draft tubes within the reactor vessel.

[0352] SG sys tem 100 may be a pressurized allothermal spouted-bed gasifier that includes multiple spouting tubes and draft tubes to provide substantially uniform solids circulation and heat transfer within a radiatively heated reactor vessel 103 (e,g,, catalytic combustion chamber 160). Spouting: tubes 105 may be disposed below a particulate bed 108 (e.g,, spouted bed 112) and may be connected to a common gas-supply manifold 111. Each spouting tube 105 may terminate in an upward- facing nozzle 107 configured to discharge spouting gas and atomized slurry feed into the lower bed region (e g.. of the particulate bed 1 OS), The nozzles 107 are distributed in a regular pattern, across the reactor base. In some embodiments, a reactor vessel 103 has about a one-meter diameter and about sixteen spouting tubes 105.

[0353] In some embodirncnts, above and between the spouting tubes 105 are open-sided or venturi-shaped draft tubes 109 that extend vertically through the particulate bed 108. In some embodiments (e.g., reactor vessel 103 has about a one-meter diameter and about sixteen spouting tubes 1(15), about nine draft tubes 109 are provided, each defining an interior passage 131 for upward flow of entrained particles and gas. The lower ends 132 of the draft tubes 109 are positioned slightly above the plane of the outlets of the spouting tubes 105 (e,g., offset by one-half to one lube diameter) to allow tire spouting jets to expand and mix with bed solids before reaching the draft-tube 109 openings.

[0354] In some embodiments, the spouting tubes 105 and draft tubes 109 are not in direct fluid communication. Instead, the jets issuing from the spouting tubes 105 generate local spout zones that impart lateral momentum to the bed solids, which are then entrained mto (he adjacent draft tubes 109 through their open sides. The combined action of multiple spouts and draft tubes: 109 establishes a network of? circulating cells 115 within the bed, resulting in substantially uniform particle mixing and may have a recycle loop time of approx imately ten seconds.(003551 Heat may be supplied to the bed e.g., particulate bed 108) through the surrounding radiatively heated wall 116, and the indirect coupling of flows of spouting tubes 105 said draft tubes 109 allows heat to be evenly distributed across substantially the entire annular zone, avoiding channeling and minimizing erosion witbin the draft tubes 109,(00356](00357] In some embodiments, a pressurized spouted-be gasifier includes a cylindrical or slightly conical reactor vessel (e,g., reactor vessel 103) enclosing a particulate bed (e,g,?particulate bed 108) configured to provide indirect radiant and convective heating. The reactor (e.g., reactor vessel 103) may include under-bed spouting tubes (e.g.* spouting tubes 105) distributed eireumferentially or in a regular array near the vessel base, and substantially vertically (e.g., vertically) oriented draft tubes (e.g., draft tubes 109) extending upward through the bed (e.g,, particulate bed 108),(00358] In some embodiments (e.g., a representative large-scale configuration), such as a one-meter-diameter reactor, about sixteen spouting tubes 105 are arranged to discharge upward into the lower bed region (e.g., particulate bed 108), while about nine draft tubes 109 provide particle-circulation channels and internal gas-solid separation pathways. Each spouting tube 105 may introduce a mixture of spouting gas and atomized slurry feed into the bed (e.g., particulate bed 108), generating localized spout zones that entrain particles and feed solids laterally toward adjacent draft tubes 109,(00359] In some embodiments, the spouting tubes 105 are not in direct fluid coninmniearion with the draft tubes 109, Instead, each spouting jet expands freely into the bed (e.g.,, particulate bed 108), transferring momentum to surrounding particles before teaching the lower openings of the draft tubes 109, The draft tubes 109, in turn, draw entrained particles upward by the combined effects of gas drag and pressure differential induced by the surrounding spout cells. This indirect coupling between spouts (e.g., spouting tubes 105) and draft tubes 1.09 may maintain overall bed stability and may prevent excessive erosion or localized channeling,(00360] The separation between the spouting, discharge points and the draft-tube intakes provides performance advantages of one or more of; (I) substantially uniform circulation of solids throughout the bed cross-section (e.g,, particulate bed 108), improving temperature uniformity and gas-solid contact compared to conventional systems; (2) independent control of spouting and entrainment flows, allowing improvement of momentum, balance and pressure drop compared to conventional systems; (3) reduced risk of jet impingement erosion or clogging within the draft tubes 109 compared to conventional systems; and / or (4) morseven distribution of radiative heat flux across the annular bed zone (e.g., particulate bed 108),. improving conversion efficiency and preventing localized quenching compared to conventional systems.

[0361] In some embodiments, the lower edges of the draft tubes 109 are positioned slightly above the discharge planes of the spouting tubes 105 (e.g., offset by approximately one-half to one tube diameter); This spacing allows jet momentum to -diffuse within the bed (e.g., particulate bed 108) before Intersecting the draft-tube intake. The draft tubes 109 may incorporate open sides or Venturi -throat sections to enhance entrainment factor (E) while maintaining pressure drop (e.g., moderate pressure drop) and recycle loops (e.g., substantially steady ten-second average particle recycle loops).[003621

[0363] In some embodiments, a. gasification reactor (e.g., multi-spout, multi-draft-tub reactor) includes a vessel 103 (e.g., reactor vessel) enclosing a particulate bed 108, spouting tubes 105 (e.g under-bed spouting tubes) arranged to discharge spouting gas and feedstock into a lowerof the particulate bed 108, and draft tubes 109 (e.g., each having open sides or a Venturi-shaped section) extending vertically through the particulate bed 108 to establish particle-circulation loops. Each spouting tube 105 may be configured to discharge (e.g.,:indirectly) into the particulate bed 108 region rather than, directly into any draft tube 109, such that the spoutitig gas induces particle entrainment into the draft tubes 109 through lateral momentum transfer within the particulate bed 108 (e.g., to establish multiple circulating solids-fiow loops within the reactor),

[0364] In some embodiments, tile number of spo uting tubes 105 is between about 4 and about 32 and the number of draft tubes is between about 3 and about 16.[003651 in some embodiments, inlets of the draft tubes 109 (e.g., draft-tube inlets) are positioned above outlets of the spouting tubes 105 (e.g., spouting-tube outlets) by a vertical offset (e.g., of about one-half t about one tube diameter above the outlets of the spouting tubes 105) sufficient to allow the spouting jet to expand and mix before entering the draft¬ tube intake.

[0366] In some embodiments, arrangement of spouting tubes 105 and draft tubes 109 is configured to produce an average particle recycle time of approximately ten seconds, presiding substantially uniform gas Svhd contact and ^arbon xom. eisjon efficiency exceeding about 90 percent.

[0367] In some embodiments, separati on of injection zones of spou ting tubes 105 and draft tubes 109 (e.g., spouting and draft-tube injection genes) reduces localized gas velocitieswithin the draft tubes to minimize erosion and to maintain bed stability (e.g., of the particulate bed 108) under pressurized operation.

