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Sommaire du brevet 2741386 

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Disponibilité de l'Abrégé et des Revendications

L'apparition de différences dans le texte et l'image des Revendications et de l'Abrégé dépend du moment auquel le document est publié. Les textes des Revendications et de l'Abrégé sont affichés :

  • lorsque la demande peut être examinée par le public;
  • lorsque le brevet est émis (délivrance).
(12) Brevet: (11) CA 2741386
(54) Titre français: SYSTEME ET METHODE PERMETTANT LE TRAITEMENT DE MATERIAU POUR GENERER DES GAZ SYNTHETIQUES
(54) Titre anglais: SYSTEM AND METHOD FOR PROCESSING MATERIAL TO GENERATE SYNGAS
Statut: Octroyé
Données bibliographiques
(51) Classification internationale des brevets (CIB):
  • B01J 19/08 (2006.01)
  • B01J 4/00 (2006.01)
  • B01J 19/20 (2006.01)
  • C10L 3/08 (2006.01)
(72) Inventeurs :
  • JENSEN, ROBERT CHRISTIAN (Canada)
  • HOUZE, GRAHAM CAMPBELL (Canada)
(73) Titulaires :
  • RESPONSIBLE ENERGY INC. (Canada)
(71) Demandeurs :
  • RESPONSIBLE ENERGY INC. (Canada)
(74) Agent:
(74) Co-agent:
(45) Délivré: 2013-01-08
(86) Date de dépôt PCT: 2010-10-22
(87) Mise à la disponibilité du public: 2012-04-22
Requête d'examen: 2011-05-27
Licence disponible: S.O.
(25) Langue des documents déposés: Anglais

Traité de coopération en matière de brevets (PCT): Oui
(86) Numéro de la demande PCT: PCT/CA2010/001663
(87) Numéro de publication internationale PCT: 2741386
(85) Entrée nationale: 2011-05-27

(30) Données de priorité de la demande:
Numéro de la demande Pays / territoire Date
61/366,327 Etats-Unis d'Amérique 2010-07-21

Abrégés

Abrégé anglais





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.

Revendications

Note : Les revendications sont présentées dans la langue officielle dans laquelle elles ont été soumises.





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

Description

Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.



CA 02741386 2012-06-28

1014-002 -PCT
SYSTEM AND METHOD FOR PROCESSING
MATERIAL TO GENERATE SYNGAS
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a Canadian national entry of PCT Patent Application
No.
PCT/CA2010/001663 filed on October 22, 2010.

FIELD OF THE INVENTION
The invention relates generally to material processing and, more particularly,
to
system and method for processing material to generate syngas.

BACKGROUND
Disposal of Municipal Solid Waste (MSW) and Municipal Solid Sludge (MSS) are
significant issues throughout the world, and especially in the developed
world. The
traditional techniques of either burying or incinerating MSW and MSS are
resulting in
significant problems. Landfills are increasingly running out of space and
there is
becoming a large requirement to truck huge amounts of MSW/MSS to distant
locations due to the public's unwillingness to have landfills in their
neighborhood.
The environmental impact of dumping the MSW and MSS and/or incinerating it in
a
traditional fashion are enormous with toxins leaching into the soil
surrounding
landfills and potentially carcinogenic elements entering the air during
incineration.
The public interest in environmentally acceptable solutions is growing and the
push
has been in most developed countries to Reduce, Reuse and Recycle in order to
limit
the MSW that makes it to the landfills and reduce the energy used in dealing
with it.
In some situations, benefits have been gained during the processing of MSW and
MSS. During incineration, there is often reuse of the heat generated in order
to create
electricity or heat one or more facilities. In landfills, there have been
successful
attempts to capture methane that is released in the breakdown of the MSW over
time.
This methane can then be used in a combustion chamber to create heat energy or
within a chemical process to form more complicated compounds. The problem is
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CA 02741386 2011-05-27

1014-002 -PCT
these solutions do not solve the underlying environmental problems and do not
come
close to properly capturing the energy within the MSW and MSS.

One technology that has been developed to better process MSW is called plasma
arc
gasification. In plasma arc gasification, a plasma arc is generated with
electrical
energy in order to reduce complex carbon-containing molecules into smaller
constituent molecules. This molecular breakdown occurs without the presence of
oxygen, ensuring that combustion does not occur. The process uses pyrolysis to
molecularly breakdown the complex carbon compounds into simpler gas compounds,
such as carbon monoxide CO and carbon dioxide CO2, and solid waste (slag). The
process has been intended to reduce the volumes of MSW being sent to landfill
sites
and to generate syngas, a useful gas mixture, as an output.

Syngas describes a gas mixture that contains varying amounts of hydrogen H2,
carbon
monoxide CO, and carbon dioxide CO2, generated through the gasification of a
carbon-containing compound. Syngas is combustible, though with typically less
than
half the energy density of natural gas. It is used as a fuel source or as an
intermediate
product for the creation of other chemicals. When used as fuel, coal is often
used as
the source of carbon by the following reactions:
C+024CO2
CO2+C-*2CO
C+H2O- CO+H2
This is a mature technology that has seen a renewed interest as a cleaner
method of
combusting coal than the traditional use of solid coal. When used as an
intermediate
product in the production of other chemicals such as ammonia, natural gas is
typically
used as the feed material, since methane has four hydrogen atoms which are
desirable
for syngas production and methane makes up more than 90% of natural gas. The
following steam reforming reaction is used commercially:
CH4 + H2O 4 CO + 3 H2
The traditional syngas generation technologies using coal and natural gas as
feed
inputs differ from plasma arc gasification in that they occur within a
controlled
oxygen environment whereas the plasma arc gasification occurs in an oxygen-
free
environment. Though designated oxygen-free, through the molecular breakdown of
input material, there will be the production of small quantities of oxygen
within the
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1014-002 -PCT
process. Further, the coal and natural gas techniques use consistent input
materials
which results in consistent syngas composition, while plasma arc gasification
implementations to date typically use MSW as input material in which feedstock
variability leads to syngas variability.

Unfortunately, thus far, there have been no municipal scale implementations of
plasma arc gasification due to a number of limiting aspects of the technology.
Firstly,
most implementations of the technology have not been designed to manage the
high
flow rate of MSW that would be required in a commercial facility. Further, the
pyrolysis techniques used have led to high levels of contaminant compounds
such as
tars, rather than the full conversion to hydrogen H2, carbon monoxide CO,
carbon
dioxide CO2 ) and hydrocarbons (Cl to C4s). The inconsistent nature of the MSW
input material has led to high variability in the quality of the generated
syngas. Yet
further, high levels of energy are consumed in the creation of the plasma arc
and, in
some instances, in drying the MSW prior to processing due to moisture limits
on the
input materials, while the generated syngas has a low calorific value,
typically less
than half of the BTU content of natural gas. These concerns have limited this
technology, despite the significant benefits of converting MSW into a valuable
product such as syngas.

Against this background, there is a need for solutions that will mitigate at
least one of
the above problems, particularly enabling the generation of syngas from input
material such as MSW and/or MSS in an efficient manner.

SUMMARY OF THE INVENTION
The present invention is directed to system and method for processing material
to
generate syngas. In various embodiments of the present invention, a reactor
chamber
is implemented with a plurality of electrodes that can generate an arc within
the
reactor chamber when electricity is applied. 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 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
3


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1014-002 -PCT
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.
According to a first broad aspect, the present invention is a system
comprising: a
reactor chamber having a material input opening; a plurality of electrodes at
least
partially protruding into the reactor chamber; a material feed system within
the reactor
chamber; and a gas removal system within the reactor chamber. The electrodes
are
operable to generate an arc within the reactor chamber when electricity is
applied to
them. The material feed system is operable to move material from the material
input
opening towards the electrodes at a controlled rate. The gas removal system is
operable to extract gas generated from breakdown of the material.

In an embodiment of the present invention, the material feed system comprises
a
material feed screw operable to move material from the material input opening
towards the electrodes at a controlled rate when rotated. In some cases, a
control
system may be 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.
In an
embodiment, the material feed screw comprises a central shaft and at least one
flute
connected to the central shaft. The flutes may be perforated and/or serrated.
The
system may further comprise 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 and/or the gas removal system may be
integrated with the material feed screw. In some embodiments, the system may
further comprise a material injection system operable to move material into
the
reactor chamber. The material injection system may comprise a material
injection
screw operable to move material towards the material input opening when
rotated.
The material injection system may compress the material in order to seal the
material
input opening and prevent gas from escaping from the reactor chamber through
the
material injection system.

4


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According to a second broad aspect, the present invention is a method for
generating
gas within a reactor chamber. The reactor chamber comprises 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 comprises: 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. In some embodiments, the
method further comprises: 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.

