US 20120161451A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2012/0161451 A1
Struble et a].
(54)

(43) Pub. Date:

Jun. 28, 2012

PRODUCTION OF LIQUID FUEL OR

H02K 7/18

(2006.01)

ELECTRIC POWER FROM SYNTHESIS GAS

B01J 19/00

(2006.01)

IN AN INTEGRATED PLATFORM

(52)

US. Cl. ....... .. 290/1 R; 585/899; 585/800; 422/600;

422/187; 422/50; 422/83

75

( )

Inventors:

(73) Assignee?

Dou las Struble, Maumee, OH

(US)g; Robert Schuetzle,

(57)

Sacramento: CA (Us)

system(s) and process(es) are provided to produce synthesis

SYNTERRA ENERGY, Maumee,

OH (Us)

(21) APP1- NOJ

13/333,486

(22)

Dec- 21: 2011

Filed:

ABSTRACT

gas (syngas) from carbonaceous feedstock and synthesize the

syngas into liquid fuel and related byproduct substances.
Dissipated heat and byproduct substances are utiliZed to sup
ply energy to the system(s) and process(es). Utilization of
dissipated heat and the byproduct substances as energy
sources alloWs the system(s) and process(es) to be imple
mented Without input from external energy sources. Byprod
uct substances also are recycled for reconversion to syngas.

Related U-s- Application Data

Syngas is produced in a gasi?cation platform through a multi

(60) Provisional application No. 61/426,303, ?led on Dec.

22 2010'

phased gasi?cation process compiisiiigpyioiysis of iiie cam

bonaceous feedstock, steam reformatlon (or react1on) of
pyrolysis gas, and cleaning of syngas ejected from such steam
reformation. The syngas is catalytically converted into a

Publication Classi?cation
(51) Int. Cl.
C10L 1/04
(200601)
G01N 35/00
(200601)

product comprising the liquid fuel and the byproduct sub

stances. Separation of the product enables supply of the liquid
fuel and the byproduct sub stances for enabling, in part, opera
tion of the system(s) and implementation of the process(es).

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US 2012/0161451Al

PRODUCTION OF LIQUID FUEL OR

ELECTRIC POWER FROM SYNTHESIS GAS
IN AN INTEGRATED PLATFORM

Jun. 28, 2012

syngas production and conversion of syngas into liquid fuels

or marginally exploit such aspects.
SUMMARY

PRIORITY CLAIM

[0001] This application claims the bene?t of US. Provi

sional Patent Application Ser. No. 61/ 426,303 entitled PRO
DUCTION OF LIQUID FUEL OR ELECTRIC POWER
FROM SYNTHESIS GAS IN AN INTEGRATED PLAT

FORM and ?led Dec. 22, 2010, the entirety of Which is

incorporated by reference.

[0005] The folloWing presents a simpli?ed summary of the

subject disclosure in order to provide a basic understanding of
some aspects thereof. This summary is not an extensive over

vieW of the various embodiments of the subject disclosure. It

is intended to neither identify key or critical elements nor
delineate any scope. Its sole purpose is to present some con
cepts in a simpli?ed form as a prelude to the more detailed

description that is presented later.

[0006]

TECHNICAL FIELD

[0002]

The subject disclosure relates to production of bio

fuel from feedstock and, more speci?cally, yet not exclu

sively, to production of synthesis gas (syngas) from feedstock

and synthesis of the syngas into liquid fuel, electric poWer, or

related byproduct substances.

BACKGROUND

[0003] A convergence of various ?nancial factors, such as

increase in fossil fuel costs; market forces (e.g., adherence to

One or more embodiments of the subject disclosure

provide system(s) and process(es) for producing synthesis

gas (syngas) from carbonaceous feedstock (biomass, coal,
etc.) and synthesiZe the syngas into liquid fuel and related
byproduct substances. The syngas is produced in a gasi?ca
tion stage While the liquid fuel is produced in a liquidi?cation
stage in Which the syngas is catalytically converted into the
liquid fuel. The gasi?cation stage can be a multi-phase gas
i?cation process comprising a gasi?cation phase, a steam

reformation phase, and a cleaning phase. LikeWise, the liq

uidi?cation stage is a multi-phase liquidi?cation process
comprising a syngas conditioning phase, a fuel synthesis

sustainable energy consumption paradigms); and geopolitical

conditions (instability in oil-rich regions, climate change,

phase, and a product separation phase. Byproduct substances

include gas-phase hydrocarbons and solid-phase hydrocar
bons outside of the liquid-phase hydrocarbon range. Byprod

etc.) has reneWed interest in gasi?cation of organic or carbon

aceous materials, often called feedstock, to generate combus

uct substances are utiliZed (directly or indirectly) to supply

tible synthesis gas (or syngas) for reneWable generation of

(es) and are recycled for reconversion to syngas. Dissipated

heat is recovered to provide thermal energy to the system(s)
and process(es). Utilization of the byproduct substances and
dissipated heat as energy sources render the system(s) and

fuel. Synthesis gas can be utiliZed to generate electricity With

reduced CO2 emissions compared to electricity derived from

fossil fuel. In addition, feedstock utiliZed for generation of

synthesis gas is largely encompassed by post-processed (or

ganically or synthetically) Waste; therefore, feedstock is

intrinsically sustainable. Amongst various gasi?cation pro

cesses commonly employed for generation of synthesis gas is
pyrolysis. Such process produces byproducts, such as chars
or tars, in addition to production of synthesis gas. In conven

tional gasi?cation systems, the feedstock is dried and sup

plied into a stirred, heated kiln. As the feedstock passes

through the kiln, combustible synthesis gas is produced and is

continuously removed from the kiln. HoWever, production of
synthesis gas in conventional gasi?cation systems is gener
ally inef?cient, With an energy balance that renders produc
tion of fuel or electricity derived thereof commercially non

viable. In addition, conventional processes generally

exacerbate commercial viability issues With elevated opera
tional costs associated With process ine?iciencies related to

manipulation of produced byproducts. In addition, poorly

designed management of the byproducts also result in syn
thesis gas of lesser quality, With ensuing loW quality of
derived fuels and ensuing limited commercial thereof.
[0004] In addition, various conventional technologies are

energy (e.g., thermal, electric) to the system(s) and process

process(es) energy e?icient, enabling achievement of high

conversion yields (yield of syngas-to-fuel conversion)iin
certain scenarios, the system(s) and process(es) achieve con

version yield suf?ciently high to render the system(s) and

process(es) energetically self-sustained, operating Without

input from external energy sources. As an example, instead of
natural gas, the gas-phase hydrocarbons can be utiliZed to ?re

burners. As another example, gas-phase hydrocarbons can be

employed for poWer production. Solid-phase hydrocarbons

are recycled to the gasi?cation phase (e.g., a pyrolysis phase)
as feedstock material or to the steam reformation phase for

re-conversion to syngas. Dissipated heat from the gasi?cation

process can be harnessed and recycled into the byproduct
substances prior to being introduced into the system(s) and
process(es) described herein.