[0368] In some embodiments, configuration of spouting tubes 105 and draft tubes.109 (e.g., the spouting and draft-tabs configuration) distributes radiative and convective heating substantially uniformly across the particulate bed 108 to enhance allothential gasification efficiency.00369] In some embodiments, the draft tubes 109 include at least one of longitudinal open side1-, a come^mg-tluough-dKCiging \ cniutt sCUion an<l<<i pe'ioralcd Livret openings configured to enhance the entrainment factor (E),

[0370] In some embodiments, heat is supplied to the particulate bed 08 by an annular catalytic combustion system, and the multi-tabe arrangement distributes radiative heat substantially uniformly across the bed cress-section,

[0371] In sortie embodiments, the reactor vessel has a diameter between about 0.3 and about 2,0 meters and the arrangement ot spouting and draft tubes maintains substantially stable spouting under pressurized operation at about >10 bar.109372]

[0373] In some embodiments, the multi-spout, multi-draft-tube architecture allows linear and modular scale-up of the SG platform from the single-tube SGI -•* SG10 ••••* SGI00 systems,

[0374] In some embodiments, a multi-spout, ninlti--draft-tu'bc spouted-bed gasifier includes multiple under-bed spouting tabes 11)5 that operate in conjunction with multiple vertically oriented draft tubes 109 to produce, distributed circulation cells 115 throughout a laxge-diameter reactor. This enables substantially uniform solids cireulation, lower gas demand, and substantially stable spouting at scales previously unattainable in conventional spouted- bed gasifiers,

[0375] In some embodiments, the SG system 100 of FIG. IP has a multi-spout base array.

[0376] In some embodiments, the SG system 100 has about sixteen spouting tubes 105 that are distributed substantially evenly across the reactor base. Each spouting tube 105 may terminate in an upward-facing nozzle. The spouting tubes 150 may tie into a shared gas / steam manifold 111. Each spouting tube 150 may inject spouting gas and atomized slurry feed.

[0377] The SG system 100 may have a multi-draft-tubc internal circulation structure.About nine vertically oriented draft tubes 1.09 may be positioned above / between the spouting tubes 107. The draft tubes 109 may have open sides or Venturi -throat sections. The inlets of the draft tabes 109 may be vertically offset from outlets of spouting tube 107 by about.0.5tube diameter to about I tube diameter. In some embodimafts, there may not be direct fluid communication between spouting tubes 107 and draft tubes 109.

[0378] The SG system 100 may have indirect momentum-coupled spoubdraft-tube hydrodynamics. Each spouting jet may expand laterally through the bed. Jet momentum may entrain solids into adjacent. draft tubes 109 via open sides of the draft rubes 109. The combined spout-draft-tube system may provide multiple synchronized recycle loops. This may result in substantially uniform temperature distribution and about 10-secoud particle recycle time.108379] The SG system 1(1(1 may have radiative wall heating compatibility. The geometry may allow substantially even distribution of radiative heat from the catalytic wall. This may reduce (e.g., minimize) channeling, dead zones, and / or erosion within draft tubes 109. |00380] The SG system 100 may have scaling architecture (eg., about 1 -meter diameter). Multi-spout aivay and nwl ti~draft~tube configuration may be used (e.g,, for a 1 -meter diameter reactor). This may establish linear scale-up path from small modular units (SG ) to large aliothertnal reactors.in some embodiments, one or more draft tubes 109 (e.g., multiple draft tubes and Venturi geometries). Each draft tube 109 may include a window and a skirt that is sized with a reactor diameter. The one or more draft: tubes 109 may be configured to provide stabilization associated with the spouted gas Inlet and reduce nozzle-gas demand under pressurized operation,(00382] In some embodiments, the SG system 100 may further include a cone insert and apex nozzle configured to generate a submerged jei using fluid at reactor pressure within multi-spot arrays.

[0383] in some embodiments the SG system includes a dital-path slurry feed including an over-bed injector and an under-bed spouting-tube pathway that has iu-tobe fluid flashing and liquid-to-gas (L / G) mass ratio control associated with spout-exit temperature and plenum difference in pressure (e.g., applies to each spouting tube 105 individually or the spouting tubes 105 collectively).(00384] In some embodiments, the architec ture of FIG. 1 P is no t a simple sealing of the single-spout design. The architecture of FI G. 1 P includes one ormore of:

[0385] Distributed multi -spout momentum injection:

[0386] indirectly coupled muhi- draft-tube entrainment:

