Canadian Patents Database / Patent 2741386 Summary

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(12) Patent: (11) CA 2741386
(54) English Title: SYSTEM AND METHOD FOR PROCESSING MATERIAL TO GENERATE SYNGAS
(54) French Title: SYSTEME ET METHODE PERMETTANT LE TRAITEMENT DE MATERIAU POUR GENERER DES GAZ SYNTHETIQUES
(51) International Patent Classification (IPC):
  • B01J 19/08 (2006.01)
  • B01J 4/00 (2006.01)
  • B01J 19/20 (2006.01)
  • C10L 3/08 (2006.01)
(72) Inventors (Country):
  • JENSEN, ROBERT CHRISTIAN (Canada)
  • HOUZE, GRAHAM CAMPBELL (Canada)
(73) Owners (Country):
  • RESPONSIBLE ENERGY INC. (Canada)
(71) Applicants (Country):
  • RESPONSIBLE ENERGY INC. (Canada)
(74) Agent: MURRAY, SEAN
(45) Issued: 2013-01-08
(86) PCT Filing Date: 2010-10-22
(87) PCT Publication Date: 2012-04-22
Examination requested: 2011-05-27
(30) Availability of licence: N/A
(30) Language of filing: English

(30) Application Priority Data:
Application No. Country Date
61/366,327 United States of America 2010-07-21

English Abstract





The present invention is directed to system and method for processing material
to
generate syngas. A reactor chamber is implemented with a plurality of
electrodes that
can generate an arc within the chamber when electricity is applied to them.
The arc
can be used to create free radicals which along with the heat and light of the
arc
breakdown material comprising carbonaceous material, such as Municipal Solid
Waste (MSW), into gas components that form syngas. The syngas can be extracted

from the reactor chamber and be used for various commercial purposes. The
reactor
chamber may comprise a material feed system operable to move material from a
material input opening in the reactor chamber towards the electrodes at a
controlled
rate. Further, the reactor chamber may comprise a water injection system
within the
reactor chamber operable to inject water into the reactor chamber while
electricity is
applied to the electrodes. Yet further, the reactor chamber may comprise a gas

removal system within the reactor chamber operable to extract gas generated
from
breakdown of the material from a plurality of gas removal locations. The gas
removal
system may be integrated within the material feed system.


Note: Claims are shown in the official language in which they were submitted.




WHAT IS CLAIMED IS:

1. A system comprising:
- a reactor chamber having a material input opening;
- a plurality of electrodes at least partially protruding into the reactor
chamber, the electrodes operable to generate an arc within the reactor
chamber when electricity is applied to them;
- a material feed screw within the reactor chamber operable to move
material from the material input opening towards the electrodes at a
controlled rate when rotated, the material feed screw comprising a central
shaft and at least one flute connected to the central shaft; and
- a gas removal system within the reactor chamber operable to extract gas
generated from breakdown of the material.


2. A system according to claim 1 further comprising a control system operable
to
manage a speed of rotation of the material feed screw based upon a monitored
aspect of the gas extracted by the gas removal system.


3. A system according to one of claims 1 and 2, wherein at least a portion of
the
flute is perforated.


4. A system according to one of claims 1 to 3, wherein at least a portion of
the
flute is serrated.


5. A system according to one of claims 1 to 4 further comprising a water
injection system within the reactor chamber operable to inject water into the
reactor chamber while electricity is applied to the electrodes, the water
injection system being integrated with the material feed screw.


6. A system according to claim 5, wherein the water injection system comprises

a water injection pipe integrated within the central shaft of the material
feed
screw, the water injection pipe protruding out of an end of the material feed
screw; wherein a portion of the water injection pipe that protrudes out of the

end of the material feed screw comprises a water injection element.



53




7. A system according to one of claims 1 to 6, wherein the gas removal system
is
integrated with the material feed screw.


8. A system according to claim 7, wherein the gas removal system comprises a
gas removal pipe integrated within the central shaft of the material feed
screw,
the gas removal pipe protruding out of an end of the material feed screw;
wherein a portion of the gas removal pipe that protrudes out of the end of the

material feed screw comprises a gas removal nozzle.