According to a third broad aspect, the present invention is a system
comprising: a
reactor chamber operable to receive material; a plurality of electrodes at
least partially
protruding into the reactor chamber; a water injection system within the
reactor
chamber and a gas removal system within the reactor chamber. The electrodes
are
operable to generate an arc within the reactor chamber when electricity is
applied to
them. The water injection system is operable to inject water into the reactor
chamber
while electricity is applied to the electrodes. The gas removal system is
operable to
extract gas generated from breakdown of the material.

In an embodiment of the present invention, the water injection system is
operable to
inject water into the reactor chamber at a controlled rate. In some cases, the
system
comprises a control system operable to control the rate at which water is
injected into
the reactor chamber by the water injection system based upon a monitored
aspect of
the gas extracted by the gas removal system. The monitored aspect of the gas
may be
a level of moisture within the gas extracted by the gas removal system, a
level of one
or more component parts of syngas within the gas extracted by the gas removal
system, and/or a level of contaminants within the gas extracted by the gas
removal
system. The system may further comprise a material feed system within the
reactor
chamber operable to move material from a material input opening within the
reactor
chamber towards the electrodes. The water injection system may be integrated
within
the material feed system. The water injection system may also be coupled to a
water
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1014-002 -PCT
source operable to heat water that is to be provided to the water injection
system; for
example, using heat from the gas extracted from the reactor chamber.

According to a fourth broad aspect, the present invention is a method for
generating
gas within a reactor chamber. The reactor chamber comprises 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 comprises: causing insertion of material into the reactor chamber, the
material
comprising carbonaceous material; causing injection of water into the reactor
chamber
while electricity is applied to the electrodes; and causing extraction of gas
generated
from the breakdown of the material from the reactor chamber.

In an embodiment of the present invention, the causing injection of water into
the
reactor chamber is at a controlled rate. In some cases, the method further
comprises:
monitoring the gas extracted from the reactor chamber; and controlling the
rate at
which water is injected into the reactor chamber based at least partially upon
results
from the monitoring. In some cases, the method further comprises causing
heating of
the water to be injected into the reactor chamber using the gas extracted from
the
reactor chamber.

According to a fifth broad aspect, the present invention is a system
comprising: a
reactor chamber operable to receive material; a plurality of electrodes at
least partially
protruding into the reactor chamber; and a gas removal system within the
reactor
chamber. The electrodes are operable to generate an arc within the reactor
chamber
when electricity is applied to them. The gas removal system is operable to
extract gas
generated from breakdown of the material from a plurality of gas removal
locations
within the reactor chamber.

In an embodiment of the present invention, the gas removal system is operable
to
extract gas generated from breakdown of the material from a first location of
the
plurality of gas removal locations in a first state and extract gas generated
from
breakdown of the material from a second location of the plurality of gas
removal
locations in a second state. The first location may be a first distance from
the
electrodes within the reactor chamber and the second location may be a second
6


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1014-002 -PCT
distance from the electrodes within the reactor chamber, the first distance
being less
than the second distance. In some cases, the system comprises a material feed
system
within the reactor chamber operable to move material from a material input
opening
within the reactor chamber towards the electrodes. The gas removal system may
be
integrated within the material feed system.

According to a sixth broad aspect, the present invention is a method for
generating
gas within a reactor chamber. The reactor chamber comprises 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, the
material comprising carbonaceous material; and causing extraction of gas
generated
from the breakdown of the material from at least one of a plurality of gas
removal
locations within the reactor chamber.

In an embodiment of the present invention, the causing extraction of the gas
comprises causing extraction of gas generated from the breakdown of the
material
from a first location of the plurality of gas removal locations in a first
state and
causing extraction of gas generated from the breakdown of the material from a
second
location of the plurality of gas removal locations in a second state. The
first location
may be a first distance from the electrodes within the reactor chamber and the
second
location may be a second distance from the electrodes within the reactor
chamber, the
first distance being less than the second distance. In some cases, the method
further
comprises: monitoring the gas extracted from the reactor chamber; and
controlling
which one of the plurality of gas removal locations to extract the gas based
at least
partially upon results from the monitoring.

According to a seventh broad aspect, the present invention is a system
comprising: a
reactor chamber having a material input opening; a plurality of electrodes at
least
partially protruding into the reactor chamber; a material feed system within
the reactor
chamber; and a gas removal system integrated within the material feed system.
The
electrodes are operable to generate an arc within the reactor chamber when
electricity
is applied to them. The material feed system is operable to move material from
the
7


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1014-002 -PCT
material input opening towards the electrodes. The gas removal system is
operable to
extract gas generated from breakdown of the material.

In an embodiment of the present invention, the material feed system comprises
a
material feed screw operable to move material from the material input opening
towards the electrodes when rotated. The material feed screw comprises a
central
shaft and at least one flute connected to the central shaft. The gas removal
system
comprises a gas removal pipe integrated within the central shaft of the
material feed
screw. In some cases, the gas removal system is operable to extract gas
generated
from breakdown of the material from a plurality of gas removal locations
within the
reactor chamber.

According to an eighth broad aspect, the present invention is a method for
generating
gas within a reactor chamber. The reactor chamber comprises 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 comprises: causing insertion of material into the reactor chamber, the
material
comprising carbonaceous material; causing movement of the material towards the
electrodes with a material feed system; and causing extraction of gas
generated from
the breakdown of the material from a gas removal location within the material
feed
system. In some cases, the causing extraction of gas comprises causing
extraction of
gas generated from the breakdown of the material from a plurality of gas
removal
locations within the material feed system.

According to a ninth broad aspect, the present invention is a material
injection system
for moving material into a reactor chamber for processing into gas. The
material
injection system comprises: a material injection screw operable to move
material
towards the reactor chamber when rotated from a first portion to a second
portion.
The material injection screw comprises a central shaft and at least one flute
connected
to the central shaft. A diameter of the central shaft of the material
injection screw at
the first portion is less than a diameter of the central shaft at the second
portion.

In an embodiment of the present invention, material is compressed when moved
from
the first portion of the material injection screw to the second portion
sufficient to
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mitigate gas from being output from the reactor chamber through the material
injection system. The material injection screw may further comprise a third
portion
and the material injection screw may be 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 may be greater than a diameter of the central
shaft at the
third portion. In some cases, the material injection system may further
comprise a
control system operable to manage a speed of rotation of the material feed
screw
based upon a monitored aspect of gas generated within the reactor chamber. In
some
embodiments, the material injection system may further comprise a water
injection
element operable to inject water into material within the material injection
system, a
tar injection element operable to inject tar into material within the material
injection
system, and/or a means for heating material within the material injection
system.
According to a tenth broad aspect, the present invention is a system
comprising: a
reactor chamber operable to receive material; a plurality of electrodes at
least partially
protruding into the reactor chamber; a tar injection element within the
reactor
chamber; and a gas removal system within the reactor chamber. The electrodes
are
operable to generate an arc within the reactor chamber when electricity is
applied to
them. The tar injection element is operable to inject tar into the reactor
chamber
while electricity is applied to the electrodes. The gas removal system is
operable to
extract gas generated from breakdown of the material and the injected tar
within the
reactor chamber.

In an embodiment of the present invention, the system further comprises a
water
injection system within the reactor chamber operable to inject water into the
reactor
chamber while electricity is applied to the electrodes. The tar injection
element may
be operable to inject tar into the reactor chamber proximate to the plurality
of
electrodes and/or the water injection system may be operable to inject water
proximate to the plurality of electrodes. In some cases, the water injection
system is
operable to inject water into the reactor at a controlled rate. The rate of
injection of
water into the reactor chamber by the water injection system may be at least
partially
based upon a rate of injection of tar into the reactor chamber by the tar
injection
element. In an embodiment of the present invention, the system further
comprises a
CO2 injection element within the reactor chamber operable to inject CO2 into
the
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reactor chamber while electricity is applied to the electrodes. The CO2
injection
element may be operable to inject CO2 into the reactor chamber proximate to
the
plurality of electrodes.

According to an eleventh broad aspect, the present invention is a method for
generating gas within a reactor chamber. The reactor chamber comprises 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 comprises: causing insertion of material into the reactor
chamber,
the material comprising carbonaceous material; causing injection of tar into
the
reactor chamber while electricity is applied to the electrodes; and causing
extraction
of gas generated from the breakdown of the material and the tar from the
reactor
chamber.

In an embodiment of the present invention, the method further comprises
causing
injection of water into the reactor chamber while electricity is applied to
the
electrodes. The causing injection of water into the reactor chamber may be at
a
controlled rate. The rate of injection of water into the reactor chamber may
be at least
partially based upon a rate of injection of tar into the reactor chamber. In
some cases,
the method further comprises causing injection of CO2 into the reactor chamber
while
electricity is applied to the electrodes.