[0387] Uniterm solids circulation via synchronized recycle cells;100388] Compatibility with radiative allothermal wall heating; and / or(00389] Pressurized, erosion-minimizing geometry capable of 1 -m diameter scale;|00390| FIGS. 2 A-H illustrate submerged jet spouted bed reactors 110 of SG systems (e.g., SG systems 100 of one or more of FIGS. 1A-C), according to certain embodiments.J00391] In same embodiments, material 220 (e.g., solid 104, fluid-solid mixture 106) is atomized via spout 216, In some embodiments, the fluid 102 that enters the fluid inlet.206 (e.g., submerged jet spouted bed nozzle) and forms the spout 216 is water or steam. The fluid actuator 130 may be a steam generator, pump, or blower. In some embodiments, the material 220 (e.g., solid 104, paste, etc.) that is to be gasified by SG system 100 includes irregular particles, particles that are greater than a threshold size (e.g,, big particles), particles that agglomerate, etc, These particles may not easily be put into slurry form for atomization by conventional systems.(00392] In some embodiments, the fluid inlet 206 (e.g., submerged jet spouted bed nozzle) is conftgiued to cause recirculation of material 220 (e.g., in the interior volume 212).(00393] The addition of heat to the material 220 in submerged jet spouted bed reactor 110 may form syngas in the submerged jet spouted bed reactor 110 which may be recycled (e.g., provided to the catalytic combustion) to generate the radiation environment on the outer surface of the submerged jet spouted bed reactor I 10 (e.g., within the catalytic combustion). J00394] In some embodiments, a pump may be on one side of the submerged jet spouted bed reactor 110 and a slurry tank may be on die other side of the submerged Jet spouted bed reactor 110.(00395] The SG system 100 may perform torrefaetion. This may be a thermal treatment process that alters chemical composition of physical properties of biomass to improve quality as a fuel, Torrefaetion may include heating in atr oxygen-deprived environment. Torrefacliotr may include water and volatile organic compounds (VOCs) being removed from biomass and hemicellulose fractious being degraded which may result in a denser, higher energy content that is lower in moisture than original biomass. Torrefaetion may improve fuel quality of biomass for combustion and gasification applications. Torrefaetion may make biomass more hydrophobic. Torrefaetion may cause biomass to absorb less moisture and to be more stable, Torrefaetion may char the particles. Torrefaetion may be used to make a paste.(00396] The SG system I 00 may be an allotherraal system (e.g., supply energy from the outside). For example, submerged; jet spouted bed reactor 1 W may be heated from the outside (e.g., combustion in the catalytic combustion);(00397] Referring, to FIG. 2 A, in some embodiments, the submerged jet spouted bed reactor 110 includes a material inlet 202 (e.g,, solid inlet), a material outlet 204 (e.g., solid outlet,fluid-solid mixture. outlet), a fluid inlet:2.06 (e.g,, gas inlet), a fluid outlet 208 (e.g., gas outlet), and walls 210 that form an interior volume 212. In some embodiments, the walls 210 form a cylindrical portion (e,g., upper portion) and a cone portion (lower portion) of the submerged jet spouted bed reactor 110, The fluid inlet 206 may be in the bottom of the cone portion <, lou ei portion) l he fluid outlet 2t>.x may be in ihe top of rhe cylindrical portion {e g, upper portion). The walls 210 and interior volume 212 may form an annulus 14 around the fluid inlet 206 (c,g., around an axis of foe fluid inlet 206). The wal ls 210 in the cone portion, may have about 15 to about 30-degree angle compared to the axis of the walls in the cylindrical portion.(00398) Material 220 (e g., solid 104, fluid-solid mixture 106) may enter the interior volume 212 via the material inlet 202 and fluid 102 may enter the interior volume, via the fluid inlet 206. As the fluid 102 enters the interior volume 212, it may form a spout 216 through the material 220 and may form a fountain 218 abo ve the material 220 The spout 216 and fountain 218 may cause the material 220 to mix within the interior volume 212.(00399) An outer surface of the walls? 10 may cause catalytic combustion to heat the material 220 within the interior volume.(00400) SG system 100 may recycle syngas provided by the submerged j et spouted bed reactor 110 to create a radiation environment from the walls 210.(004011 The submerged jet spouted bed reactor 110 (e.g., of one or more of foe FIGS, of the present disclosure) may be shaped, similar fo the submerged jet spouted bed reactor 110 of FIG. 2A.(00402) in some embodiments, foe spout 21 (e.g., fluid inlet 206) has about a 10 cm diameter through a plate. In some embodiments, holes that are about 1 cm in diameter are through the plate Fluid 102 may be provided through the spout 216 and the holes to fluidize the bed of material 220. The fluid 102 may be one or more of steam, water, cold slurry (e.g., under rapid entry’ and radiation environment, the cold slurry becomes steam with particles), syngas, steam and carbon dioxide from syngas, andfor the like.(00403) FIG. 2B illustrates a submerged jet spouted bed reactor 110. The submerged jet spouted bed reactor 110 may include a cylinder 230 (e.g., cylindrical portion of walls 10), a duct 232, and a blower 234. Blower 234: may provide fluid 102 into fluid inlet 206 of cylinder 230 via duct 232. In some embodiments, blower 234 is a fluid actuator 130 that includes one or more of a steam generator, pump, blower, actuator, etc.(00404) FIG, 2C illustrates a submerged jet spouted bed reactor 110. The submerged jet spouted bed reactor I III may include a cylinder 230 (e.g., cylindrical portion of walls 210)and material 220 within the interior Volume of the cylinder 2311 proximate the fluid inlet 206. The submerged jet spouted bed reactor 110 may include an irradiance component 236 (e.g„ UV light, solar component, etc,) that irradiates the inaterial 220 to cause the material 220 to be heated (e.g., in addition to or instead of the cataly tic combustion on the walls 210), (00405) In some embodiments, SG system 100 is a solar energy enhanced system (e.g., send UV light or solar energy through the spout 216), In some embodiments, one or more solar panels (e.g., and a solar concentrator) may provide the solar energy.(00406) FIG, 2D illustrates a submerged jet spouted bed reactor 110. 'Hie submerged jet spouted bed reactor 110 may he substantially tubular, The submerged jet spouted bed reactor 110 may be made from: steel, from an alloy (e.g,, Inconel 625), and / or the like. The submerged jet spouted bed reactor 11.0 may include quartz as the reactor material and / or a high temperature ceramic sleeve as a liner,(00407) A catalytic combustion may be disposed around the submerged jet spouted bed reactor 110. A syngas production plenum 240 may receive syngas produced by submerged jet spouted bed reactor 110 and syngas plenum 242 may receive the syngas from syngas product plenum 240 to provide to the catalytic combustion. 'The catalytic combustion may be a tubs or other conduit that surrounds the submerged jet spouted bed reactor 11 G to impart heat to the submerged jet spouted bed reactor 110, The catalytic combustion may be insulated (e.g., with ceramic insulation 244 or other type of insultation). Submerged jet spouted bed reactor 110 may include one or more ports 246 (e.g., material inlet 202, material outlet 204, fluid inlet 206, and / or fluid outlet 2G8).(00408) FIG. 2E illustrates a submerged jet spouted bed reactor 110 (e,g., tube reactor). The submerged jet spouted bed reac tor 110 andor catalytic combustion nay be configured to be removable for catalyst servicing and other maintenance. This may allow a user to construct a SG system 100 that includes multiple tubes, which in turn may enable the user to construct a SG system 100 that may be sized to the user’s individual needs. The modular construction of the SG system 100 (e.g,. gasifier system) may facilitate construction, transport, and disassembly of the SG system 100. The submerged jet spouted bed reactor 11 (e.g,, reactor tubes) may be configured so that they are connectable to an fish collector. The SG System 100 may have mnovable fittings (e.g„ seals access 250, pressure shells 252, etc.) for periodic cleaning.(00409) FIG, 2F illustrates a submerged jet spouted bed reactor 110 (e.g.,, tube reactor) within a SG system 10Q. The SG system 100 (e.g., reactor assembly) may include multiple submerged jet spouted bed reactors 110 (e.g,, multiple tube reactors, modular tube reactors).Individual submerged jet spouted bed reactors 110 (e.g., tubes) may be separately removeable to facilitate maintenance of the units. A SG system 1.00 may be constructed from multiple single reactor tubes (e.g., submerged jet spouted bed reactors 110) A SG system 100 may be constructed as a scalable system that includes a few tubes for a small-scale application or multiple tubes for a larger-scate operation.

[0410] In some embodiments, the submerged jet spouted bed reactors 110 (e.g.. reactor vessels) are tubular. In some embodiments, the submerged jet spouted bed reactors 110 (e.g., reactor vessels) are not tubular. The submerged jet spouted bed reactors 110.may be beat, curved, or otherwise, nonlinear in configuration. SG system 100 may rase drop-tube reactors and / or vertically-oriented reactors.[004111 FIG, 2G illustrates a Submerged jet spouted bed reactor 110 (e.g., tube reactor) and a catalytic combustion chamber 160. The catalytic combustion may include a fluid inlet 260 (c g mtakc tegion to receive one or more Of syngas, CO, air, etc.), an annulus portion 262, and a fund manifold 2. In some embodiments, the fluid may flow in a direction opposite to the direction o I’ the products of the submerged jet spouted bed reactor 110 (e.g., in a counter* cunrent type amngc ent). In some embodiments, the fluid may flow in. the same direction of the products of the submerged jet spouted bed reactor 110. The annulus portion 262 may be a controlled annulus dimensions that allow for repeatable results from catalytic reactions. The fluid manifold 264 niav be a region that has fluid (e.g., svflgas, CO, air, etc.) for introduction into the catalytic combustion.