9. A system according to claim 7, wherein the gas removal system comprises a
gas removal pipe integrated within the central shaft of the material feed
screw,
the gas removal pipe having an elongated hole along the length of the pipe
which leaves a portion of the circumference of the gas removal pipe open;
wherein the central shaft of the material feed screw comprises a plurality of
vents, each vent being at a different length along the central shaft and at a
different location along the circumference of the central shaft; whereby, the
elongated hole within the gas removal pipe may be aligned with one of the
vents in the central shaft of the material feed screw while being not aligned
with another one of the vents based upon a rotation of the gas removal pipe;
wherein the gas removal pipe is operable to be rotated such that the elongated

hole within the gas removal pipe is aligned with one of the vents in the
central
shaft of the material feed screw in a first position and aligned with another
one
of the vents in a second position.


10. A system according to one of claims 1 to 9 further comprising a material
injection system operable to move material into the reactor chamber, the
material injection system comprising a material injection screw operable to
move material towards the material input opening when rotated.


11. A system according to claim 10 further comprising a control system
operable
to manage a speed of rotation of the material injection screw based upon a
monitored aspect of the gas extracted by the gas removal system.


12. A system according to one of claims 10 and 11, wherein the material
injection
screw comprises a central shaft and at least one flute connected to the
central



54




shaft; and wherein the material injection screw comprises first and second
portions and the material injection screw is operable to move material from
the
first portion to the second portion, a diameter of the central shaft of the
material injection screw at the first portion being less than a diameter of
the
central shaft at the second portion.


13. A system according to claim 12, wherein the material injection screw
further
comprises a third portion and the material injection screw is operable to move

material from the second portion to the third portion, a diameter of the
central
shaft of the material injection screw at the second portion being greater than
a
diameter of the central shaft at the third portion.


14. A system according to one of claims 10 to 13, wherein the material
injection
system comprises a means for heating material within the material injection
system.


15. A system according to claim 14, wherein the material injection system
comprises an external jacket surrounding at least a portion of the material
injection screw, the external jacket operable to receive a heated substance.


16. A system according to claim 15, wherein the heated substance comprises gas

extracted by the gas removal system.


17. A method for generating gas within a reactor chamber, the reactor chamber
comprising a plurality of electrodes at least partially protruding into the
reactor chamber, the electrodes operable to generate an arc within the reactor

chamber when electricity is applied to them, the method comprising:
- causing insertion of material into the reactor chamber and movement of
the material towards the electrodes at a controlled rate, the material
comprising carbonaceous material; and
- causing extraction of gas generated from the breakdown of the material
from the reactor chamber;
- wherein the causing movement of the material towards the electrodes at a
controlled rate is using a material feed screw comprising a central shaft
and at least one flute connected to the central shaft.







18. A method according to claim 17 further comprising:
- monitoring the gas extracted from the reactor chamber; and
- controlling the rate at which the material is moved towards the electrodes
based at least partially upon results from the monitoring.


19. A method according to one of claims 17 and 18 further comprising injecting

water into the reactor chamber while electricity is applied to the electrodes.


20. A method according to claim 19, wherein a water injection system
integrated
within the material feed screw is used for the injecting water into the
reactor
chamber.


21. A method according to claim 20, wherein the water injection system
comprises a water injection pipe integrated within the central shaft of the
material feed screw, the water injection pipe protruding out of an end of the
material feed screw; wherein a portion of the water injection pipe that
protrudes out of the end of the material feed screw comprises a water
injection
element.


22. A method according to one of claims 17 to 21, wherein a gas removal system

integrated within the material feed screw is used for causing extraction of
gas
generated from the breakdown of the material from the reactor chamber.


23. A method according to claim 22, wherein the gas removal system comprises a

gas removal pipe integrated within the central shaft of the material feed
screw,
the gas removal pipe protruding out of an end of the material feed screw;
wherein a portion of the gas removal pipe that protrudes out of the end of the

material feed screw comprises a gas removal nozzle.


