Solid Fuel Burner-Gasifier with Bulk Solids Pump

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Solution Overview

Problem

Conventional fixed bed gasifiers face limitations in controlling fuel feed and residence time due to gravity-dependent fuel movement, leading to inefficiencies in gasification, energy waste, and incomplete combustion, which restricts the production of high-quality syngas and biochar.

Innovation Solution

A bulk solids pump system with a rotating spool and sleeve-shaped chambers is used to thermally process solid fuels, allowing for controlled feed and heat recycling, which enhances the production of pyrolysis gases, syngas, tar, char, and torrefied products by maintaining a consistent flow and increasing residence time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If gravity feed is used to move solid fuel through gasification zones, then fuel movement is passive and simple, but fuel flow consistency deteriorates due to bridging, tunneling, and clogging

Engineering Contradiction:

Improvefuel feeding mechanismVSAvoidfuel flow consistency

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The patent replaces the gravity-based mechanical system with a controlled solids pumping system using a rotating spool mechanism. This mechanical substitution enables precise control of fuel flow rates and consistent delivery to the gasifier, eliminating the bridging and tunneling problems inherent in gravity feed systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operational parameters by introducing a controlled feeding mechanism that regulates fuel flow rate, residence time, and distribution uniformity. The rotating spool system allows adjustment of rotational speed and fuel delivery timing, transforming the uncontrolled gravity feed into a parameter-controlled process.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If fixed bed gasifier operates as a whole system, then process integration is achieved, but control of individual processes deteriorates making isolation difficult

Engineering Contradiction:

Improveprocess control flexibilityVSAvoidsystem control structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent segments the gasification process into distinct zones (drying, pyrolysis, reduction, combustion) with independent control capabilities. The solids pump enables separate control of fuel delivery to each zone, allowing individual process optimization while maintaining overall system integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces dynamic control capabilities through the rotating spool mechanism, which can adjust fuel delivery rates and timing for different zones. This dynamic control allows the system to adapt to varying operational requirements while maintaining process separation and control flexibility.

Inventive Principle:

Principle #15Dynamics

3Productivity

If residence time in each process zone is limited by gravity feed, then fuel moves quickly through the system, but thermal processing completeness deteriorates

Engineering Contradiction:

Improvefuel processing speedVSAvoidresidence time

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent implements continuous fuel delivery through the rotating spool mechanism, maintaining consistent fuel flow and thermal processing throughout the gasification zones. This continuous action ensures complete thermal processing while maintaining high productivity through controlled residence times in each zone.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution improves the efficiency and quality of thermal processing by maintaining consistent fuel flow and heat recycling, reducing energy waste, and enabling continuous operation while producing high-quality thermal products.

Implementation Method 1

one or more sleeve shaped chambers surrounding all or a portion of at least an axial extent of the curved passage to permit containment of heated gases to heat solid fuel within the curved passage

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

pyrolysis of solid fuel into a biochar material for soil remediation and carbon sequestration

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 3

torrefaction of solid fuel into a higher energy density and moisture resistant fuel for power production

Methodology Applied

Scientific EffectTorrefaction: Heat Treatment

Data Source

PatentUS9541285B2Solid fuel burner-gasifier methods and apparatus

Publication Date: 2017.01.10 ENGEL THOMAS WOLFGANG

AI summary

A system for thermally processing solid fuel to produce pyrolysis gases, syngas, tar, char, and/or torrefied products, which includes a bulk solids pump having a curved passage to move a feedstock therein and wherein the pump includes a spool supported for rotational movement. A sleeve shaped chamber or chambers surround all or a portion of at least an axial extent of said curved passage to permit containment of heated gases to heat solid fuel within the curved passage to thermally process the feedstock within the pump.