[0412] SG system 100 may include a seal 266 (e.g,:)metal C-ring seal) that allows for differential axial thermal growth. SG system 100 may use one or more slurries, such as coal slurry, wood slurry, biomass slurry, sewage slurry, and / or other types of slurries (e.g,, any solid fuel material may be used in the slurry).[O0413| FIG. 211 illustrates a submerged jet spouted bed reactor 110. The submerged jet spouted bed reactor 110 may include one or more fluid inlets 206. In. some embodiments, the submerged jet spooled bed reactor I IP includes a fluid inlet. 2iioA {e... spout fluid inlet) to form the spout:216 and a fluid inlet 206B (e,g., fluidizing fluid inlet) to form a fluid-solid mixture 106. Plenum 270 may be used to mix one or more fluids 102, solids 104, and / or fluid-solid mixtures 106. Distributor 272 may include one or more of a material ialct202, material outlet 204, and / or fluid outlet 208.[004141 FIGS. 3A-B illustrate ash separators 140 (e.g., ash collectors, ash) of SG systems 100, according to certain embodiments.5.0{004151 Referring to FIG. 3A„ aft ash separator 140 may be made from a material such as Inconel 625 alloy (e.g., Inconel 625 ' alloycollection vessel). Mesh 304 (e.g., a200-size mesh) may be used to separate ash from the submerged Jet spouted bed reactor 110 (e.g., drop tube reactor). The submerged jet spouted bed reactor 110 (e.g., reactor tube) may be connected to the ash separator 140 by a fastener 302 (e.g., flare nut) or ether connector,{00416] In some embodiments, the ash separator 140 may have a flare fitting (e.g, 37” flare fitting) connected to (e.g., welded onto) a flanged cover for connection to submerged jet spouted bed mactor 110. In some embodiments, ash separator 140 has a port (eg., outlet, 14” port) that exhausts (e.g., to cooling and GC systems).{09417] In some embodiments, the SG system 100 may he nm in a batch approach, where the SG system 100 is run until the ash separator 140 becomes filled or Fouled with ash, at which time the SG system 100 is deactivated and the ash separator is cleaned. In some embodiments, the SG system 100 may be run in a continuous manner, in whnh the ash separator 140 is cleaned or replaced during operation of the SG system 100. In some embodiments, the ash is automatically routed from the ash separator 140 as input to the submerged jet spouted bed reactor 110 (e.g., to be recycled).{094181 Referring to FIG. 3B, a SG system 100 may include an ash separator 140 and a submerged jet spouted bed reactor 110. The ash separator 140 (e.g.. ash collector system) may be connected te a submerged jet spouted bed reactor 110 (e.g., reactor assembly). The SG system 100 includes a submerged jet spouted bed reactor 110 that is a tubular reactor that is coaxial with a catalytic combustion. The submerged jet spouted bed reactor 11.0 produces syngas from slurry that is introduced into the inlet of the submerged jet spouted bed reactor no.{09419] The SG system 100 may include a unit for ash removal (e.g.. ash separator 140) and a unit for gas cleanup (e.g., fluid separator 150). The unit for gas cleanup may be a sulfur scrubber. In some embodiments, a sulfur scrubber includes a bed of sorbent (e.g., a can or other vessel) through which the product syngas passes. In some embodiments,, the sorbent is a regenerable sorbent (e.g,, RVS-1 available from Sud~Chemie).100420 The SG system 100 (e.g., submerged jet spouted bed reactor 110 and / or catalytic combustion chamber 160) may provide exhaust 320 and may have ash removal gas cleanup 322.{09421] In some embodiments, the present disclosure provides for various flowrates. Slurry flowrates into a particular reactor may be in the range of from about 1 gallon per minute(g / in) to about 10 g / min or even 50 g / min. Flowrates of fluids may be in the range of from about 0.1 standard liters per minute (SLPM) to about 10 SLPM, 20 SL.-PM, or even 50 SLP. M.J00422] The working examples disclosed herein are illustrative only and do not limit the scope of the disclosed systems and methods.

[0423] In some embodiments, the present disclosure provides gasifiers (e.g., SCI systems 100). Gasifiers may include a reactor vessel (e.g., submerged jet spouted bed reactor 110). The reactor vessel may have an inner diameter in the range of from about 0.1 to about 10 inches, or from about 1 inch to about 5 inches, or from about 2 to about 3 inches. The reactor vessel may also have a length in the range of from about 0.1 meters to about 10 meters. 'These dimensions are illustrative only, and it should be understood that the optimal reactor size will depend on the needs of the user. The difference in radii between a reactor and the heating conduit (e.g,, catalytic combustion s that surrounds the reactor (i.e., the coaxial tube that carries syngas to provide heat t > the reactor) may be in the range of from about 0.01 inches to about 10 inches. Illustrati e ratios of the inner diameter of the reactor tube to the inner diameter of the heating conduit may be from 1: 1,0001 to 1:20, although larger ratios are within the scope of the present disclosure.

[0424] In some embodiments-, the combustion conduit may be wrapped about the reactor. The ratio of the diame ters of the reactor to the combustion conduit may lie from 1: 100 to 100: 1, or from 1:50 to 50:1, or even 1:2 to 2:1. The reactor tube and the heating conduit may be intertwined or configured such that the heating conduit is characterized as being wrapped around the reactor tube,

[0425] The reactor y a lso be Surrounded by a heating Conduit (e.g.. a tube filled with hot fluid) or even electric or catalytic heaters. The inlet of the reactor vessel may be cortical. Such an Inlet affects the amount of recireulating flow that contacts the interior of the reactor.Reducing recirculati ng flow may reduc e particle, deposi tion on the walls of the reactor. The ccmical-shaped flow straightener may reduce the amount ofrecireulating flow near the walls of the reactor,