According to a twelfth broad aspect, the present invention is a system
comprising: a
reactor chamber operable to receive material; a plurality of electrodes at
least partially
protruding into the reactor chamber; a CO2 injection element within the
reactor
chamber; and a gas removal system within the reactor chamber. The electrodes
are
operable to generate an arc within the reactor chamber when electricity is
applied to
them. The CO2 injection element is operable to inject CO2 into the reactor
chamber
while electricity is applied to the electrodes. The gas removal system is
operable to
extract gas generated from breakdown of the material and the injected CO2
within the
reactor chamber.

In an embodiment of the present invention, the system further comprises a
water
injection system within the reactor chamber operable to inject water into the
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chamber while electricity is applied to the electrodes. The CO2 injection
element may
be operable to inject CO2 into the reactor chamber proximate to the plurality
of
electrodes and/or the water injection system may be operable to inject water
proximate to the plurality of electrodes. In some cases, the water injection
system is
operable to inject water into the reactor at a controlled rate. The rate of
injection of
water into the reactor chamber by the water injection system may be at least
partially
based upon a rate of injection of CO2 into the reactor chamber by the CO2
injection
element. In an embodiment of the present invention, the system further
comprises a
tar injection element within the reactor chamber operable to inject tar into
the reactor
chamber while electricity is applied to the electrodes. The tar injection
element may
be operable to inject tar into the reactor chamber proximate to the plurality
of
electrodes.

According to a thirteenth broad aspect, the present invention is a method for
generating gas within a reactor chamber. The reactor chamber comprises 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 comprises: causing insertion of material into the reactor
chamber,
the material comprising carbonaceous material; causing injection of CO2 into
the
reactor chamber while electricity is applied to the electrodes; and causing
extraction
of gas generated from the breakdown of the material and the CO2 from the
reactor
chamber.

In an embodiment of the present invention, the method further comprises
causing
injection of water into the reactor chamber while electricity is applied to
the
electrodes. The causing injection of water into the reactor chamber may be at
a
controlled rate. The rate of injection of water into the reactor chamber may
be at least
partially based upon a rate of injection of CO2 into the reactor chamber. In
some
cases, the method further comprises causing injection of tar into the reactor
chamber
while electricity is applied to the electrodes.

These and other aspects of the invention will become apparent to those of
ordinary
skill in the art upon review of the following description of certain
embodiments of the
invention in conjunction with the accompanying drawings.

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BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of embodiments of the invention is provided herein
below, by
way of example only, with reference to the accompanying drawings, in which:

Figures 1A and 113 are first and second perspective views respectively of a
material
processing system according to an embodiment of the present invention;

Figures 2A and 2B are a top angular view and a cross-sectional side view
respectively
of an FRG reactor according to an embodiment of the present invention;

Figures 3A, 3B and 3C are a top angular view, a top view and a side view
respectively
of a material injection system operable to move material into the FRG reactor
of
Figures 2A and 2B according to one embodiment of the present invention;

Figure 4 is a side view of a sample material injection screw that may be
within the
material injection system of Figures 3A, 3B and 3C;

Figures 5A, 5B and 5C are a top angular view, a top view and a side view
respectively
of a material injection system according to an alternative embodiment in which
the
material injection system includes attachments for injection of tars and/or
water;
Figures 6A, 6B and 6C are a cross-sectional side view, a top angled view and a
side
view respectively of a material injection system according to an alternative
embodiment in which the material injection system includes an external jacket;
Figures 7A and 7B are a top angled view and a side view respectively of a
material
feed screw system that may be within the FRG reactor of Figures 2A and 2B
according to an embodiment of the present invention;

Figure 7C is an assembly diagram for the material feed screw system of Figures
7A
and 7B;

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Figures 7D and 7E are a zoomed in view of the top and bottom portion
respectively of
the material feed screw system of Figures 7A and 7B;

Figures 8A and 8B are a top angled view and a side view respectively of a
material
feed screw according to an alternative embodiment in which the material feed
screw
includes perforations;

Figures 8C and 8D are top angled views of material feed screws according to
additional alternative embodiments in which the material feed screw includes
alternative perforation designs;

Figures 8E and 8F are a top angled view and a side view respectively of a
material
feed screw according to an alternative embodiment in which the pitch of the
flute is
increased;
Figures 8G and 8H are a top angled view and a side view respectively of a
material
feed screw according to an alternative embodiment in which the pitch of the
flute is
increased and the edge of the flute is serrated;

Figures 9A, 9B and 9C are a top angled view, a side view and a cross-sectional
side
view respectively of a material feed screw system according to yet another
alternative
embodiment of the present invention in which syngas removal may occur at a
plurality of locations;

Figure 9D is an angled top view of a syngas removal pipe within the material
feed
screw system of Figures 9A, 9B and 9C according to an embodiment of the
present
invention;

Figure 9E is a zoomed in view of the bottom portion of the material feed screw
system of Figures 9A, 9B and 9C;

Figure 9F is a zoomed in view of the bottom portion of an alternative material
feed
screw system to that of Figures 9A, 9B and 9C in which the syngas removal pipe
end
is not perforated;

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Figures 10A, 10B and 10C are an angled top view, a top view and a cross-
sectional
side view respectively of the bottom portion of the FRG reactor of Figures 2A
and 2B
according to an embodiment of the present invention in which three electrodes
are
used;

Figures 11A, 11B and 11C are an angled top view, a top view and a cross-
sectional
side view respectively of the bottom portion of the FRG reactor of Figures 2A
and 2B
according to an alternative embodiment in which six electrodes are used;
Figures 12A, 12B and 12C are an angled top view, a top view and a cross-
sectional
side view respectively of the bottom portion of the FRG reactor of Figures 2A
and 2B
according to an alternative embodiment in which six parallel pairs of
electrodes are
used;
Figures 13A, 13B and 13C are an angled top view, a side view and a cross-
sectional
side view respectively of an electrode that may be used within the FRG reactor
of
Figures 2A and 2B according to an alternative embodiment in which a tungsten
tip is
used;
Figure 14A is an angled top view of an electrode system according to an
alternative
embodiment of the present invention which includes injectors for tar, water
and/or
CO2;

Figures 14B and 14C are a cross-sectional side view and a cross-sectional
front view
respectively of the electrode system of Figure 14A;

Figure 14D is an assembly diagram for the electrode system of Figure 14A;

Figure 15A is an angled top view of an electrode support structure using
wheels
according to one embodiment of the present invention.

Figure 15B is a zoomed in view of the wheel structure of Figure 15A with the
support
structure removed for clarity;

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Figure 16 is an angled top view of an alternative electrode support structure
using belt
systems;

Figures 17A and 17B are a top angled view and a zoomed in view respectively of
a
further alternative electrode support structure using a clamp/rail
arrangement;

Figure 17C is a top angled zoomed in view of the clamp/rail arrangement of
Figures
17A and 17B with the support structure removed for clarity;
Figure 18A is a top angled view of a brush assembly for electrifying an
electrode
according to an embodiment of the present invention;

Figures 18B and 18C are a top angled view and a zoomed in view respectively of
the
brush assembly of Figure 18A with cooling lines and fittings removed for
clarity;
Figure 18D is a top angled view of the brush assembly of Figure 18A as
installed on
the electrode support structure of Figure 17A;

Figure 19A is a top angled view of a contact clamp assembly for electrifying
an
electrode according to an embodiment of the present invention;

Figures 19B and 19C are a side view and a top angled view respectively of the
contact
clamp assembly of Figure 19A with cooling lines and fittings removed for
clarity; and
Figure 19D is a top angled view of the contact clamp assembly of Figure 19A as
installed on the electrode support structure of Figure 17A.

It is to be expressly understood that the description and drawings are only
for the
purpose of illustration of certain embodiments of the invention and are an aid
for
understanding. They are not intended to be a definition of the limits of the
invention.



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DETAILED DESCRIPTION OF EMBODIMENTS
The present invention is directed to system, apparatus and method for
processing
material to generate syngas. As will be described herein below, the system of
the
present invention includes a number of different distinct mechanical elements
that
together allow for an efficient process flow from material input to syngas
output. The
system, according to some embodiments of the present invention, is designed to
allow
for processing of material in a controlled manner through management of
various
aspects of the process including, but not limited to, free radical generation,
material
movement rate, arc electrical power and syngas extraction locations.
The key material input needed to generate syngas is carbonaceous material
(i.e.
material containing carbon-based molecules). In various embodiments, the input
material may be a wide range of carbonaceous materials or carbonaceous
material
mixed with extraneous non-carbonaceous material. In the case that it is a
mixture of
material, the extraneous material may be sorted out or processed into a waste
output
as will be described. In some embodiments, the input material may be Municipal
Solid Waste (MSW) and/or Municipal Solid Sludge (MSS). In other embodiments,
the input material may comprise construction waste (ex. wood, plywood, chip
board,
shingles, etc.), agricultural waste (ex. wood chips, plant matter, mulch,
other biomass,
etc.), rubber tires, medical waste, coal, oil, waxes, tars, liquids such as
water
containing carbonaceous material and/or gases such as carbon dioxide. In some
embodiments, there may be limits on the proportion of the material that can
comprise
liquids and/or gases. Although examples of input material are provided, it
should be
understood that the scope of the present invention should not be limited by
these
example materials. Other material may be used as an input to the system of the
present invention including, but not limited to, solid carbonaceous material
and semi-
solid carbonaceous material.