[0007] Syngas is produced in a gasi?cation platform that

enables the multi-phased gasi?cation process. The gasi?ca
tion platform can enable pyrolysis of the carbonaceous feed

available for conversion of syngas into liquid fuel or byprod

stock, steam reformation (or reaction) of pyrolysis gas, and

cleaning of syngas produced through such steam reformation.
The gasi?cation platform also can enable other thermody
namic processes to decompose and gasify the carbonaceous

uct substances. Such technologies typically exploit syngas

feedstock material. Clean and dry syngas is collected in the

generated in a gasi?cation stage and convert the syngas into

liquidi?cation platform and conditioned for fuel synthesis.

The conditioning is implemented in a conditioning phase and

liquid fuel. Yet, such conventional technologies generally

perform such conversion ine?iciently and demand signi?cant
capital expenditure or require feedstock sourcing that the
infrastructure exploited by such conventional technologies

nologies exploit infrastructure designed according to design

includes polishing and compression of collected syngas in

addition to blending of the compressed syngas With recycled
syngas that is part of byproduct substances. After preparation,
conditioned syngas is catalytically converted into a product
comprising the liquid fuel and the byproduct substances. The

principles that either fails to consider aspects of integration of

product is separated in the product separation phase; separa

cannot support. Moreover, many of such conventional tech

US 2012/0161451Al

tion of the product enables supply of the liquid fuel and the
byproduct substances for enabling, at least in part, operation
of the system(s) and implementation of the process(es)

Jun. 28, 2012

of the subject disclosure. The assessment platform can be part

of example system illustrated in FIG. 1.
[0014] FIG. 5 presents an example embodiment of a gasi?

described herein.

cation platform for producing synthesis gas in accordance

[0008] When compared to conventional technologies for

production of liquid fuels from gases, the system(s) and pro
cess(es) disclosed herein provide at least the folloWing advan
tages. (i) Versatility of feedstock utiliZation. The system(s)

With aspects described herein.

[0015] FIGS. 6A-6B illustrated an example embodiment of
a pyrolyZer chamber in accordance With aspects described
herein. The illustrated pyrolyZer chamber can be part of the

can operate, and the process(es) can be implemented, Without

production disruption even in scenarios in Which feedstock

gasi?cation platform presented in FIG. 5.

properties vary signi?cantly amongst production run. Such

uidi?cation platform for producing liquid fuel in accordance

versatility of feedstock utiliZation alloWs a variety of resource

recycle circuits, Which reduces or minimiZes Waste of

With aspects described herein.

[0017] FIG. 8 presents an example method for producing

byproduct substances and dissipated heath, and increases or

maximizes overall ef?ciency of operation. (ii) Positive energy
balance. At a time of achieving a production of clean synthe
sis gas or a time interval thereafter, the multi-phased gasi?

liquid fuel from synthesis gas in an integrated platform

according to aspects described herein.
[0018] FIG. 9 illustrates an example method for producing
synthesis gas in accordance With aspects described herein.
[0019] FIG. 1 0 illustrates an example method for producing

cation process disclosed herein can be effected in an energy

[0016]

FIG. 7 illustrates an example embodiment of a liq

self- sustained mode, Wherein equipment that implement such

liquid fuel and related byproduct substance(s) according to

multi-phased gasi?cation process operates Without input

aspects described herein.

from external energy sources. Resources recycled from the

[0020] FIGS. 11-12 present example methods for integrat

ing production of synthesis gas and synthesis of liquid fuels

fuel production meet energy demands of the system(s) that

implement the process for fuel production. The latter is par

according to aspects described herein.

ticularly, though not exclusively, important for system(s)

(e. g., plants) operating in remote areas Where electric poWer
or natural gas is not available to energy the system(s). (iii)
Customization of utiliZation of resource recycle circuits for
conditions of fuel market. This ?exibility also alloWs for the

process to be adjusted to meet peak market demands by

increasing or decreasing the byproduct recycle streams. For
example if diesel prices are high then all resource recycle
circuits can be adjusted to maximiZe diesel production, or if

electric prices are high, additional gas phase hydrocarbons

(e.g., tail gas and syn gas) can be produced for electric gen
eration.

[0009]

To the accomplishment of the foregoing and related

ends, the one or more aspects comprise the features herein

after fully described and particularly pointed out in the

claims. The folloWing description and the annexed draWings
set forth in detail certain illustrative features of the one or
more aspects. These features are indicative, hoWever, of but a

feW of the various Ways in Which the principles of various

aspects may be employed, and this description is intended to
include all such aspects and their equivalents.

DETAILED DESCRIPTION

[0021]

The subject disclosure is noW described With refer

ence to the draWings, Wherein like reference numerals are

used to refer to like elements throughout. In the folloWing

description, for purposes of explanation, numerous speci?c

details are set forth in order to provide a thorough understand

ing of the subject disclosure. It may be evident, hoWever, that

the various embodiments of the subject disclosure may be

practiced Without these speci?c details. In other instances,

Well-knoWn structures and devices are shoWn in block dia

gram form in order to facilitate describing the subject disclo

sure.

[0022] As employed in this speci?cation and annexed

draWings, the terms component, unit, system, struc
ture, platform, interface, and the like are intended to
include a computer-related entity or an entity related to an
operational apparatus With one or more speci?c functional
ities, Wherein the entity can be either hardWare, a combination
of hardWare and softWare, softWare, or softWare in execution.
One or more of such entities are also referred to as functional

elements. As an example, a component may be, but is not

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 illustrates an example system for production

of liquid fuel from synthesis gas in accordance With aspects of
the subject disclosure.
[0011] FIG. 2 illustrates an example gasi?cation platform
that enables generation of synthesis gas in accordance With

aspects of the subject disclosure. The example gasi?cation

platform can be part of the example system illustrated in FIG.
1.

[0012]

FIG. 3 illustrates an example liquidi?cation plat

limited to being a process running on a processor, a processor,

an object, an executable, a thread of execution, a program,

and/or a computer. As another example, a component can be

an apparatus With speci?c functionality provided by

mechanical parts operated by electric or electronic circuitry
Which is operated by a softWare or a ?rmWare application
executed by a processor, Wherein the processor can be inter
nal or external to the apparatus and executes at least a part of
the softWare or ?rmWare application. An illustration of such a
component can be a Water pump. In addition or in the alter

native, a component can provide speci?c functionality based

form that enables conversion of syngas into a hydrocarbon

on physical structure or speci?c arrangement of hardWare

product comprising liquid fuel in accordance With aspects of

elements; an illustration of such a component can be a ?lter or

the subject disclosure. The example liquidi?cation platform

a ?uid tank. As yet another example, a component can be an

can be part of the example system presented in FIG. 1.