24. A method according to claim 22, wherein the gas removal system comprises a

gas removal pipe integrated within the central shaft of the material feed
screw,
the gas removal pipe having an elongated hole along the length of the pipe
which leaves a portion of the circumference of the gas removal pipe open;
wherein the central shaft of the material feed screw comprises a plurality of



56




vents, each vent being at a different length along the central shaft and at a
different location along the circumference of the central shaft; whereby, the
elongated hole within the gas removal pipe may be aligned with one of the
vents in the central shaft of the material feed screw while being not aligned
with another one of the vents based upon a rotation of the gas removal pipe;
wherein the gas removal pipe is operable to be rotated such that the elongated

hole within the gas removal pipe is aligned with one of the vents in the
central
shaft of the material feed screw in a first position and aligned with another
one
of the vents in a second position.


25. A method according to one of claims 17 to 24, wherein a material injection

system is used for the causing insertion of material into the reactor chamber,

the material injection system comprising a material injection screw operable
to
move material towards the chamber when rotated.


26. A method according to claim 25 further comprising:
- monitoring an aspect of the gas extracted from the reactor chamber; and
- controlling the speed of rotation of the material injection screw based at
least partially upon results from the monitoring.


27. A method according to one of claims 25 and 26, wherein the material
injection
screw comprises a central shaft and at least one flute connected to the
central
shaft; and wherein the material injection screw comprises first and second
portions and the material injection screw is operable to move material from
the
first portion to the second portion, a diameter of the central shaft of the
material injection screw at the first portion being less than a diameter of
the
central shaft at the second portion.


28. A method according to claim 27, wherein the material injection screw
further
comprises a third portion and the material injection screw is operable to move

material from the second portion to the third portion, a diameter of the
central
shaft of the material injection screw at the second portion being greater than
a
diameter of the central shaft at the third portion.



57




29. A method according to one of claims 25 to 28 further comprising heating
material within the material injection system.


30. A method according to claim 29, wherein an external jacket, surrounding at

least a portion of the material injection screw, operable to receive a heated
substance is used for the heating material within the material injection
system.


31. A method according to claim 30, wherein the heated substance comprises gas

extracted from the reactor chamber.



58


A single figure which represents the drawing illustrating the invention.

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Admin Status

Title Date
(86) PCT Filing Date 2010-10-22
(85) National Entry 2011-05-27
Examination Requested 2011-05-27
(87) PCT Publication Date 2012-04-22
(45) Issued 2013-01-08

Maintenance Fee

Description Date Amount
Last Payment 2017-10-02 $200.00
Next Payment if small entity fee 2018-10-22 $100.00
Next Payment if standard fee 2018-10-22 $200.00

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee set out in Item 7 of Schedule II of the Patent Rules;
  • the late payment fee set out in Item 22.1 of Schedule II of the Patent Rules; or
  • the additional fee for late payment set out in Items 31 and 32 of Schedule II of the Patent Rules.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Request for Examination $200.00 2011-05-27
Registration of Documents $100.00 2011-05-27
Filing $400.00 2011-05-27
Final $318.00 2012-09-17
Maintenance Fee - Application - New Act 2 2012-10-22 $100.00 2012-10-18
Maintenance Fee - Patent - New Act 3 2013-10-22 $300.00 2013-10-23
Maintenance Fee - Patent - New Act 4 2014-10-22 $100.00 2014-10-21
Maintenance Fee - Patent - New Act 5 2015-10-22 $200.00 2015-10-19
Maintenance Fee - Patent - New Act 6 2016-10-24 $200.00 2016-10-11
Maintenance Fee - Patent - New Act 7 2017-10-23 $200.00 2017-10-02

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Abstract 2011-05-27 1 27
Description 2011-05-27 52 2,556
Claims 2011-05-27 20 793
Drawings 2011-05-27 45 751
Cover Page 2012-12-27 2 60
Description 2012-06-28 52 2,556
Claims 2012-06-28 6 228
Representative Drawing 2012-06-27 1 14
Cover Page 2012-06-27 2 59
Abstract 2012-08-02 1 27
PCT 2011-05-27 12 866
Prosecution-Amendment 2012-02-10 2 62
Prosecution-Amendment 2012-04-23 1 19
Prosecution-Amendment 2012-06-14 3 115
Prosecution-Amendment 2012-06-28 19 669
Correspondence 2012-08-29 4 194
Correspondence 2012-09-17 1 35