In the case of the input material being MSW or another input material that may
have a
mixture of carbonaceous material and extraneous material, a pre-sort may be
performed. For instance, recyclable materials (ex. metals, glass, useable
plastics, etc)
and hazardous materials (ex. radioactive materials, batteries, fluorescent
light bulbs,
etc.) may be pre-sorted out. Extraneous material that is input to the system
as will be
described will effectively result in additional waste. For example, as will be
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described, metals may be melted and form pellets and other non-organic
material (ex.
glass, ceramics, etc.) may be melted and form vitrified granular material that
may
encapsulate heavy metals.

Figures 1A and 1B are first and second perspective views respectively of a
material
processing system according to an embodiment of the present invention. As
shown,
the material processing system comprises first and second conveyors 100,102
operable to move input material into a shredder 104. Along conveyor 100,
operators
may sort the input material in order to remove non-organic material for
recycling and
hazardous materials for proper disposal. The remaining material, which would
normally comprise significant organic material, is conveyed by the conveyor
102 and
dropped into the shredder 104. The shredder 104 is operable to reduce the
material in
size sufficient for further processing. The maximum size that the shredder 104
reduces the input material to is dependent upon dimensions within the
remainder of
the particular system.

The material processing system of Figures 1A and 1B further comprises a third
conveyor 106, a load hopper 108, a material feed conveyor 110, a material
injection
system 112 and a Free Radical Gasification (FRG) reactor 114, that can more
generally be referred to as a reactor chamber. From the shredder 104, the
input
material is dropped onto the third conveyor 106 which carries the material
into the
load hopper 108. Feed conveyor 110 then transfers the input material into a
top
opening within the material injection system 112. In some cases, the size that
the
shredder 104 reduces the input material is determined by dimensions within the
material injection system 112. In embodiments of the present invention, each
of the
conveyors 100,102,106,110 is controlled to deliver material into the material
injection
system 112 at a desired rate. The desired rate may change based on conditions
within
the system. For example, the desired rate of input may be adjusted based upon
aspects of the resulting syngas from the system.
The input material, after being dropped into the top opening within the
material
injection system 112, is moved towards the FRG reactor 114 and may further be
compressed by the material injection system 112. This movement can be done
through a number of techniques including, but not limited to, a screw
mechanism.
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The process of moving the material towards the FRG reactor 114 and compressing
the
material for one particular embodiment of the present invention will be
described in
more detail with reference to Figures 3A, 3B, 3C and 4.

The material is input into an opening near the top of the FRG reactor 114 by
the
material injection system 112. As will be described with reference to Figures
2A and
2B, rotational motion of a screw mechanism within the FRG reactor 114 causes
the
input material to move downward through the FRG reactor 114. Within the lower
portion of the FRG reactor 114 is a plurality of electrodes as will be
described in
detail with reference to Figures 10 to 14 which when electricity is applied,
generates
an arc with a high intensity light and high heat. The arc combined with the
possible
injection of water into the FRG chamber 114, allows for a Free Radical
Gasification
(FRG) zone to form. Material exposed to the high intensity light and high heat
of the
arc is reduced from long organic molecular chains to simpler molecules.
Additionally, the arc cleaves molecules, producing highly reactive free
radicals which
then can also reduce even more molecules. The free radicals act in parallel to
the
thermolytic reactions to break down the long organic molecular chains, thus
improving the amount of material broken down in the process. This can lead to
lower
energy usage per unit of material processed.
The input material is directed into the FRG zone by the screw mechanism within
the
FRG reactor 114 at a rate that that can be substantially similar to the
conversion rate
of the material into syngas within the FRG zone. A large portion of the
resulting
molecular structures from the breakdown of the material can comprise
components of
syngas such as hydrogen (H2) and carbon monoxide (CO). The syngas that is
produced is at a high temperature and is drawn off in one or more locations in
close
proximity to the FRG zone, at various elevations above the FRG zone and/or
near the
top of the FRG reactor 114. The syngas may contain contaminants such as
vapourized tars, water vapour and particulate matter. In some embodiments, the
syngas is extracted from a location close to the FRG zone, as the syngas at
this
location may have the least amount of contaminants, thus reducing the cost of
subsequent cleaning of the syngas. In other embodiments, syngas extraction may
be
at locations further above the FRG zone to allow the syngas, which will be at
a high
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temperature, to contribute to pyrolysis of the input material. Pyrolysis can
additionally breakdown long chain molecules within the input material.

Within the system of Figures 1A and 1B, the syngas extracted from the FRG
reactor
114 is piped along syngas transfer pipe 120 to a condensate tank 122 in which
water
can be used to cool the syngas causing condensation of entrained water and
contaminant vapours in the condensate tank 122. The cooling water can be
inserted
into a water jacket (not shown) enclosing the condensate tank 122 and/or into
a coil
(not shown) within the tank 122 from water pipe 124 and through a water valve
126
that can control the flow of water into the condensate tank 122. The cooling
water,
while cooling the hot syngas within the condensate tank 122, will increase in
temperature as a result. This warmed water may then be piped from the water
jacket
and/or coil within the condensate tank 122 through water pipe 128 to the top
of the
FRG reactor 114 and injected into the FRG reactor 114 as will be described
with
reference to Figure 2B. The high intensity light and high heat of the arc
cause
homolytic bond cleavage of the water molecules resulting in a significant
source of
free radicals within the FRG reactor 114. The contribution of this additional
source of
free radicals can aid in energy requirement reduction and can also provide a
significant source of desirable atoms which ultimately form the resulting
syngas.
Some of the hydrogen from the water molecules becomes H2 and some of the
oxygen
from the water molecules combines with carbon to form CO.

Although in the system of Figures 1A and 1B, the same water is used as a
cooling
agent for the syngas and as the water for the generation of free radicals
within the
FRG reactor 114, it should be understood that in other embodiments this may
not be
the case. In some embodiments, a separate cooling agent could be used to
reduce the
temperature of the syngas while water may be injected into the FRG reactor 114
from
an alternative source.

To aid in waste product management, water may also be maintained in a pool at
the
bottom of the FRG reactor 114. Non-organic material such as glass, ceramic,
dirt etc.
that enter the FRG reactor 114 within the input material will become molten in
or near
the FRG zone and drop into the water pool at the bottom of the FRG reactor 114
(below the FRG zone) to cool into vitrified particles. Similarly, metal pieces
that
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enter within the input material will be melted in or near the FRG zone and
become
metal pellet-like particles in the water pool. In some embodiments of the
present
invention, the level in the water pool is maintained below the FRG zone and is
maintained by a leveling system with an external water reservoir tank 226.
Water is
supplied to the external tank 226 through water pipe 130.

The pellet-like waste components from the non-organic material and metal can
be
removed through a hole in the bottom of the FRG reactor 114 and dropped onto a
waste conveyor 116. The waste components can then be conveyed to a waste
receptacle container 118 where they can be sorted and processed into saleable
commodities such as aggregates and metals. The waste conveyor 116 is angled
upwards from the hole in the bottom of the FRG reactor 114 to above the waste
receptacle container 118 such that, although water from the water pool may
enter the
waste conveyor 116, the level of the water in the waste conveyor 116 will be
below
the top of the waste conveyor 116 and therefore will not typically enter the
waste
receptacle container 118. The elevation of the waste conveyor 116 may further
accommodate differences in pressure between the FRG reactor 114 and the waste
conveyor 116 that could change the level of the water within the waste
conveyor 116.

The syngas that exits the condensate tank 122 may be removed and processed to
further remove contaminants such as water, tars and vapourized metals. The
syngas,
once cleaned, may be used for many well-known purposes including, but not
limited
to, as fuel feedstock for combustion in heating systems, boilers and/or
electrical
generators or as an input within a conversion process to produce diesel fuel,
methanol
or ammonia.

Prior to starting the material processing system of Figures 1A and 113, an
oxygen
purging process may be performed within the FRG reactor 114. Specifically, a
non-
oxygen containing gas (ex. Nitrogen) may be input to the FRG reactor 114
through
purge supply pipe 132. This non-oxygen containing gas is used to substantially
remove all available oxygen from the FRG reactor 114, thus preventing
combustion
within the FRG reactor 114 when the input material is brought into contact
with high
temperatures from the arc.