[0426] The heating conduit may include a catalyst, which catalyst may be selected for inactivity with carbon monoxide arid oxygen or even air. Catalysts, such as platinum, palladium, rhodium, or a combination thereof are suitable, as are catalysts used in catalytic converters. Such catalysts are, e.g., COM] 0 can be obtained from BASF Industries, The reactor tube may be disposed within a catalytic combustor tube. The heating conduit and the reactor may be coaxial, or one may be wrapped around the other. The heating tube and the reactor may be intertwined with one another in a braided or helical arrangement, in someembodiments. The fluids in the heating conduit and reactor may be arranged in a concurrent or countercurrent arrangement.J00427] Also provided are methods of gasifying a fuel. Material may be introduced to a reactor chamber that is heated by radiative heat, and the atomized fuel may be heated in the reactor chamber so as to gasify at least a portion of the atomized fuel to a syngas that may include hydrogen, carbon monoxide, carbon dioxide, methane, or any combination thereof.(00428] At least a portion of the radiative heat may be supplied by reacting a fluid in a chamber m thermal communication w ith the reactor chamber. This heat may he supplied by catalytically reacting carbon monoxide and air with a catalyst, which catalyst may include platinum, lead-copper, and the like, The gas used in the catalytic combustor may include CO, Hr, methane (C1%1 and the like. The syngas that is itself produced in the reactor may be used as the heat-generating fluid in die catalytic combustor. The syngas may include, for example, 30-50% CO, 40-60% Hz, and 1 -3 CHv(00420] The temperature of an Interior wall of the reactor chamber (e.g.,, submerged jet spouted, bed reactor I Uli may be in the range of from about WO deg. C. to about 1500 deg. C_, or from 1000 deg. C. to about 1100 deg C. Temperatures may be in the range of from about 850 deg. C. to about 1200 deg. C. The pressure within the reactor may be in the range of from about 1 airn to about 20 atm, or from about 10 atm to about 20 atm. The residence time within the reactor ehamber (e.g,, submerged jet spouted bed reactor 110) is in the range of from about 0.01 seconds to about 10 minutes, or from about 30 seconds to about 2 minutes. The residence time may be about 60 seconds. The residence time may depend on the user’s needs and the desired degree of gasification. The residence times may be in the range of from about I to about 10 seconds. The particles in the submerged jet spouted bed reactor 110 may be substantially completely mixed in about 30 seconds.100430] The proportion of fuel to fluid in the slurry may be in the range of from about 1: 100 to about loo 1, or even in the range of from about 1:5 to about 5: 1. Slurries may have a weight ratio of fuel to water of about 1: 1.. In certain embodiments, the slurry comprises about 55-64% of fuel (s.g., coal) and about 45-35% of water by weight,(00431] In the case of coal slurry feeds, the feed may be in a range from 45:55-65:35 (wt. Cdal'.wt. water). For biosolids slurries, the slurry may be in a range from 25:75-65:35 (wt. biosolidtewt. water,), depending on type of pretreatment such as totmfection or hydrothermal treatment and biosolids can be formed from wood, biomass such as switchgrass, com stover, wheatstraw, peanut shells, and the like. Slurries may include hydrothermal ly treated sewage sludge or other biosolids mixed with coal in: a water slurry.(00432] The Slurry may include feel particles having an average particle size in the range of fem about 20 mierous to about 200 microns, or fem about 50 microns to about 100 microns, or e ven about 60-70 microns. The slurry may include a rnonodisperse particle population or a polydisperse particle population. The particles may differ from one another in terms of size or even in terms of composition. For example, the feel slurry* may include both coal and wood particles. The. disclosed gasifiers may process two or more different slurries, which processing may be performed in parallel.(00433 ] Particulates, ash, and / or other material evolved during the gasification process may be removed. This maybe accomplished by filtration, a water bath, a precipitator, and the like. A variety of separators, including vacuum and. cyclone separators may fee used to separate ash fem product syngas. Ash collection systems are available from Pollution Systems (i rw.poliutionsysteiBS.com), General Electric (www.ge.com), and other manufacturers known in the field W <r scrubbers, electrostatic precipitators, and bag filters are all considered suitable collector systems. The system may also include cooled tubing that cools evolved syngas to a reduced temperature.(00434] In some embodiments, the SG system I 00 (e,g., gasification, unit) includes a vertical reactor, manufactured from Haynes 230 and being capable of continuous operation at a simultaneous pressure and temperature of 300 psia (20 atmospheres) and 1,000 degrees Celsius, respectively. The rop-tabe is five feet (5’) long and has an imicr and outer diameter of three inches (3.0") and three and a half inches (3,5'’), respectively. The reactor wall inner surface is healed in about 1,000 degrees Celsius to provide the energy required for the endothermic gasification process utilizing radiation as the primary mode of heat transfer ftom the reactor wall to the reactants. Reactors may have lengths that differ fem the length of the foregoing reactor, as they may have a length in the range of from about 0.1 m to about 1 m, about 5 m, about 10 m, about 20 m, or even longer.(00435] The reactor wall may be externally heated with no axial (steam wise) temperature gradient, over a length, of four feet (49 using two annular ceramic radiant electric heaters employing resistive heating elements. Reactor temperature is controlled by modulating the electrical power io fee heaters. A catalytic combustor may be used on the external surface of the reactor wall in place of-— or in addition to— -radiant heaters.(00436] The flanged drop-tube reactor exit may be connected to a solid phase (ash) separation and recovery system that utilizes gravity and aerodynamic drag to separate solid particles from gases exiting the reactor. The ash recovery system also serves as a first stage condenser for separating water vapor from the reactor gases. A face seal configurationutilizing elastomeric seals may be used to seal between the drop-tube reactor and the ash recovery system.|0O437j Downstream of the ash recovery system a second stage., water cooled, condenser may be used for final removal of any water vapor and consequent delivery of dry gases to an exhaust open to the atmosphere. Prior to the atmospheric exhaust a fine needle valve may be used to supply backpressure onto rhe reactor and control desired reactor operating pressure. A vacuum pump may be used for extraction of dry gas samples from the exhaust line, and the samples are in turn sent to a device (e.g., Agilent 3000 A micro gas chromatograph) and analyzed in real time to determine type and amount of species found in the reactor exhaust ■gas, The chromatograph may be calibrated for identification of hydrogen, methane, nitrogen, oxygen. Carbon monoxide, carbon: dioxide, ethylene, arid Other various heavy hydrocarbon species.|O0431?| A coal slurry injection system may be disposed at the top of the reactor. The injector geometry produces sluty droplet diameters of about 80 microns with a range from 5 microns to about 150 microns.(00439) Coal shiny is delivered to the injection system utilizing a precision, stepper motor driven, syringe pump capable of high pressure (teg., BOO psi.) fluid delivery. 800 psi is not a specifically required pressure, however, as the optimal pressure will depend on the user’s needs and process parameters. Slurry can be delivered adequately also by a positive displacement pump such as a Moyno (www.moyao.cam) progressing cavity pump.(00440) Carbon dioxide and nitrogen gases may be delivered to the gasification system from standard high-pressure bottles connected to compuier-controlled mass flowmeters. A series of comp'otcr-coatrolied solenoid valves can be used for remote initiation of gas flow.