[0013] FIG. 4 depicts an example embodiment ofan assess
ment platform that can regulate operation of a gasi?cation
platform, a liquidi?cation platform, and at least one recycling
circuit for byproduct substances in accordance With aspects

apparatus that provides speci?c functionality through elec

tronic components Without mechanical parts, the electronic
components can include a processor therein to execute soft

Ware or ?rmWare that provides at least in part the functional

ity of the electronic components. An illustration of such appa

US 2012/0161451Al

Jun. 28, 2012

ratus can be control circuitry, such as a programmable logic

cation platform 110 and liquidi?cation platform 140 are inte

controller. The foregoing example and related illustrations

grated, at least in part, through a set of one or more resource

are but a feW examples and are not intended to limiting.

Moreover, While such illustrations are conveyed for a com

least one byproduct substance produced in the gasi?cation

feedback circuit(s) 160 that can enable recycling syngas or at

ponent, the examples also apply to a system, a structure, a

stage or in the liquidi?cation stage. In addition, at least one

platform, an interface, and the like.

resource feedback circuit can enable reutiliZation of process

[0023] In addition, the term or is intended to mean an

inclusive or rather than an exclusive or. That is, unless

heat generated in various phases of the gasi?cation stage or

speci?ed otherWise, or clear from the context, the phrase X

[0028] Gasi?cation platform 120 enables a decomposition

and gasi?cation stage that is a multi-phase gasi?cation pro

employs A or B is intended to mean any of the natural

inclusive permutations. That is, the phrase X employs A or

B is satis?ed by any of the folloWing instances: X employs
A; X employs B; or X employs bothA and B. 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 speci?ed otherWise or clear from the context
to be directed to a singular form.

[0024]

Furthermore, the term set as employed herein

excludes the empty set; e.g., the set With no elements therein.
Thus, a set in the subject disclosure includes one or more
elements or entities. As an illustration, a set of synthesis gas
collection structures includes one or more synthesis gas col
lection structures; a set of devices includes one or more

devices; a set of regulators includes one or more regulators;

etc.

[0025]

Various aspects or features Will be presented in

the liquidi?cation stage.

cess comprising a gasi?cation phase, a steam reformation

phase, and a cleaning phase. The gasi?cation phase is a non

combustion gasi?cation phase in Which feedstock material
110 is gasi?ed. Various types of feedstockmaterial 110 can be

employed in the gasi?cation phase, such as biomass (Wood,

rice, corn, or sugar cane harvest Waste, etc.), municipal Waste

(moist or dry), farm compost, coal, petroleum coke, and the

like. The gasi?cation phase yields gas and byproduct solids.
In an embodiment, the gasi?cation phase is a pyrolysis phase
that yields pyrolysis gas Which includes synthesis gas (syn
gas) and other gases comprising heavier molecules. In addi

tion, in such embodiment, the byproduct solids resulting from

gasi?cation can include incompletely pyrolyZed feedstock
material, such as char, bio-char, or the like. In certain embodi
ments, the gasi?cation phase can incorporate steam from an
external source (not shoWn) to react gas that results from

terms of systems that may include a number of devices, com

gasi?cation and produce a larger concentration of synthesis

ponents, modules, and the like. It is to be understood and

appreciated that the various systems may include additional

gas (syngas) or a syngas With better chemical composition. In

certain embodiments, e. g., example embodiment 200 pre

devices, components, modules, etc., or may not include all of

the devices, components, modules etc. discussed in connec

sented in FIG. 2, gasi?cation platform 120 includes a pyroly

sis unit 204 that enables the gasi?cation phase. The pyrolysis

tion With the ?gures. A combination of these approaches also

can be used.

unit 204 includes structure that enables injection of feedstock

material 110 into at least one gasi?cation chamber (e.g., a

[0026] As described in greater detail beloW, the subject

disclosure provides system(s) and method(s) for produce syn

tion of oxygen and moisture content in the feedstock material

pyrolysis chamber). In an aspect, the structure alloWs regula

110 via atmosphere purging and steam injection. In addition,

thesis gas (syngas) from carbonaceous feedstock and synthe

siZe the syngas into liquid fuel and related byproduct sub
stances. The system(s) and method(s) disclosed herein enable
a unique integration of a non-combustive gasi?cation process
and platform With a matched gas-to-liquid process and liq
uidi?cation platform that alloWs highly ef?cient conversion

[0029] The gasi?cation phase is implemented at predeter

mined pressure (PP) and temperature (TP). In addition,

of carbonaceous feedstock material that can be economically

sourced into clean liquid fuel. In an aspect, the unique inte

decomposition and gasi?cation of the feedstock material 110

is effected for a predetermined period ATP. Speci?c values of

gration and related design principles is founded at least on (i)

pressure PP, temperature TP, and At], can be determined

through simulation or experimentation. In one or more

reutiliZing and recycling byproducts substances produced in

the gasi?cation process and the gas-to-liquid process in order
to attain desired or satisfactory (e.g., maximal) liquid fuel

production, (ii) mitigating or avoiding Waste-generating pro

cesses, and (iii) sharing thermal energy (e.g., heat ?oW(s))
betWeen the gasi?cation platform and the liquidi?cation plat
form in order to attain desired or satisfactory (e.g., optimal)

e?iciency.
[0027]

In connection With the draWings, FIG. 1 is a block

diagram that illustrates an example system 100 for production

of liquid fuel from synthesis gas in accordance With aspects of
the subject disclosure. The synthesis gas is produced in a
gasi?cation stage While the liquid fuel is produced in a liq
uidi?cation stage in Which syngas produced in the gasi?ca
tion stage is catalytically converted into the liquid fuel.
Example system 100 includes a gasi?cation platform 120 that
enables the gasi?cation stage, Which yields clean syngas 130.
In addition, example system 100 includes a liquidi?cation
platform 140 that consumes the clean syngas 130 and enables

the liquidi?cation stage, Which yields liquid fuel 150. Gasi?

pyrolysis unit 204 includes a disposal structure (see, e. g.,

FIG. 4) that maintains at least pressure condition and alloWs
byproduct solids to be discarded or reutiliZed.

embodiments, PP ranges from about 25 psi to 100 psiiloWer

or higher values also can be employed; and TP ranges from
nearly 10000 F. to nearly 1750 F. In addition, 10
minAtP36 min, Where min is the abbreviation of the
term minutes; in an embodiment, AI], is equal to about 3 6 min
and in another embodiment AI], is equal to about 10 min.
Values of PP elevated With respect to atmospheric pressure

alloW high e?iciency, e.g., high gas yield, of the gasi?cation

phase.
[0030]

The gas produced in the gasi?cation phase includes

syngas and, in certain scenarios, the gas is substantially syn

gas. Such syngas generally has an H2/CO molar ratio that is
non-ideal for fuel production. Accordingly, at least a portion
of the gas produced in the gasi?cation phase is streamed to the
steam reformation phase in Which the syngas in the gas is

reacted With steam (e.g., superheated steam) and thus

reformed into reacted syngas, Which his raW syngas With

H2/CO molar ratios more suitable for liquid fuel production.