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As an additional safety feature, the FRG reactor 114 may be fitted with a low
pressure
burst disk or a reusable Pressure Safety Relief Valve (PSRV) 252 (shown in
Figure
2B) and a relief pipe 134 operable to dump gas to a safe location (ex.
external to a
building) if the pressure within the FRG reactor 114 exceeds a designed limit.
These
safety features could be used in the case that a significant problem occurred
such as a
blockage in the syngas transfer pipe 120.

Figures 2A and 2B are a top angular view and a cross-sectional side view
respectively
of the FRG reactor 114 according to an embodiment of the present invention.
Shown
in Figures 2A and 2B, the FRG reactor 114 comprises an FRG reactor top section
200, an FRG reactor main body section 202, an FRG reactor transition section
204, an
FRG reactor base section 206 and an FRG reactor bottom section 208 assembled
together to form the outer shell of the FRG reactor 114. Each of the sections
of the
FRG reactor 114 has a corresponding refractory liner with sufficient
refractory
properties to withstand the high temperatures within the FRG reactor 114
caused by
the arc and to provide insulation to the outside of the FRG reactor 114. In
particular,
the FRG reactor 114 comprises a top section refractory liner 210, a main body
refractory liner 212, a transition refractory liner 214, a base refractory
liner 216 and a
bottom refractory liner 218 that each are within the inner surface of a
corresponding
one of sections 200,202,204,206,208 respectively. In some embodiments, two
layers
of refractory liners are utilized for each section: an inner layer with high
refractory
properties but poor insulation properties that can withstand the high
temperatures of
the arc and exposure to the input material being converted; and an outer layer
coupled
to the inner wall of the FRG reactor 114 with superior insulation properties.
Together the main body, transition and base sections 202,204,206 of the FRG
reactor
114 form an upright cylindrical chamber with a first diameter in the main body
section 202 and a second smaller diameter within the base section 206. The
transition
section 204 is cylindrical with a narrowing diameter from top to bottom, from
the first
diameter to the second diameter. The top section 200 and the bottom section
208
enclose and seal the cylindrical chamber.

The sections of the FRG reactor 114 in Figure 2A comprise openings for various
pipes and apparatus. For instance, the top section 200 comprises openings for
the
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material injection system 112; a flexible water coupling 250 coupled to the
water pipe
128; the low pressure burst disk/PSRV 252 coupled to the relief pipe 134; a
syngas
outlet pipe 240 that is coupled via a flexible syngas line coupling 254 to the
syngas
transfer pipe 120; and a secondary syngas outlet pipe 256 that is coupled to a
secondary syngas control valve 258. The secondary syngas outlet pipe 256 may
be
used in a number of manners in various embodiments of the present invention.
In
particular, the secondary syngas outlet pipe 256 may provide a complementary
syngas
extraction location; provide an alternative syngas extraction location in case
of a
partial or complete obstruction in the syngas outlet pipe 240; and/or provide
a location
to extract the non-oxygen containing gas used in the oxygen purging process
described above.

The base section 208 comprises openings for a plurality of electrodes 224 that
protrude through the base section from outside of the FRG reactor 114 to
inside.
Within the embodiment of Figures 2A and 2B, there are three electrodes 224
each
protruding horizontally into the FRG reactor 114 at 120 from each other and
almost
meeting at the center of the base section 206. The electrodes have a gap
between
them in which the arc will form when electricity is conducted through the
electrodes
224. Different configurations for the electrodes 224 will be described in
detail with
reference to Figures 10 to 14. The bottom section 208 comprises an opening for
removal of waste components to the waste removal conveyor 116 as described
above.
The FRG reactor 114 of Figure 2B further comprises a Material Feed Screw (MFS)
220 that is operable to move the input material from the opening in the FRG
reactor
114 with the material injection system 112 towards the arc (and the FRG zone)
formed by the electrodes 224 in operation. The MFS 220 comprises a feed screw
shaft 702 with one or more protruding feed screw flutes 700 as will be
described with
reference to Figures 7A to 7E. The MFS 220 is positioned vertically within the
center
of the FRG reactor 114 with the top end of the feed screw shaft 702 protruding
through the top section 200 and the bottom end of the feed screw shaft 702
ending
above the electrodes 224. In the embodiment of Figure 2A, the bottom end of
the
feed screw shaft 702 ends at approximately the seam between the transition
section
206 and the base section 208. The top end of the feed screw shaft 702 is
coupled to
an MFS drive system 238 external to the FRG reactor 114 through a bearing and
seal
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element 236. The MFS drive system 238 is operable to rotate the MFS 220 which
will in turn result in the movement of the input material from the top of the
FRG
reactor 114 towards the arc formed by the electrodes 224.

The rate of rotation of the MFS 220 may be controlled in a number of manners.
In
one embodiment, the rate of rotation of the MFS 220 may be controlled by a
computing apparatus (not shown). In other embodiments, the rate of rotation of
the
MFS 220 may be modified manually or may be of a fixed rate. In one embodiment,
the rate of rotation of the MFS 220 may be determined based upon a monitored
aspect
of the syngas being extracted from the FRG reactor 114. In other embodiments,
the
rate of rotation of the MFS 220 may be determined based upon a rate of
breakdown of
the input material.

As will be described in detail with reference to Figures 7A-7E, the FRG
reactor 114
further comprises a syngas removal system 234 that is integrated within the
feed
screw shaft 702 in Figure 2B. The syngas removal system 234 comprises a syngas
removal pipe 704 implemented inside the feed screw shaft 702 and coupled at
the top
end to the syngas outlet pipe 240 external to the FRG reactor 114. The syngas
outlet
pipe 240 is coupled via a flexible syngas line coupling 254 to the syngas
transfer pipe
120 and therefore to the condensate tank 122. The lower end of the syngas
removal
pipe 704 protrudes from the lower end of the feed screw shaft 702 and has a
nozzle on
the end. The nozzle, as shown in Figure 2B, is above the electrodes 224
(approximately at the seam between the transition and base sections 204,206)
and in
operation would be close to the arc formed by the electrodes 224, thus
allowing for
removal of syngas from a location close to the FRG zone. It should be
understood
that in other embodiments, the syngas removal system 234 may allow for removal
of
the syngas from alternative locations further from the FRG zone as will be
described
with reference to Figures 9A-9F. In some embodiments of the present invention,
a
differential between the internal pressure of the FRG reactor 114 and
atmospheric
pressure can allow for improved removal of syngas through the nozzle in the
syngas
removal pipe 704 and/or other alternative locations.

Further, as will be described in detail with reference to Figures 7A-7E, the
FRG
reactor 114 comprises a water injection system 232 integrated within both the
feed
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screw shaft 702 and the syngas removal pipe 704 in Figure 2B. The water
injection
system 232 comprises a water injection pipe 706 implemented inside both the
feed
screw shaft 702 and the syngas removal pipe 704 and coupled at the top end to
the
water pipe 128 external to the FRG reactor 114. The lower end of the water
injection
pipe 706 protrudes from the lower end of the feed screw shaft 702 and has a
nozzle on
the end. The nozzle, as shown in Figure 2B, is adjacent to the electrodes 224
and in
operation would be above the arc formed by the electrodes 224, thus allowing
for
injection of water into the FRG zone. In some embodiments, the nozzle of the
water
injection pipe 706 may be close to the FRG zone but sufficiently far as to not
melt the
nozzle. The injection of water into the FRG zone will allow for the generation
of
additional free radicals as the arc breaks down the water molecules into their
base
components. The hydrogen within the water molecules may then be extracted
within
the syngas as H2 and the oxygen may combine with carbon molecules to form
carbon
monoxide (CO), both of which are significant components of syngas. The syngas
removal system 234 will be described in detail

Although the embodiment described with reference to Figures 7A-7E has the
syngas
removal pipe 704 and the water injection pipe 706 integrated within the MFS
220, this
should not limit the scope of the present invention. In alternative
embodiments of the
present invention, one or both of the syngas removal and the water injection
may not
be integrated within the MFS 220. In these alternative embodiments, the syngas
removal may occur in a different location and/or the water injection may occur
in a
different location or not at all.