(00441 ) System instrumentation may include themwcouples andpressure transducers monitoring: temperatures and pressures at various locutions throughout the system.Instrumentation is attached to a computer-controlled data acquisition system sampling at 5 hertz per channel,(00442) Coal slurry samples were prepared by sifting raw pulverized coal through a 1.06- micron rnesh. Mechanical agitation was uti lized for uniform mixing of the coal, water, arid additi ves. Slurry flow rates ranging from about I to 4 grams per minute were investigated along with reactor pressures variations ranging from a boot 1 to 5 atmospheres; other flow rates may be used.(00443) The flow rate of the slurry may, for example, be from about 1 g / min at 1 atm pressure in the reactor to about 20 g / min at 10 atm reactor pressure to about 40.g / min at 20atm reactor pressure. At the end of each test, samples of solid phase product are collected from the ash recovery system for subsequent chemical analysis and determination of carbon content.|00444j A similar procedure to the one described above, was utilized to study the gasification of biomass (e.g,, torrefied beechwood),J00445] An increase in reactor diameter from 1 inch to 3 inches results in a reactor wall with reduced build-up of solid product after a two-hour test. The difference in product build-up on the reactor wall is attributed to a rceirculaitun flow field established in a vertical drop-tube reactor due to gas temperature gradients between the top and bottom of the reactor. In some embodiments, for a fixed flow rate of slurry and fluid (e,g„ spout fluid), the recirculation region may diminish in strength with an increase in reactor diameter, resulting in lower velocities and lower radial and axial flow momentum into the reactor wall and Injector base.|O0446| The maximum flow rates of slurry and fluid (e.g,, spout fluid) can be increased while reactor pressure is increased accordingly. In some embodiments, no significant reactor wall build-up occurs during & pressure test at about 5 atm. In some embodiments, the recirculation region diminishes in strength with an increase in pressure due to an increase in gas phase density, which yields lower velocities (e.g., a pressure increase by a factor of fi ve would result in reactor velocities decreasing by a factor of five), which effect is consistent with a Stokes number analysis.|00447| Gas phase product species may be measured using a gas chromatograph. These measurements may be taken frequently throughout the startup and steady operation of the gasifier. Condensed phase products may be collected over (he duration of the test and analyzed post-test. The analysis of solid product composition is made once for each test. Water content in the product stream may be reconstructed using an atom balance.1004481 Four representative tests shown: here to demonstrate the effect of changing the primary system parameters on carbon conversion. These parameters are pressure, residence time, and C'Or content. COs was introduced to test for the anticipated benefits to carbon, conversion, Below is a table with test parameters,, carbon conversion,, and theoretical carbon con version; the latter is presented to evaluate the measured result against the theoretical maximum conversion at these test conditions,[O04495 A comparison shows the progression from all CO2 to all bo. The measured carbon conversion increases as one switches from CO: to all Na. A 5-percentage point increase in carbon conversion i demonstrated. In contrast, the theoretical carbon conversion shows a 7- percentage point decrease when CQ» is replaced by N2 indicating die expected benefit of CChaddition. For example, for a slurry flow of5 g / mm and a reactor pressure of about 10 atm, a fluid flow (e.g., via the spout) of about 2.5 SLPM may be used.J00450| In some embodiments, article resonance time is about 8 seconds. Referring to figure 4A, over 90% carbon conversion may be obtained in about 3 x 10 second cycles which may yield a resonance time of about 30 seconds for about 90% carbon con version outcome.1004511 Table irCarbon: | Carbon Slurry flow CCfe flow ISb Flow Pressure Tem.p. conversion conversion (g / mi.n! (SLPM) (SLPM) (psia) (deg. C.) measured theoretical 2 % 0 15 1000 66.9% 1 84.8% 4; 1.2 IftI is ibob 68.3% 77,8% 4 vfo 12 15 1000 71,9% 77,4% 4 1,2 10.8 75 1000 63.6% 78.5%J DI -■ Particle resonance(004521 Some e mbodi mem s illustrate providing adequate thermal energy to the reactor wall by catalytic combustion of syngas at the outer surface of the reactor wait A tube was coated with catalyst and placed within a quartz outer shed to confine reaction gases. Syngas was mixed with air at an equivalence ratio of abo ut 1.02 and the mixture was heated to about 120 degrees Celsius prior to the reactor inlet. Thermocouples placed on the inside of the catalytic tube recorded temperatures during operation while a gas chromatograph was used io determine the extent of combustion of the inlet gases. Complete con version of the hydrogen and carbon monoxide was observed while achieving a reactor temperature of about 870 degrees Celsius.(00453] The present disclosure provides a robust reactor design at small scaie-“-yasily capable of being scaled. The present disclosure also provides successful operating configuration for reactor and established relationships between reactor diameter, injector diameter, shirr, flowrate, and reactor pressure. Also demonstrated are the advantages of high- pressure operation for improved operation to operate at high through put with reduced capital costs as compared with atmospheric systems. The disclosed reactors may be used to successfully gasify biomass made from torrefied beech wood, and reactor wall heating via catalytic combustion of syngas (e.g., &■ CO) being employed over a catalyst coated reactor tube.(00454] FIGS. 4A-G illustrate graphs associated with SG systems, according to certain embodiments,(0O455| FIG. 4A illustrates a graph 400A associated with a SG system 100, according to certain embodiments. Iu some embodiments, SG system 100 may be a recycle system that allows conversion (e.g., complete conversion) of biomass feedstock to syngas by sizing the submerged jet spouted bed reactor 110 and Stary flowrate (e„g., of solid 104, of fluid-solid mixture 106, etc.). In a SG system, a single pass carbon conversion may have an effect on. carbon throughput to produce fixed syngas output with substantially complete carbon conversion (e.g,, 10(1% carbon conversion).(09456] Graph 400A. may illustrate recycles required vs per-recycle conversion (e.g,, at about 10 second per recycle at about 1000 degrees Celsius and about 10 bar). In graph 400A, the y-axis may he the number of recycles needed. The x-axis may be percentage of single¬ pass conversion (c g., carbon conversion) per recycle.|00457] In some embodiments, the carbon content of the ash (e.g:,, output of the submerged jet spouted bed reactor 110) may be measured to determine how much carbon was converted. If the percentage of converted carbon is below a threshold amount, the throughput (e g., flow rate) may be increased. The residence time may remain the same and the size of the reactor and / or the flow rate may be increased to convert a greater amount of the carbon.|00458] 'Flic curve of graph 400A may be used to design size of the SG system WO (e.g., submerged jet spouted bed reactor.110) to substantially complete ly convert all material 220 to syngas.J00459] FIGS. 4B-F may illustrate a spou ted bed gasifier of the present disclosure. FIGS.4B-F may illustrate a spouted bed simulation. study with fluorescent plastic beads tbat simulate actual use of the spouted bed gasifier.(00460] FIG, B illustrates a graph 400B associated with a SG system 1110, according to certain: embodiments. The central spout velocity curve of FIG. 4B may demonstrate the spout is a submerged jet.100461] FIG. 4G illustrates a graph 400C associated with a SG system 100, according to certain embodiments. The bead flux curve of FIG. 4G may demonstrate that the bed particles also form a submerged jet.(09462] FIG. 4JJ illustrates a graph 4000 associated with a SG system 100, according to certain embodiments. The entrainment curve of FIG. 4D demonstrate how the spout, captures the bead particles.