In an aspect, the steam reformation phase yields consistent

US 2012/0161451Al

raW syngas, wherein the consistent raW syngas can be satu

rated syngas4e.g., syngas With nearly the highest H2/CO

molar ratio. Reaction of produced syngas With steam is sus
tained for a period AIR, Which in certain embodiments can

satisfy AIREIO seconds (s), or AIR equal to about 10 s; e.g.,

3 SATR5 s. The product of the steam reformation phase is
reacted syngas, Which can be supplied to the cleaning phase to
yield clean syngas 130. In example embodiment 200, gasi?

Jun. 28, 2012

phase, a fuel synthesis unit 308 that enables catalytic conver

sion of the conditioned syngas into the hydrocarbon product,
and a separation unit 312 that enables separation of the hydro

carbon product into solid-phase hydrocarbons, liquid-phase

hydrocarbons, gas-phase hydrocarbons, and Water. The Water
that results from such separation is referred to as Waxy Water.

[0033]

As indicated supra, in example system 100, a set of

one or more resource feedback circuit(s) 160 can enable

cation platform 120 includes a steam reformation unit 208

recycling syngas or at least one byproduct substance pro

that enables the steam reformation phase.

[0031] The clean syngas 130 generally is saturated and can

duced in the gasi?cation stage or in the liquidi?cation stage.

be generated through removal of particulate matter (pm), tars,

and other contaminants (sulfur-based compounds, soluble
acid gas(es), etc.) from the reacted syngas produced in the

The set of one or more resource feedback circuit(s) 160 also

enable recuperating dissipated heat or Water. Moreover, at

least one resource feedback circuit can enable reutiliZation of

process heat, or dissipated heat, generated in various phases

steam reformation phase. Structure that enables the cleaning

of the gasi?cation stage or the liquidi?cation stage. The set of

phase can include a set of cyclones through Which raW gas is

one or more resource feedback circuit(s) 160 can be divided

circulated. In addition, the cleaning phase can include liquid

into tWo categories, each category including tWo sub-sets,

based refrigeration of the reacted syngas 150, Which is satu

rated dirty syngas at elevated temperature, e.g., 1000 F. or
about 1000 F. In certain embodiments, cleaning phase does
not include a cooling stageifor example, reacted syngas is
not circulated through an entrained heat-?oW exchangeri

With each sub-set including at least one resource feedback

and thus temperature of the reacted syngas can range from

about 1700 F. to about 1750 F. In an aspect, the temperature
of the reacted syngas is reduced to about saturation tempera

ture (e.g., 237 F. under certain conditions) through, for

example, ambient-temperature liquid coolant (e.g., Water)

circuit: (I) A ?rst category is intra-feedback loops. A ?rst

sub-set of resource feedback circuits 162 in such category
includes at least one resource feedback circuit deployed
Within gasi?cation platform 120. The at least one resource
feedback circuit can direct condensate Water from the clean

ing phase to the steam reformation phase; for example, in an

embodiment, the condensate Water can originate in the gas
cleaning unit 212 and it can be supplied to the steam refor
mation unit 208. ReutiliZation of Water increases ef?ciency of

that removes the particulate matter, the tars, and other con
taminants from the reacted syngas. In additional or alternative
aspects, the temperature of the reacted syngas can be reduced

the multi-phased gasi?cation process and equipment (e.g.,

example gasi?cation system 200) that carry out such process.

to temperatures beloW the saturation temperature (for

example, 237 F. under certain conditions) or to temperatures
above the saturation temperature, but that are substantially

ment of such equipment (e.g., example gasi?cation system

loWer than the temperature at Which the reacted syngas exits

the steam reformation phase. It is noted that in one or more

In addition, reutilization of Water can enable, in part, deploy

200) in remote locations With limited access to Water or Where

Water is obtained through costly process(es) such as desalin

iZation. In addition or in the alternative, the at least one
resource feedback circuit can be a Water return loop that

than about 237 F., While in alternative or additional embodi

supplies Water from a ?rst structure that enables the cleaning

phase to a second structure in the cleaning phase. Moreover,

ments, the temperature of the reacted syngas is higher than

or as another alternative, the at least one resource feedback

embodiments, the temperature of the reacted syngas is loWer

about 237 F. In example embodiment 200, gasi?cation plat

circuit can direct steam generated in the steam reformation

form 120 includes a gas cleaning unit 212 that enables the gas

phase to the gasi?cation phase, Wherein the steam can be

injected into a feedback injection phase or into a gasi?cation
chamber in Which decomposition and gasi?cation of feed
stock material 110 occurs; for example, in an embodiment,

cleaning phase. In such example embodiment, gasi?cation

platform 120 also includes a gas drying unit 216 for cooling
the syngas and removing moisture therein.

[0032]

Liquidi?cation platform 140 enables a liquidi?ca

tion stage that is a multi-phase liquidi?cation process com

prising a gas conditioning phase, a fuel synthesis phase, and

a product separation phase. Clean syngas 130 or a portion
thereof is collected in the liquidi?cation platform 140 and
conditioned in the gas conditioning phase for fuel synthesis.
The gas conditioning phase includes polishing and compres
sion of at least a portion of the clean syngas 130, and blending
of recycled syngas that is part of byproduct substances With
syngas resulting from such compression. Conditioned syngas
(e. g., syngas that is blended and compressed) is catalytically
converted into a hydrocarbon product in a fuel synthesis

the steam can ?oW from steam reformation unit 208 to pyroly
sis unit 204. Furthermore, or as yet another alternative, the at
least one resource feedback circuit can transport dissipated

heat, through combustion air, for example, from the gasi?ca

tion phase to the steam reformation phase for production of
steam; as an example, in an embodiment, process heat

released in pyrolysis unit 204 can be recovered and supplied

to the steam reformation unit 208. A second sub-set of
resource feedback circuits 164 in the intra-feedback loops
category includes at least one resource feedback circuit

deployed Within liquidi?cation platform 140. The at least one

resource feedback circuit can supply unreacted syngas from

phase, Wherein the hydrocarbon comprises the liquid fuel 150

and byproduct substances. The hydrocarbon product is sepa
rated in the product separation phase; separation of the hydro
carbon product enables supply of the liquid fuel 150 and the
byproduct substances for enabling, at least in part, operation
of liquidi?cation platform 140 and gasi?cation platform 120.

the product separation phase to the gas conditioning phase;

In certain embodiments, e.g., example embodiment 300 pre

sented in FIG. 3, liquidi?cation platform 140 includes a gas

resource feedback circuits 166 in such category includes at

conditioning (cond.) unit 304 that enables the conditioning

byproduct substance from gasi?cation platform 120 to liq

for example, in an embodiment, separation unit 312 can sup

ply the unreacted syngas to gas conditioning unit 304.