As shown in Figure 2A, the external water reservoir tank 226 is adjacent to
the FRG
reactor 114 and is coupled to a water pipe 228 that passes through the base
section
206 into the FRG reactor 114, a pressure equalization pipe 230 that passes
through the
transition section 204 into the FRG reactor 114 and the water pipe 130 which
is
coupled to a source of water. A water level may be maintained at a desired
level
within the external water reservoir tank 226 using one of a plurality of well-
known
water leveling techniques (ex. a float level system). The pressure
equalization pipe
230 ensures the pressure in the FRG reactor 114 above the water pool remains
the
same as the pressure above the water level in the tank 226. Water can freely
flow
between the tank 226 and the FRG reactor 114 via the water pipe 228 and, due
to the
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pressure being matched with the pressure equalization pipe 230, gravity will
cause
water to flow into the FRG reactor 114 until the water level is equal to the
water level
in the external water reservoir tank 226. As water is consumed within the FRG
reactor 114 or exits through the waste conveyor 116, the leveling system adds
more
water to maintain the water pool at the appropriate water level. This
embodiment of
water leveling of the water pool in the FRG reactor 114 allows for a range of
operating water levels with varying distances relative to the FRG zone to be
controlled by an operator and/or a computing apparatus by controlling the
water level
within the tank 226.
In order to allow an operator to monitor aspects within the internal operation
of the
FRG reactor 114, the top section 200 further comprises a pressure gauge and
transducer 244 and the main body section 202 comprises a plurality of
temperature
probes 242. The pressure gauge can provide immediate visual indications of
internal
pressure within the FRG reactor 114. The pressure transducer may be connected
to a
computing apparatus (not shown) and provide information on the pressure within
the
FRG reactor 114 to an operational control system. The operational control
system
may be able to adjust many aspects of the overall system to manage the
pressure
within the FRG reactor 114. In some embodiments, a syngas control valve (not
shown) may be implemented after the condensate tank 122 to stabilize the
internal
pressure within the FRG reactor 114 at a desired level. In one embodiment,
that level
may be 1 PSI, though in other embodiments, other pressure levels within the
FRG
reactor 114 may be desired. An operational control system managed by an
operator
and/or a computing apparatus may control the syngas control valve in response
to the
measured pressure levels in the FRG reactor 114 received from the pressure
guage
and pressure transducer 244. An operator and/or a computing apparatus may
further
monitor temperatures within the FRG reactor 114 using the temperature probes
242.
Further, in the embodiment of Figures 2A and 2B, the top section 200 and the
main
body section 202 each comprise a sight port 260 that can be used to monitor
the
progress of movement and/or breakdown of the input material within the FRG
reactor
114. The sight ports 260 may comprise a clear quartz material, though other
materials
may also be used. Although the site ports 260 may become dirty as the FRG
reactor
114 is in use, during start-up, the site ports 260 may provide an ability to
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observe inside the FRG reactor 114 including the MFS 220. Further, the site
ports
260, in some embodiments, may provide access to withdraw a sample of the input
material and/or be adapted to add a tertiary syngas removal pipe. In some
embodiments, no site ports are included within the FRG reactor 114.

Yet further, in the embodiments of Figures 2A and 2B, a purge injection ring
246
surrounds the FRG reactor 114, in this case around the base section 206. The
purge
injection ring 246 is coupled to a plurality of purge injection sites that
protrude
through the walls of the FRG reactor 114, in this case through the base
section 206,
and is further coupled to the purge supply pipe 132. The purge supply pipe 132
is
coupled to one or more tanks containing a non-oxygen containing gas (ex.
Nitrogen)
and supplies the non-oxygen containing gas to the purge injection ring 246
which can
subsequently be injected into the FRG reactor 114 during the purging process
to
remove oxygen from the FRG reactor 114 prior to operation of the system.
In operation, the FRG reactor 114 operates to produce syngas through the
molecular
breakdown of the input material. This entails breaking chemical bonds with
both
thermal decomposition and the action of free radicals. The free radicals are
formed,
from both input material and injected water, using the high intensity light
and high
temperature generated by the electric arc. The temperature within the FRG
reactor
114 is controlled by the electrical energy applied to the electrodes 224 in
order to
create a zone of free radicals (the FRG zone) that can be used to stimulate
further
molecular breakdown. In addition to the primary means of temperature control,
other
means of controlling the temperature are the rate of entry of input material,
rate of
removal of gas, and the rate of injection of water. The final composition of
the syngas
can be manipulated through control of the conversion temperatures.

It should be noted that pyrolysis will also occur within the input material
due to the
high temperatures within the FRG reactor 114, producing significant amounts of
syngas. Further, as the gas progresses upwards within the FRG reactor 114, the
heated gas may result in pyrolysis within the cooler input material that has
not yet
reached the FRG zone close to the arc, breaking down some of the molecular
structures within this material. Further, vaporous components (ex. tars, gums,
etc.)
within the gas that moves upwards in the FRG reactor 114 may condense onto the
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cooler input material above the arc and then subsequently be moved into the
FRG
zone by the MFS 220. These components may then be broken down and contribute
positively to the production of the syngas.

Figures 3A, 3B and 3C are a top angular view, a top view and a side view
respectively
of the material injection system 112 operable to move material into the FRG
reactor
114 according to one embodiment of the present invention. Shown in Figures 3A,
3B
and 3C, the material injection system 112 comprises a cylindrical barrel 302
that
encloses a Material Injection Screw (MIS) 400. The barrel 302 is coupled to a
mounting flange 304 at one end that enables the material injection system 112
to be
mounted horizontally to a corresponding opening within the top section 400 of
the
FRG reactor 114. The barrel 302 comprises an opening in the top surface of the
cylindrical body sufficient in size to allow material conveyed to the material
injection
system 112 from the shredder 104 to enter the barrel 302 between flutes on the
MIS
400. The material injection system 112 further comprises an injection screw
drive
300 mounted to the barrel 302 and connected to the MIS 400 that is operable to
rotate
the MIS 400 in order to move input material that enters through the opening in
the top
of the barrel 302 towards the FRG reactor 114. The injection screw drive 300
may be
controlled locally or by a central computing apparatus (not shown) to manage
the feed
rate. In some embodiments, the injection screw drive 300 may be able to sense
problems in the material injection system 112, such as a blockage caused by
the
particular input material inserted (ex. metal jamming the MIS 400) through
monitoring of torque on the MIS 400. In response, the injection screw drive
300 may
send a warning message to an operator, terminate the rotation of the MIS 400
and/or
reverse rotation of the MIS 400.

The opening in the top surface of the barrel 302, in the embodiment of Figures
3A, 3B
and 3C, is close to the opposite end of the barrel 302 from the mounting
flange 304,
which will be coupled to the FRG reactor 114. This distance between the
opening in
the top surface of the barrel 302 and the FRG reactor 114 allows the material
injection
system 112 to affect the input material in one of a number of ways prior to
the
material entering the FRG reactor 114. In embodiments of the present
invention, as
the rotation of the MIS 400 causes the input material to move towards the FRG
reactor 114, the material may encounter changing conditions along the length
of the
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MIS 400 that cause compression of the material. In particular, an increase in
the
diameter of a shaft of the MIS 400 and/or a reduced flute pitch of the MIS 400
can
reduce the volume between sequential flutes of the MIS 400, effectively
imparting
significant compression on the material. The compressed material can form an
effective seal against the low internal pressure within the FRG reactor 114
and
prevent syngas and other gaseous components from exiting the FRG reactor 114
via
the material injection system 112. At the end of the material injection system
112
mounted to the FRG reactor 114, the shaft of the MIS 400 may have a diameter
reduction and/or the flute pitch of the MIS 400 may be increased to allow the
input
material to expand prior to entering into the FRG reactor 114. Gas that
permeates out
of the FRG reactor 114 may be forced back into the FRG reactor 114 by the
movement of the input material.

Figure 4 is a side view of one particular sample MIS 400 that may be within
the
material injection system 112 of Figures 3A, 3B and 3C. It should be
understood that
the material injection screw 400 depicted in Figure 4 is only a sample
embodiment of
the MIS 400 and other implementations could be designed to allow movement of
the
input material into the FRG reactor 114. In this embodiment, the MIS 400
comprises
four segments, labeled Length A, Length B, Length C and Length D in Figure 4.
In
Length A, the shaft of the MIS 400 is of uniform diameter and the MIS 400 has
a
uniform flute pitch, which would allow the MIS 400 in operation to move the
input
material but not to significantly provide compression. In Length B, the shaft
of the
MIS 400 has an increasing diameter left to right, which allows in operation
for
compression of the input material as it passes the Length B of the MIS 400. In
Length C, the shaft of the MIS 400 has uniform diameter, greater than the
uniform
diameter of Length A. This uniform diameter maintains the input material in
compressed form as it passes the Length C in operation, which can provide an
effective seal preventing gaseous material from exiting the FRG reactor 114
through
the material injection system 112. In Length D, the shaft of the MIS 400 has a
decreasing diameter left to right, which may allow for some expansion of the
input
material and easier injection of the input material into the FRG reactor 114.