(09463) 'FIG; 4E illustrates a graph 400E associated with a SG system I 00, according to certain embodiments. The streamline curve of FIG. 4E may demonstrate how particles in the jet recirculate.|0O464| FIG. 4F illustrates a graph 4O0F associated with a SG system 100, according to certain embodiments. FIG. 4F demonstrates the ratio of the Megawatt Thermal (MWth) output of the reactor (e.g., SG system 100, submerged jet spouted bed reactor 110) to the length in meters of the gasifier reactor tube (e.g.?submerged jet spouted bed reactor 110). (09465) FIG. 4G illustrates a graph 400G associated with a SG system 100, according to certain embodiments, FIG. 4G illustrates thermal output (M Wth) vs bed diameter (m), (09466) FIG. 5 is a block diagram illustrating a computer system 500, according to certain embodiments. The computer system 500 may be part of the SG system I Oh. The computer system 500 may be the controller 101 of the SG system 100 (e.g., to perform one or more of the methods of the present disclosure, to control flow rate, to control actuators, etc.), (00467) Tn some embodiments, computer system 500 is connected (e.g., ia a network, such as a Local Area Netsvork (LAN), a.u intranet, an extranet, or the Internet) to other computer systems. In some embodiments, computer system 500 operates in the capacity of a servef or a client computer in a client-server environment, or as a peer computer in a peer-to-peer or distributed network environment. In some embodiments, computer system 500 is provided by a personal computer (PC), a tablet PC, a Set-Top Box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a server, a network router, switch or bridge, or any device capable of executrag a. set of instructions (sequential or otherwise) that specify actions to be taken by that device. Further, the term "computer'’ shall include any collection of computers that individually or jointly execute a set (or multiple sets) of instructions to perfonri any one or more of the methods described herein,(09468) in a further aspect, the computer system 500 includes a processing device 502, a volatile memory 504 (e.g., Random Access Memory (RAM)), a non- volatile memory 506 (e.g., Read-Only Memory (ROM) or Elechically-Erasabte Programmable ROM (EEPROM)), and a data storage device 516, which communicate with each other via a bus 508.(00469) In some embsdimen ts, processing device 502 is provided by one or more processors such as a general purpose processor (such as, for example, a Complex Instruction Set Computi ng t CI SC) microprocessor, a Reduced Instruction Set Computing (RISC) microprocessor, a Very Long Instaietion Word (VIJ'W) microprocessor, a microprocessorimplementing other types of instruction sets, or a microprocessor implementing a Combination of types of instraciion seis) or a specialized processor (such as, for example, an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), a Digital Signal Processor (DSP), or a network processor),|0047O| Ln some embodiments, computer system 500 further includes a network interface device 522 (e.g., coupled to: network 574), In some embodiments, computer system 500 also includes a video display unit 510:(e,g., an LCD), an alphanumeric input device 512 (e.g., a keyboard), a cursor control device 514 (e,g,, a mouse), and a signal generation device 520, J00471] In some implementations, data storage device 516 includes a non- ansitory computer-readable storage medium 524 on which store instructions 526 encoding any one or more of the methods or junctions described herein, including instructions for implementing methods described herein,|O0472| In some embodiments, instructions 526 also reside, completely or partially, within volatile memory 504 and / or within processing device 502 during execution thereof by computer system 500, hence, irt some embodiments, volatile memory 504 and processing device 502 also constitute machine-readable storage media,|00473| While computer-readable storage medium 524 is shown in the illustrative examples as a single medium, the term "computer “readable storage medium" shall include a single medium or multiple media (e.g., a centralized or distributed database, andfor associated ciicb.es and servers) that store the one or more sets of executable instructions. The term "computer-readable storage medium" shall also include any tangible medium that is capable of Storing or encoding a set of instructions for execution by a computer that cause the computer to perform any one or more of the methods described herein. The term "computer* readable storage medium” shall include, but not h I nnted to, solid-state memories, optical media, and magnetic media,|00474 In some embodiments, the methods, components, and features described herein are implemented by discrete hardware components or are in tegrated in the functionality of other hardware components such as ASICs, FPGAs, DSPs, or similar devices. In some embodiments, the methods, components, and features are implemented by firmware modules or functional circuitry within hardware devices. In some embodiments, the methods, components, and features are implemented in any combination of ha rdware devices and computer program components, or in computer programs.|00475| Unless specifically stated:otherwise, terms such as “identifying,” "receiving,” "causing,” ‘training,”“generating,” "providing,” "obtaining,” “inferrupting” "determining,”“transmiting,” or the like, referto actions and processes performed or implemented by computer systems that manipulates and transforms data represented as physical (electronic) quantities within the computer system registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such, information storage, transmission or display devices. In some embodiments, the terms "first," “second," "third,” "fourth,'' etc. as used herein are meant as labels to distinguish among different elements and do not have an ordinal meaning according to their numerical designation.JO0476] Examples described herein also relate to an apparatus for performing the methods described herein. In some embodiments, this apparatus is specially constructed for performing the methods described herein or includes a general-purpose computer system selectively programmed by a computer program stored the computer system. Such, a contputer program is stored in a computer-readable tangible storage medium,|0O477] Some of the methods and illustrative examples described herein are not inherently related to any particular computer or other apparatus. In some embodiments,, various g etai- purposc systems are used in accordance with the teachings described herein. In some embodiments, a more specialized apparatus is constructed toperform methods described herein and / or each of their individual functions, routines, subroutines, or operations.Examples of the structure for a variety of these systems are set forth in the description above. |00478] The above description is intended to be illustrative, and not restrictive. Although the present disclosure has been described with references to specific illustrative examples and implementations, it will be recognized that the present disclosure is not limited to the examples and implementations described. The scope of the disclosure should be determined with reference to the following claims, along with the hill scope of equivalents to which the claims are entitled|O0479] The preceding description sets forth numerous specific details such as examples of specific systems, components, methods, and so forth in order to provide a good understanding of several embodiments of the present disclosure. It will be apparent to one skilled in the art, however, that at least some embodiments of the presen t disclosure may be practiced wi thout these specific details. In other instances, well-known components or methods are not described in detail or are presented in simple block diagram format in order to avoid unnecessarily obscuring the present disclosure. Tirus, the specific details set forth are merely exemplary. Particular implementations may vary from these exemplary details and still, be contemplated to be within the scope of the present disclosure.