[0034] (II) A second category is inter-feedback loops. Inter

feedback loops are distributed amongst gasi?cation platform
120 and liquidi?cation platform 140. A ?rst sub-set of
least one resource feedback circuit that transports at least one

US 2012/0161451Al

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Jun. 28, 2012

concentration of impurities, etc.) of the clean syngas, and at

circuit can supply steam from the steam reformation phase

least a portion of the clean syngas 170 fuels or energizes

enabled by gasi?cation platform 120 to a fuel synthesis phase

enabled by liquidi?cation platform 140. A second sub-set of
resource feedback circuits 168 in such category includes at

equipment that enables at least one of the gasi?cation phase,

the steam reformation phase, or the cleaning phase. Such
energy self-sustained mode of implementation of the multi

least one resource feedback circuit that transports at least one

phased gasi?cation process that embodies the gasi?cation

byproduct substance from liquidi?cation platform 140 to gas

stage described herein is at least another advantage of the

i?cation platform 120. The at least one resource feedback

subject disclosure; energy self-sustained mode of implemen

tation is generally not accomplished in conventional gasi?
cation systems.

circuit can supply solid-phase hydrocarbons produced in liq

uidi?cation platform 140 to a feedstock material input phase
effected in gasi?cation platform 120; in an aspect, the solid

phase hydrocarbons (e.g., Fischer-Tropsch Waxes) can be

employed to adjust the feedstock material moisture content to
a desired level. In addition or in the alternative, the at least one

resource feedback circuit can supply gas-phase hydrocar

bons, e.g., tailgas, ejected from liquidi?cation platform 140

as fuel for burners that heat structures in either the gasi?cation
phase or the steam reformation phase; such tailgas can have
substantially the same British Thermal Unit (BTU) per stan
dard cubic foot as that of product syngas generated in the
gasi?cation platform 140. The at least one resource feedback

circuit also can recycle gas-phase hydrocarbons ejected from

liquidi?cation platform 140, e.g., tailgas, into the steam ref
ormation phase for reformation into raW syngas. Further
more, or as yet another alternative, the at least one resource

feedback circuit can supply an aqueous portion of liquid

phase hydrocarbons produced in the liquidi?cation platform

140 to the steam reformation phase enabled by the gasi?ca
tion platform 120; as an example, in an embodiment, the

aqueous portion of liquid-phase hydrocarbons can be sup

plied from separation unit 312 to structure for steam produc
tion Within the steam reformation unit 208.
[0035] In example system 100, at least one resource feed
back circuit in the set of one or more resource feedback

circuit(s) 160 can provide tailgas or syngas, or both, to exter

nal poWer generator(s) 170 in order to produce electricity. The

[0038]

Example system 100 also includes an assessment

platform 180, Which can regulate various operational aspects

of liquid fuel production and manage resources associated
thereWith in accordance With aspects described herein. To
implement such regulation, assessment platform 180 can
monitor a set of operational conditions of one or more of

gasi?cation platform 120 or liquidi?cation platform 140. The

set of operational conditions can include (A) input condition

(s), (B) processing condition(s), and (C) output condition(s).

(A) An input condition characterizes at least one value of at
least one variable related to input entities (e.g., feedstock
material (e.g., 110), steam, a volume of Waxy Water . . . )

injected into a process (e.g., example method 700) for pro

duction of liquid fuel or electric poWer described herein; or

equipment operating in a mode capable to manipulate the

input entities according to such process. (B) A processing
condition characterizes at least one value of at least one

variable related to entities that enable the process for produc

tion of liquid fuel or electric poWer described herein. As an
example, one of such entities can be a gasi?cation unit (e.g.,
pyrolysis unit 204) and the at least one variable can be tem

perature (e.g., TP) and pressure (e.g., PP), Which establish, at

least in part, a gasi?cation condition for feedstock material
gasi?ed in the gasi?cation unit. As another example, one of
such entities can be a steam reformation unit (e.g., 208) and
the at least one variable can be temperature of steam injected

electricity can be exploited to energize equipment or one or

into the steam reformation unit (e.g., 208). (C) An output

more structures (e.g., motor drives that rotate a set of drums in

condition characterizes at least one value of at least one

pyrolysis chamber 406) Within gasi?cation platform 120 or

liquidi?cation platform 140.

[0036]

Additionally, at a time of achieving production of

clean syngas 130 or after a time interval thereafter, gasi?ca

tion of feedstock 110 and liquidi?cation of clean syngas 130

variable related to output entities, such as a hydrocarbon

product comprising solid-phase hydrocarbons, liquid-phase

hydrocarbons (e.g., 680), and gas-phase hydrocarbons (e.g.,
670).
[0039]

To monitor at least one operational condition, the

disclosed herein can be effected in an energy self-sustained

mode. Utilization of produced clean syngas to fuel or to

tional conditions of example system 100. To collect such data,

produce electricity and energize the various structures that

enable the gasi?cation stage or the liquidi?cation stage leads

at least one sensor in a set of sensors to perform measure

to emissions that are loW, similar to emissions that result When

ments; output of such measurements supplies the data. In an

clean natural gas is utilized, for example. Clean syngas pro

duced in the gasi?cation stage described herein is carbon

embodiment, e.g., example embodiment 400 illustrated in

assessment platform 180 can collect data related to opera

assessment platform 180 can perform measurements or cause

neutral, Wherein carbon-based emissions are avoided. In

FIG. 4, the data can be retained in data storage 456 Within a

memory 450 that is part of the assessment platform 180 or is

addition, utilization of produced clean syngas also alloWs for

consistent gas (e.g., gas With consistent chemical composi

functionally coupled thereto. Assessment platform 180 can

implement (e.g., execute) control logic that establishes one or

tion) to be provided to one or more structures that enable the

more features of data collection. As an example, the control

logic can establish a mode of measurement4e.g., real-time

gasi?cation stage or the liquidi?cation stage. In contrast, it

should be appreciated that With various conventional gasi?
cation processes, the combustion of the feedstock (e.g., feed
stock material 110) provides process heat (e.g., process of
combustion (POC) heat) that produces large amounts of con
taminants and introduces process variation related to feed

stock type, composition size, and moisture.