It should be understood that the embodiment of Figures 3A-3C is only one
particular
implementation of the material injection system 112. Figures 5A, 5B and 5C are
a top
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angular view, a top view and a side view respectively of the material
injection system
112 according to an alternative embodiment in which the material injection
system
112 includes attachments for injection of tars and/or water. As shown, the
opening in
the top surface of the barrel 302 is covered by a material injection system
hopper 504
that can be used to aid in the insertion of material into the material
injection system
112. The hopper 504 comprises a top opening in which it may receive input
material
from the feed conveyor 110, a bottom opening that matches the opening in the
top
surface of the barrel 302 and an attachment 502 operable to allow additional
components, such as tars, to be mixed with the input material.
The tars may come from waste within the overall system, for example tars may
be
produced from pyrolysis and may precipitate out of the FRG reactor 114 to the
condensate tank 122, or may come from an external source. The tars are higher
molecular weight by-products that are carbon-containing flammable material but
are
not sufficiently volatile to form a desired component of the syngas. The
addition of
tar to the input material can be beneficial in a number of ways. For one, the
tar is
carbonaceous and may be consumed within the FRG reactor 114, thus increasing
the
production of syngas. Further, the tars may fill interstices within the input
material
when compressed by the MIS 400, which may improve the ability of the input
material to prevent gas from exiting from the FRG reactor 114 through the
material
injection system 112. Yet further, the tars may aid in lubricating the inside
of the
barrel 302 and/or the MIS 400. One should understand that in some embodiments
the
addition of tars may not be conducted and/or may not gain one or more of these
benefits.
Further in Figures 5A, 5B and 5C, in some embodiments of the present
invention, the
barrel 302 of the material injection system 112 may comprise a water
attachment 500
operable to allow water to be added to the input material within the barrel
302. As
shown, the water attachment 500 may be approximately halfway along the length
of
the barrel 302, in this case at the transition between Length A and Length B
of the
MIS 400. In other embodiments, the water attachment 500 may be at another
location
on the barrel 302 or could be coupled to the hopper 504. Water may be added to
the
material injection system 112 to ensure the input material maintains a
particular
desired level of moisture. Water may be added systematically or ad-hoc based
upon
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the particular material that is being input to the material injection system
112. If the
input material is too dry, the material when compressed may not provide
sufficient
resistance to prevent gas from exiting from the FRG reactor 114. The added
water
may fill the interstices within the input material and thus prevent gas from
the FRG
reactor 114 from permeating past Length C on the MIS 400.

Figures 6A, 6B and 6C are a cross-sectional side view, a top angled view and a
side
view respectively of the material injection system 112 according to a further
alternative embodiment in which the material injection system includes an
external
jacket 600. As shown, the external jacket encircles the barrel 302 of the
material
injection system 112 and comprises an inlet 602, an outlet 604 and a drain
606. In
one embodiment, the external jacket 600 is used to heat the input material
within the
barrel 302. In this case, hot syngas produced within the FRG reactor 114 may
be
input to the inlet 602 and output from the outlet 604 to increase the
temperature of the
input material within the barrel 302 while, at the same time, cooling the
syngas. By
increasing the temperature of the input material, the system energy efficiency
may be
increased.

In another embodiment, the external jacket 600 may be used to cool the
material
within the barrel 302. As the material is compressed within the material
injection
system 112, heat may build up. By piping water (or another coolant) from the
inlet
602 to the drain 606, the material can be cooled and the energy generated in
the
compression can be used to heat the water. The heated water can then be used
to
inject within the FRG reactor 114 using the water injection system 232 as
described
previously or may otherwise be used within the system.

Figures 7A and 7B are a top angled view and a side view respectively of a
material
feed screw system comprising the material feed screw 220 of Figures 2A and 2B
according to an embodiment of the present invention. Figure 7C is an assembly
diagram for the material feed screw system of Figures 7A and 7B. Figures 7D
and 7E
are a zoomed in view of the top and bottom portion respectively of the
material feed
screw system of Figures 7A and 7B. As shown, the material feed screw system
comprises the cylindrical feed screw shaft 702; the feed screw flutes 700 that
are
connected to the outer surface of the feed screw shaft 702; the syngas removal
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704 integrated within the feed screw shaft 702; and the water injection pipe
706
integrated within the syngas removal pipe 704.

In the embodiment of Figures 7A and 7B, the flutes 700 are helical and have a
diameter to match the inner diameter of the FRG reactor 114. Through most of
the
MFS 220, the flutes 700 have a fixed pitch but, as the diameter of the flutes
700 is
reduced to match the tapering of the FRG reactor 114 in the transition section
204, the
pitch of the flutes 700 is also changed to maintain relatively constant volume
between
flutes. In this embodiment, this is done to prevent a significant compression
of the
input material, which could cause problems such as stress on the MFS 220 or
jamming of input material. In some embodiments the volume between flutes may
increase or decrease depending upon the design requirements. As shown in
Figures
8A-8H, the flutes 700 of the MFS 220 may be modified in alternative
embodiments.
For instance, the flutes 700 may have different pitch levels, include
perforations (or
small holes) in part or all of the flutes 700 and/or have a serrated edge at
the outer
diameter.

The feed screw shaft 702 within Figures 7A-7E is a hollow cylinder that is
coupled to
the MFS drive system 238 external to the FRG reactor 114. The portion of the
feed
screw shaft 702 that stretches out of the top of the FRG reactor 114 is sealed
along the
edge of the FRG reactor 114 and may be coupled to the MFS drive system 238 via
suitable bearings. The MFS drive system 238 may be controlled locally or by a
central computing apparatus (not shown) and is operable to control the rate at
which
the input material is moved downward from the opening in which the material
injection system 112 is attached to the FRG zone by controlling the rate of
rotation of
the feed screw shaft 702. In some embodiments, the MFS drive system 238 may
monitor torque on the MFS 220 to detect input material jams within the FRG
reactor
114. In response to detecting a potential jam, the MFS drive system 238 may
send a
warning message to an operator, terminate the rotation of the MFS 220 and/or
reverse
rotation of the MFS 220.

As shown in Figure 7C, the gas removal pipe 704 is integrated within the feed
screw
shaft 702 with the outer diameter of the gas removal pipe 704 being very
slightly
smaller the inner diameter of the shaft 702. The gas removal pipe 704 in this
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embodiment does not rotate with the shaft 702 and there is a seal between the
pipe
704 and the shaft 702 at the upper most edge of the shaft 702. As shown in
Figure
7E, the gas removal pipe in this embodiment comprises a nozzle at the bottom
comprising a series of small holes (in this example, hundreds of very small
holes)
which allow for syngas to enter the pipe 704 and a central orifice sufficient
to allow
the water injection pipe 706 to pass through. In other embodiments described
with
reference to Figures 9A-9F, other implementations of the gas removal pipe 704
are
illustrated.

The gas removal pipe 704 is coupled to the syngas outlet pipe 240, which is in
turn
coupled to the syngas transfer pipe 120 via the flexible syngas line coupling
254. The
flexible coupling 254 can enable the gas removal pipe 704 to be adjustable for
distance to the FRG zone. This adjustment may be done manually to optimize an
aspect of a particular syngas output or may be automated. In some embodiments,
the
pipe 704 may be adjusted in another manner to modify the distance of syngas
removal
from the FRG zone.

In some embodiments, the gas removal pipe 704 is coupled to a purge system
operable to blast a purge gas through the gas removal pipe 704 to clear the
nozzle of
contaminants that may block one or more of the holes. Further, to enable
cleaning or
other adjustments, the gas removal pipe 704 may be removed from the FRG
reactor
114 when not in operation by detaching its connection to the syngas outlet
pipe 240
and lifting it vertically.

The water injection pipe 706, of Figure 7C, is integrated within the gas
removal pipe
704 with the outer diameter of the water injection pipe 706 being
substantially less
than the inner diameter of the gas removal pipe 704. The water injection pipe
706 in
this embodiment does not rotate with the shaft 702. On the top end, the water
injection pipe 706 is connected to a flexible water coupling 250 external to
the FRG
reactor 114, which is in turn connected to the water pipe 128. As shown in
Figure 2B,
the syngas outlet pipe 240 comprises an elbow in which a section allows the
water
injection pipe 706 to pass and be connected to the flexible water coupling
250. The
location within the section of the elbow where the water injection pipe 706
exits is
sealed to prevent syngas from exiting. In one example, the seal may be a
standard
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compression seal between two flanges (not shown). On the bottom end, the water
injection pipe 706 comprises a nozzle, which may take numerous forms. In
Figure
7E, the nozzle comprises a single hole out of which water may enter the FRG
reactor
114. In other embodiments, more than one hole could be formed within the
nozzle of
the water injection pipe 706. Similar to the gas removal pipe 704, the water
injection
pipe 706 may be adjustable for distance to the FRG zone. The flexible water
coupling
250 may allow for an operator to manually adjust the positioning of the water
injection pipe 706 to optimize an aspect of a particular syngas output. The
location of
the water injection and the quantity of water injected may affect the level of
impurities within the syngas output. Too much water being injected could lower
temperatures due to heat loss in converting water to steam. Further, to enable
cleaning or other adjustments, the water injection pipe 706 may be removed
from the
FRG reactor 114 when not in operation by detaching its connection to the water
flexible coupling 250 and lifting it vertically.
Figures 8A and 8B are a top angled view and a side view respectively of the
material
feed screw 220 according to an alternative embodiment in which the material
feed
screw 220 includes perforations within the feed screw flutes 700. The
perforations in
the flutes 700 can allow the syngas to migrate upwards through the openings,
allowing cooling of the gas prior to extraction and also facilitating
pyrolysis within
input material that has not yet reached the sufficient temperatures. Further,
the
upward movement of the syngas may allow for condensing of vaporous components
such as tars onto the input material in the upper portion of the FRG reactor
114.
These condensed tars can then move, with the input material that they are
attached, to
the lower portion of the FRG reactor 114 and into the FRG zone by the MFS 220.
The perforations may take many forms including small circular holes, slotted
type
holes and/or various other shapes and sizes depending upon the desired flow of
syngas upwards through the MFS 220.