[0480] The terms“ovet,’’ “under,” “between,” “disposed on,” and “on” as used herein refer to a relative posi tion of one material layer or component wi th respect to other layers or components- For exampie, one layer disposed on, over, or under another layer may be directly in contact with the other layer or may have one or more intervening layers.Moreover, one layer disposed between two layers may be directly in contact with the two layers or may have one or more intervening layers. Similarly., unless explicitly stated otherwise, one feature disposed between two features may be in direct contact with the adjacent features or may have one or more intervening layers.

[0481] The words “example" or “exemplary” are used herein to mean serving as an example, instance or illustration. Any aspect or design described herein as “example’ or “exemplary'’ is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the words “example” or “exemplary” is intended to present concepts in a concrete fashion.

[0482] Reference throughout this specification, to “one embodiment,” “an embodiment,” or “some embodiments'' means that a particular feature, structure, or characteristic described m connection with tbs embodiment, is included in at least one embodiment. Thus, the appearances of the phrase “in one embodiment.” “in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment, In addition, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise* or clear from context, “X includes A or B” is intended to mean any of the natural inclusive permutations. That is, if X includes A; X includes B; or X includes both A and B, then “X includes A or B” is satisfied •under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended: claims should generally be construed to mean “one or more” unless specified otherwise or cleat-from context to fee directed to a singular form. Also, the terms "first,” '’second,’1“third," "fourth,” etc. as used herein, are meant as labels to distinguish among different elements and cannot necessarily have an ordinal meaning according to their numerical designation. When the term “about,” “substantially,” or “approximately” is used herein, this is intended to mean that the nominal value presented is precise, wi thin T 10%.

[0483] Although the operations of the methods here in ate shown and described in a particular order, the order of operations of each method may be altered so that certai n operations may be performed in an inverse order so that certain operations may be performed, ai least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be in an intermitent and / or alternating maimer.2it is understood that the above description is intended to be illustrative, and not restrictive. Manyother embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The scope of the disclosure should, therefore, be detennined with reference to the appended claims, along with the full scope of equi valents to which such claims are entitled.

Claims

CLAIMSWhat is claimed is:

1. A spouted gasifier (SG) system comprising:a submerged jet spouted bed reactor comprising:a plurality - f wats that form an interior volume;a material inlet configured to provide material into the interior volume; a spouted gas inlet configured to provide fluid into the material in the interior volume to form a fluid-solid mixture;one or more outer surfaces of the plurality of walls configured to perform catalytic, combustion to heat the fluid-solid mixture within the interior volume to form output material; anda material outlet configured to provide at least a portion of the output material from the interior volume.

2. The SG system, of claim I further comprising a material actuator configured to provide the material into the submerged jet spouted bed reactor.

3. The SG system of claim I further comprising a fluid actuator configured to provide the fluid into the submerged jet spouted bed reactor, wherein the fluid actuator comprises a blower or a pump.

4. The SG system of claim 1, wherein at least one of:the material comprises one or more of slurry, paste, processed sewage sludge, biomass, or coal; orthe fluid comprises one or more of stea,, water, or slurry;5. The SG system of claim 1 farther comprising a catalytic combustion chamber surrounding the submerged; jet spouted bed reactor, wherein the catalytic combustion occurs within the catalytic combustion chamber.

6. The SG system of claim 1 further comprising:a fluid separator to remove fluid, from the output material; andan ash separator to remove ash from the output material.

7. The SG system of claim 6, wherein, at least a portion of the ash is provided via the material inlet into the interior volume.h. The SG system of claim I, wherein the spouted gas inlet is a submerged jet spouted bed nozzle configured to cause recirculation of the material.

9. The SG system, of claim 1, wherein the material has average particle diameter of about 501) micrometers (p.m ).

10. The SG system of claim I, wherein the submerged jet spouted bed reactor has an azimuthal symmetry' about an axis of the spouted gas inlet.

11. The SG system of claim 1, wherein the submerged jet spouted bed reactor comprises a cylindrical vessel that is surrounded by an annular combustion chamber.

12. The SG system of claim I further comprising an irradiance component configured to irradiate the fluid-solid mixture to cause a substantially uniform temperature distribution,13. The SG system of claim 12, wherein the irradiance component is a solar concentrator,14. The SG system of claim 1, wherein SG system is to cause the fluid-solid mixture in the interior volume to have a pressure of at least 10 bar.

15. The SG system of claim 1, wherein the submerged jet spouted bed reactor further comprises a gas outlet configured to provide syngas from the interior volume, wherein at least a portion of the syngas is to undergo the catalytic combustion on the one or more outer surfaces.

16. The SG system of claim I further comprising a. draft tube comprising windows and a skirt that is sized with a reactor diameter, the draft tube being configured to provide stabilization associated with the spouted gas inlet and reduce nozzle-gas demand under pressurized operation.

17. The SG system of claim 1 further comprising a cone insert and apex nozzle Configured to generate a submerged jet using fluid at reactor pressure.

18. The SG system of claim I further comprising a dual-path slurry feed comprising an over-bed injector and an under-bed spouting-tube pathway that has In-tube fluid flashing and liquid-tongas (L / G) mass ratio control associated with spout-exit temperature and plenum difference in pressure.

19. The SG system of claim 1 further comprising a bed refresh loop comprising a standpipe, a loop-seal, a hot classifier, and lock-hoppers configured to return cleaned inert media at a threshold rate to remove material without moving parts in a hot zone.

20. The SG system of claim 1 further comprising a two-stage membrane separator configured to generate a permeate recycled to a spout plenum to stabilize hydrodynamics and to manage dew point at a particular pressure.

1. A gasification reactor comprisin:a vessel enclosing a particulate bed;a plurality of: spouting tubes arranged to discharge spouting gas and feedstock into a lower region of the particulate bed; anda plurality of draft lubes extending vertically through the particulate bed to establish pai'tieie-circulatlon loops, wherein each of the plurality of spouting tubes is configured to discharge into a bed: region of the particulate bed instead of directly into any of the plurali ty of draft tubes to cause the spouting gas to induce particle entrainment into the plurality of draft tubes through lateral momentum transfer within the particulate bed.

22. The gasification reactor of claim 21, wherein inlets of the plurality of draft tubes are positioned above outlets of the plurality of spouting tubes by a vertical offset to allow' a spouting jet to expand and mix before entering the inlets of the plurality of draft tubes.

23. The gasification reactor of claim 21, wherein arrangement of the plurality of spouting tubes and the plurality of draft tubes is configured to provide an average particle recycle time of substantially tea seconds to provide substantially uniform gas-solid contact and to provide carbon conversion efficiency exceeding about 90 percent.

24. The gasification reactor of claim 21, wherein injection zones of the plurality of spouting tubes and tire plurality of draft tubes are separated to reduce localized gas velocities within the plurality of draft tubes to reduce erosion and to maintain bed stability under pressurized operation,25. The gasification reactor of claim 21, 'wherein the plurali ty of spouting tubes and the plurality of draft tubes are configured to distribute radiative and convective beating substantiallyuniformly across the particulate bed. to improve ailotbermal gasification efficiency.

Images