[0037] In the energy self-sustained mode, production of

data collection or nearly real-time data collection, scheduled

data collection, interactive data collection, or the like. The
control logic also includes a set of computer-executable code
instructions that, When executed by a processor (e.g., proces
sor(s) 440) that is part of assessment platform 180, cause the

clean syngas is effected at a predetermined rate With a speci?c

assessment platform 180 to direct the at least one sensor in the

set of sensors to collect data according at least in part to the
measurement mode. In certain embodiments, such as

product mix standard, e.g., a speci?c quality (HZ/CO ratio,

example embodiment 400, the control logic can be retained in

US 2012/0161451Al

Jun. 28, 2012

control logic storage 452, a group of one or more controller(s)

1 10; particular operational costs; or the like. In addition, after

420 can direct the at least one sensor in the set of sensors to

establishing speci?c intended values of PP, TP, and ATP,

collect data in accordance With the measurement mode. The

assessment platform 180 can control at least one operational

set of sensors includes a ?rst group of sensors distributed in

condition (e.g., input condition(s), processing condition(s),

gasi?cation platform 120 and a second group of sensors dis

output condition(s), or any combination thereof) to achieve or

maintain the intended values. Values of the set of parameters
{PP, TP; ATP} can be based at least on one or more of (i)

tributed in the liquidi?cation platform 140; such groups of

sensors are pictorially depicted With groups of three open
circles connected to assessment platform 180. The set of
sensors also can include sensors (not depicted) distributed
Within the resource feedback circuit(s) 160. In certain

embodiments, example embodiment 400 illustrated in FIG. 4,

the set of sensors can be embodied in sensor(s) 410; the set of
sensors can include pressure gauges, ?oW gauges; thermo

couples or other temperature monitoring devices; spectro

scopic sensors, such as mass spectrometers, optical spectrom
eters, photo-detectors; or the like.

intended operational condition(s), such as amount of input

feedstock material 110, type of feedstock material 110, mois
ture level of feedstock material 110, particle siZe of feedstock
material 110, or likely or expected types of byproduct pro

duced through gasi?cation of feedstock material 110,

intended synthesis gas yield; (ii) budgetary or other ?nancial
considerations; (iii) delivery and installation costs of equip
ment to perform the primary gasi?cation phase 120; or the
like.

110 injected into the gasi?cation platform 120. Measurement

[0043] Assessment platform 180 can analyZe disposable

solid matter originated through gasi?cation of the feedstock
material 110. Disparate density of various components of

of such moisture content can be performed in accordance

With a predetermined measurement mode. In another aspect,

disposable solid matter can result in separation of more dense

material, Which can be more likely to be reformed into syngas

assessment platform 180 can measure a volume of an aqueous

in an additional cycle of gasi?cation than less dense material

such as ash. To analyZe the disposable solid matter, assess

[0040] In an aspect, assessment platform 180 can measure

moisture content of at least a portion of feedstock material

portion (e.g., a Waxy Water portion) of liquid-phase hydrocar

bons (e.g., 680) produced in the liquidi?cation platform 140.
Measurement of such volume can be performed in accor
dance With a predetermined measurement mode. In yet
another aspect, assessment platform 180 can measure volume

and composition of tailgas, or gas-phase hydrocarbons (e.g.,

670) produced in liquidi?cation platform 140. In still another

ment platform 180 can collect spectroscopic data or thermo

chemical data in situ; one or more sensors of the ?rst group of

sensors distributed in the gasi?cation platform 120 can collect

the spectroscopic data 0 the thermochemical data. Such data
in conjunction With a set of criteria (e.g., predetermined com

position of probed material) can establish if additional gas

aspect, assessment platform 180 can measure volume and

i?cation is Warranted. The set of criteria can be stored in a

composition of product syngas (e.g., syngas 130). Measure

memory or memory element (database, register(s), ?le(s),

etc.) Within assessment platform 180 or functional coupled

ments of volume and composition of tailgas or syngas can be

performed in accordance With a predetermined measurement
mode.
[0041] Based on the data related to operational conditions

of example system 100, assessment platform 180 can regulate

the various operational aspects of liquid fuel production and
manage the resources associated thereWith as described

herein. In an embodiment, e.g., example embodiment 400,

such regulation can be enabled or implemented by at least one
controller in the group of one or more controller(s) 420. In an

aspect, the control logic de?nes, at least in part, various

responses that enable assessment platform 180 to regulate

thereto.
[0044] In addition or in the alternative, assessment platform

180 can analyZe physical properties or chemical properties of

product syngas (e.g., clean syngas 130). Data collected as part
of such analysis can be contrasted With a set of quality criteria
to establish if quality of syngas Warrants bypassing the steam

reformation phase (enabled by steam reformation unit 208 in

pyrolysis unit 204, as described supra). In certain embodi
ments, assessment platform 180 also can analyZe a sample of
feedstock material 110 and determine that carbon content in
the feedstock material is suf?ciently loW so as not to justify

such operational conditions in response to such data. In

another aspect, the control logic can dictate, at least in part,
intended operational performance, such as production of syn
gas (e.g., syngas 130) and features of produced syngas, such
as syngas composition; production of Waxy Water; utiliZation
of feedstock material; utiliZation of steam; utiliZation of tail

steam reaction, and thus gas produced in the gasi?cation

phase can be supplied directly to the cleaning phase. In

gas; and so forth. In an embodiment, e.g., example embodi

for example, at least one sensor, also can measure moisture

content of feedstock material 110. Based on data collected as

ment 400, various parameters representative of performance

thresholds can enable at least in part evaluation of operational
performance; the various parameters can be retained in per

formance (perf.) target(s) storage 454. Assessment compo

nent 180 can adjust at least one control parameter (tempera
ture, pressure, How of stem, rate of feedstock loading, amount

example embodiment 200, such scenario is illustrated With a

dashed arroW representing optional direct injection of pyroly

sis gas from pyrolysis unit 204 into gas cleaning unit 212. In
the alternative or in addition, assessment platform 180, via,
part of measurements of moisture content of feedstock mate

rial 110, assessment platform 110 can adjust volume, or

amount, of steam injected into an accumulation vessel (e.g.,
403) to regulate moisture content of feedstock material col
lected in the accumulation vessel.

of feedstock loading, etc.) that regulates the various opera

[0045]

tional conditions of at least one of the gasi?cation platform or

the liquidi?cation platform in order to attain an intended

form 180 can adjust a temperature pro?le, e.g., temperature

operational performance.
[0042]

Assessment platform 180 can determine values of

Moreover, in certain embodiments, assessment plat

setpoints at various instants, in a gasi?cation unit (e.g.,

pyrolysis unit 204) in the gasi?cation platform 120 to gener
ate a satisfactory (optimal or nearly-optimal, predetermined,

the set of parameters {PP, TP; ATP} autonomously in order to

etc.) utiliZation of feedstock material 110 and an aqueous

attain speci?c output performance, including syngas quality,

syngas yield; speci?c loading rate(s) of feedstock material

portion of liquid-phase hydrocarbons (e.g., 680) produced in

example system 100. Furthermore, in an embodiment, assess

US 2012/0161451Al

Jun. 28, 2012

ment platform 180 can adjust (e.g., increase, decrease, pre

storage (not shoWn), data storage 456, control logic storage

serve, etc.) consumption of a feedback stream of a byproduct

substance in the gasi?cation platform 120 in order to achieve
an intended performance target. In a scenario, assessment
platform 180 can reduce or terminate consumption of an
external source of energy (e.g., natural gas) and increase

452, etc.). The bus 445 can be embodied in at least one ofa
memory bus, a system bus, an address bus, a message bus, or
any other conduit, protocol, or mechanism for data or infor
mation exchange among components that execute a process
or are part of execution of a process. The exchanged infor
mation can include at least one of code instructions, code
structure(s), data structures, or the like.

consumption of tailgasifor example, a volume of natural

gas, a volume of syngas, and a volume of tailgas employed to

ignite burner that provide heat to gasi?cation platform 120

can be adjusted based on operational condition(s) of liquidi
?cation platform 140. Such reduction or termination in com

bination With such increase represents an adjustment of uti

liZation of resources available to the example system 100. In

[0050] It is noted that gasi?cation platform 120, liquidi?

cation platform 140, and resource feedback circuit(s) 160
described herein include equipment, components, or other
structure for automated control of the various portions of

another scenario, assessment platform 180 can reduce or ter

gasi?cation stage, liquidi?cation stage, and related recovery

of resources (heat, byproduct substances, etc.) disclosed

minate consumption of a volume of externally supplied Water

and increase a volume of Waxy Water (e.g., aqueous portion

herein. The equipment, components, or other structure for

682).
[0046] In various scenarios, the various analyses, measure
ments, and controls effected by assessment platform 180 can

enable, at least in part, operation of example system 100 With

limited resources, particularly, though not exclusively, in
operational locations in Which feedstock is costly, such as in

remote locations, or during unusual operational conditions,

e.g., stored feedstock is unusable because of poor storage
conditions. The bene?t of achieving an energy self-sustained

mode of operation generally outWeighs the cost and related

complexity of conducting the various analyses, measure

automated control can be deployed and con?gured (e.g., pro

grammed) in accordance With various aspects described
herein and via conventional and novel control paradigms,
mechanisms, or programming.
[0051] FIG. 5 is a block diagram of an example embodi
ment 500 of a gasi?cation platform 120 that enables imple
mentation of the gasi?cation stage described hereinbefore in
connection With FIG. 1. An amount (e. g., Weight or volume)
of feedstock material 110 is supplied through a set of air-lock
valves 502a, an accumulation (acc.) vessel 503, and an accu
mulation chamber 504 into a pyrolysis chamber 506, Which

effects a primary gasi?cation phase (e.g., 120) as described

ments, and controls.

[0047] In one or more embodiments, assessment platform
180 can exploit arti?cial intelligence (AI) methods to gener
ate the foregoing assessment(s) Without human intervention
as described supra. Such AI method can exploit intelligence

supra. While illustrated With a pyrolysis chamber, in one or

more embodiments, any or most any suitable gasi?cation

(e. g., information) related to operational condition(s) of

example system 100; in certain implementations, the intelli

i?cation phase 120) as described herein. In addition, in cer

tain embodiments, a plurality of tWo or more pyrolysis cham
bers or gasi?cation chambers of other kind can be deployed

gence can be generated through inference, e. g., reasoning and

conclusion synthesis based upon a set of metrics, arguments,

chamber can be employed in example gasi?cation system

500, Wherein a suitable gasi?cation chamber has the physical

properties that enable a gasi?cation phase (e.g., primary gas

(e.g., installed, tested, and accepted) in example system 500.

or knoWn outcomes in controlled scenarios, or training sets of

The amount of feedstock material 110 can be metered prior to

data. Arti?cial intelligence methods or techniques referred to

injection into the accumulation vessel 503 through the set of

air-lock valves 502a (such set represented With thick line
segments in FIG. 5); the feedstock material 110 can be

herein typically apply advanced mathematical algorithmsi

e.g., decision trees, neural netWorks, regression analysis,
principal component analysis (PCA) for feature and pattern
extraction, cluster analysis, genetic algorithm, or reinforced
leamingito a data set.

[0048]

Such AI methodologies (AI methods, AI tech

injected at a feed rate that ranges from about 5 to about 500

dtpd (dry tons per day). The injection of the feedstock mate
rial 110 can be accomplished in part through a conveyor line
(not shoWn) that delivers the feedstock material to a hopper

niques, etc.) can be retained in method storage 458 and can

(not shoWn) functionally coupled to the set of air-lock valves

include, for example, Hidden Markov Models (HMMs) and

related prototypical dependency models can be employed.
General probabilistic graphical models, such as Dempster
Shafer netWorks and Bayesian netWorks like those created by

502a. Feedstock material 110 can collect continually in the

structure search using a Bayesian model score or approxima

tion can also be utiliZed. In addition, linear classi?ers, such as

support vector machines (SVMs), non-linear classi?ers such

as methods referred to as neural netWor methodologies,

fuZZy logic methodologies can also be employed. Moreover,

game theoretic models and other approaches that perform
data fusion, etc., can be exploited.
[0049] As illustrate in example embodiment 400, processor
(s) 440 can be con?gured to enable or can enable, at least in

part, the described functionality of assessment platform 180,

or components therein. In an aspect, to enable such function

ality, the processor(s) 440 can exploit a bus that can be part of
the assessment platform 180 to exchange data or any other
information amongst components therein and memory 450 or
elements therein (e.g., method storage 458 or an algorithm

hopper (not shoWn).

[0052] To inject an amount of feedstock material 110 into
accumulation vessel 503, at least one air-lock valve in the set

of air-lock valves 50211 is opened for a period of time suitable

to inject the amount of feedstock material 110, While each
air-lock valve in a set of air-lock valves 50219 at the opposing
end of accumulation vessel 503 remains closed. After injec
tion of the amount of feedstock material 110 is complete, the
at least one air-lock valve in the set of air-lock valves 50211 is
closed and the accumulation vessel 503 is pressurized to an
operating pressure substantially the same as the pressure of
gasi?cation phase; e. g., pressure PP in the range from about

25 psi to about 100 psi. It should be appreciated that the sets

of air-lock valves 502a and 50219 and the accumulation vessel
503 enable supply of the amount of feedstock material 110 at
any or most any predetermined pressure higher than atmo

spheric pressure. After pressurization of accumulation vessel

503, at least one air-lock valve in the set of air-lock valves

US 2012/0161451Al

Jun. 28, 2012

50219 is opened, Which allows at least a portion of the amount

of feedstock material 110 to be supplied to accumulation
chamber 504 at the operating pressure (e. g., a pressure in the
range from about 25 psi to nearly 100 psi). In addition, accu

administrative procedures such as procurement of permit(s)

for deployment of gasi?cation systems described herein (e. g.,
example system 500) can be simpli?ed.

mulation chamber 504 includes a structure, such as an auger

vieW of a steam reformation stage that is part of non-combus

or a plunger, that enables ejecting the amount of feedstock

material 110 collected in the accumulation chamber 504 to

the pyrolysis chamber 506. In an embodiment, the plunger

can be embodied in a pneumatic cylinder functionally

tion gasi?cation described herein, the feedstock material 110

injected into example gasi?cation system 500 can contain
moisture and thus it need not be dried prior to injection into
the pyrolysis chamber 506. In particular, though not exclu

coupled (e.g., through a rigid bar and suitable attachment(s))

sively, in one or more embodiments, a volume of steam can be

to a plate that can push at least a portion of the amount of

feedstock material 110 into the pyrolysis chamber 506. Accu

supplied to pyrolysis chamber 506. Injection of the volume of

steam is optionalias represented by a dashed ?at, short

mulation chamber 504 also includes at least one control valve

arroW that reaches the pyrolysis chamber 506iand alloWs

(not shoWn) that holds positive pressure (e.g., a pressure from

about 25 psi to about 100 psi) in example gasi?cation system

control of the composition of produced synthesis gas during

the various gasi?cation phases conducted in example gasi?

[0055]

In contrast to conventional gasi?cation systems, in

500.

cation system 500. In addition or in the alternative, steam can

[0053] In an aspect of the subject disclosure, the tWo sets of

air-lock valves 502a and 502b, and the accumulation vessel
503 alloW air removal from collected feedstock material 110.

be injected in the accumulation vessel 503; injection of such

steam also is optional. Injection of steam alloWs for produc
tion of synthesis gas With speci?c, predetermined chemical
composition (e.g., ratio of H2 to CO); based at least on mois

The air removal mitigates (e.g., avoids) injection of air into

the pyrolysis chamber 506 and can improve quality (HZ/CO
molar ratio, concentration of impurities, etc.) of synthesis gas
produced as part of generation of gas (e.g., pyrolysis gas)

ture of the feedstock material 110, an amount (e.g., a How or

a volume) of steam is regulated to achieve a speci?c, desired

ratio of steam to carbon for a desired syngas composition.

through the primary gasi?cation phase (e.g., 120). In an

Moreover, in additional or alternative embodiments, injection

aspect, as part of pressurization of accumulation vessel 503,

of feedstock material 110 into pyrolysis chamber 506 can

include addition of Water into the feedstock material; Water
can be injected in a speci?c Water-to-solid ratio p (a real
number). As an example, p can range from about 1 to about
1.5.

operating pressure of example gasi?cation system 500

?ushes, or purges, air contained in the feedstock material 110
collected in the accumulation vessel 503. As indicated supra,

the operating pressure can range from nearly 25 psi to nearly

100 psi.
[0054] Injection of the feedstock material 110 can be
accomplished in batch mode. The set of air-lock valves 5021)

(such set represented With thick line segments in FIG. 5)

functionally connected to accumulation chamber 504 can
enable providing the amount of feedstock material 110 in

such batch mode, With a predetermined batch cycle period or

in continuous mode; a batch cycle period can range from
about 1 minute to about 10 minutes. The amount of feedstock
material 110 that is loaded in accumulation chamber 504 is
dictated at least in part by a feed rate, e.g., a rate at Which

feedstock material 110 is supplied; it should be appreciated

that feedstock material 110 is loaded When at least one air
lock valve in the set of air-lock valves 50219 is open. In batch

mode, loading of feedstock material 110 for a batch cycle is

initiated through depressuriZation of accumulation vessel 503
to recover normal atmospheric condition from operating

pressure (e.g., nearly 25 psi to nearly 100 psi) of example

gasi?cation system 500 in order to enable an amount of feed
stock material to be collected in the accumulation vessel 503

from the hopper (not shoWn) and supplied to accumulation

[0056]

In one or more embodiments, such as the example

embodiment illustrated in FIGS. 6A-6B, the pyrolysis cham

ber 506 is a vessel 602, With an inner surface coated, or lined,
With a refractory material that can retain heat for the gasi?

cation of feedstock material; the refractory material is repre

sented With right-slanted dashed area in FIGS. 6A-6B. The
vessel 602 is a source of the heat for the gasi?cation of the
feedstock material; e. g., vessel 602 operates as a furnace. The

refractory material can insulate the interior cavity 604 of the

vessel from the outer environment. In addition, the refractory
material can be a solid With physical properties (thermal

coe?icient(s), elastic moduli, hardness, etc.) suitable for

operation in a high-pressure (e.g., from about 25 psi to about
100 psi) and high-temperature (e.g., from about 10000 F.
through about 18000 F.) environment. In an aspect, the vessel
602 is manufactured out of metal (alloyed or otherWise) and is

dimensioned to enable transportation of pyrolysis chamber

506 in any or most any conventional road; for instance, length
of pyrolysis chamber 506 along axis 609 can range from
about 30 foot (ft) to about 60 foot, Whereas Width ranges from
nearly 10 ft to nearly 12 ft and height ranges from about 10

chamber 504, as described supra. It should be appreciated that

depressuriZation of accumulation vessel 503 occurs With each
air-lock valve in the set of air-lock valves 502a and each
air-lock valve in the set of air-lock valves 50219 is closed. In an
embodiment, process gas relieved as part of the depressuriZa

foot to about 12 foot. Any other materials suitable for With

tion circulates through a baghouse (not shoWn), Which

lating material can be installed to ensure a substantive loWer

enables removal of any or most any feedstock particulate

matter that is present in the relieved process gas. In an aspect,

temperature in the environment outside vessel 602 When

relieved process gas cleansed through the baghouse (not

In FIGS. 6A-6B, the thermally insulating material can be a

portion of the right-slanted dashed area.

shoWn) is supplied to a closed circuit of combustion air to be

combusted as part of the multi-phase gasi?cation process
described herein. At least one advantage of the closed circuit
for combustion air is that process gas is not released to the

atmosphere With the ensuing environmental adequacy. Thus

standing elevated pressures (e.g., from nearly 25 psi to nearly

100 psi) also can be utiliZed.
[0057] The vessel 602 is also can be coated With thermally

insulating material; a suitable amount of the thermally insu

compared With the operating temperature inside vessel 602.

[0058]

Pyrolysis chamber 506 also includes an injection

structure 607 (e.g., an injection chamber) that collects an

amount of feedstock material to be supplied to metal drum
608. Injection structure 607 is functionally coupled to accu