Figures 8C and 8D are top angled views of material feed screws according to
additional alternative embodiments in which the material feed screw 220
includes
alternative perforation designs within the feed screw flutes 700. In Figure
8C, the
perforations are larger than in Figures 8A and 8B. In Figure 8D, the
perforations are
only within the lower flutes on the material feed screw 220. By only having
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perforations within the lower portion of the flutes 700, the syngas will more
easily
move upwards in the lower portion of the flutes 700 and then not move upwards
as
easily once the perforations stop. This change in perforations may be useful
in a
number of embodiments of the present invention. As will be described with
reference
to Figures 9A-9F, in some embodiments, gas removal takes place at different
locations above the FRG zone along the MFS 220. In these embodiments,
perforations may only be implemented in the lower flutes as per Figure 8D in
order to
facilitate easier movement of the syngas through the flutes 700 up to the
point in
which the gas removal takes place. In some embodiments, the perforations may
continue above the location at which the gas removal takes place while, in
other
embodiments, the perforations may reduce in size and/or quantity or be removed
completely above the location at which the gas removal takes place. By
including
perforations and adjusting the size, quantity and/or location of the
perforations in the
flutes 700, gas flow within the FRG reactor 114 may be managed to an extent.
Figures 8E and 8F are a top angled view and a side view respectively of the
MFS 220
according to yet another alternative embodiment in which the pitch of the
flutes 700
are increased. It should be understood that one may adjust the pitch of the
flutes 700
depending upon design requirements. For instance, a larger pitch may allow for
a
number of advantages including: increased particle size within the input
material;
reduced jamming of the input material between the edge of the flutes 700 and
the
inner wall of the FRG reactor 114; simplified manufacturing of the MFS 220;
and
additional space between the flutes which may be used for
alternative/additional
syngas removal locations as will be described with reference to Figures 9A-9F.
With
a larger pitch, there will be an increase in volume of the input material
between
adjacent flutes 700. Therefore, to maintain the same rate of input of material
being
introduced to the FRG zone as with a smaller pitch, the rotation of the MFS
220 will
need to be decreased. Due to the lower volume of input material between
adjacent
flutes 700, a smaller pitch can allow for a more controlled movement of the
input
material through the FRG reactor 114.

Figures 8G and 8H are a top angled view and a side view respectively of the
material
feed screw 220 according to one further alternative embodiment in which the
pitch of
the flutes 700 are increased compared to the flutes of Figure 7A and 7B and
the outer
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diameter edge of the flutes 700 are serrated. The serrated edge at the outer
diameter
of the flutes 700 can aid in gas migration upwards within the FRG reactor 114
and can
also reduce material accumulation along the inner wall of the FRG reactor 114.
The
internal environment within the FRG reactor 114 will have high heat with large
amounts of vapors and wet tars that may deposited on the inner wall of the
reactor
114. Serrated edges on the flutes 700 may mitigate build up of these deposits
and
may further reduce jamming along the walls of the FRG reactor and the flutes
700
(for example, jamming from metal contaminants).

Figures 9A, 9B and 9C are a top angled view, a side view and a cross-sectional
side
view respectively of the material feed screw system according to yet another
alternative embodiment of the present invention in which syngas removal may
occur
at a plurality of locations. Figure 9D is an angled top view of the syngas
removal pipe
704 within the material feed screw system of Figures 9A, 9B and 9C according
to an
embodiment of the present invention. Figure 9E is a zoomed in view of the
bottom
portion of the material feed screw system of Figures 9A, 9B and 9C. As shown,
a
plurality of vents 707 within the feed screw shaft 702 may be used for syngas
removal, each vent 707 being at a different vertical displacement along the
feed screw
shaft 702 and at a different angle along the circumference of the shaft 702.
Although
shown as holes with slots, it should be understood that vents 707 may comprise
other
openings that are slotted, perforated and/or otherwise designed to allow gas
to be
extracted. In this example, each vent 707 is approximately 120 displaced from
the
other two vents 707. The syngas removal pipe 704 comprises a vertical
rectangular
hole that creates an opening for syngas removal. The location of the syngas
removal
will depend upon which vent 707 in the shaft 702 that the syngas removal pipe
704 is
aligned with. In one example, the opening within the syngas removal pipe 704
is less
than or equal to 120 (90 in some cases) such that when the pipe 704 is
positioned
appropriately, syngas can only be removed from one of the vents 707 in the
shaft 702,
the other vents 707 being blocked by the pipe 704. In other embodiments, it
should
be understood that other numbers of vents 707 could be used (two or more) and
a
different sized and/or shaped hole within the syngas removal pipe 704 may be
used.
Figure 9F is a zoomed in view of the bottom portion of an alternative material
feed
screw system to that of Figures 9A, 9B and 9C in which the syngas removal pipe
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is not perforated. In this case, no syngas is removed from the end of the
syngas
removal pipe 704 and only the vent system as described is used for syngas
removal.
The variation on location for syngas removal provides flexibility to the
system
operations. The higher the extraction level, the lower the temperature of the
syngas at
the point of extraction and likely the more contaminants that may be present
in the
syngas. These contaminants may need to be cleaned, depending on the eventual
use
of the syngas. One particular component that is considered an impurity in the
syngas
is carbon dioxide CO2 as it is not combustible. The lower the temperature
within the
FRG reactor 114 will likely result in higher CO2 levels relative to carbon
monoxide
CO levels (which is a desirable element within the syngas). Further, lower
temperature levels will likely increase the tar content within the syngas due
to reduced
pyrolytic activity at the lower temperature. It should be noted that the level
of
impurities within the syngas may vary with the composition of the input
material. In
some embodiments, various control mechanisms, such as the location of the
syngas
removal, can be controlled to manage the syngas output in response to various
fluctuations in input material.

Figures 10A, 10B and 10C are an angled top view, a top view and a cross-
sectional
side view respectively of the bottom portion of the FRG reactor 114 of Figures
2A
and 2B according to an embodiment of the present invention in which the three
electrodes 224 are used. In this configuration, each of the three electrodes
224 are
120 horizontally displaced from the other two electrodes. Shown in Figures
10A,
10B and 10C are the FRG reactor base section 206, the FRG reactor bottom
section
208 and the base refractory liner 216 with the electrodes 224 protruding
through the
FRG reactor base section 206 and the base refractory liner 216. In one
embodiment,
the electrodes are graphite, though other electrode materials may be used
including
tungsten, molybdenum or titanium.

When electricity is applied to the electrodes 224, an arc will form adjacent
to the gap
between the electrodes 224. The actual current and voltage used on the
electrodes
may change due to a variety of design requirements. A higher voltage will
allow for
easier control of the arc and allow for a smaller diameter electrode to be
required.

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In one particular implementation, the arc may create a temperature of
approximately
6,000 C, though the temperature of the arc may vary in different design
implementations. As described, the walls of the FRG reactor 114 are lined with
refractory material. There are many grades of refractory material, but
typically the
higher the alumina content, the higher the temperature that can be withstood
(ranging
up to 1800 C). Refractory material can also be resistant to slag, molten
metals etc.
which could contact the walls of the reactor 114. The FRG reactor 114 of
Figures 2A
and 2B and as shown in Figures 10A, 10B and 10C includes a distance between
the
arc (formed in the gap between the electrodes 224) and the walls of the FRG
reactor
114. The temperature gradient through the distance and the input material can
drop
the temperature to acceptable levels for the refractory liner 216. To mitigate
heat
transfer through the refractory liners, in some embodiments, the refractory
liners
comprise a plurality of layers of refractory material, with the refractory
material
forming the inner walls having high temperature and abrasion resistance and
refractory material behind that having reasonable refractory properties and
good
insulating properties.

Graphite electrodes within the environment in the FRG reactor 114 will be
consumed
in the process, adding carbon material to the syngas output. In some
embodiments of
the present invention, to ensure the arc remains correctly formed as the
graphite in the
electrodes 224 disappears, the electrodes 224 will be pushed further into the
FRG
reactor 114 and additional electrodes will be added to the ends of the
electrodes 224
that protrude from the FRG reactor 114. To affix the additional electrodes to
the
electrodes currently in use within the FRG reactor 114, each electrode may
have a
threaded end that allows for additional electrodes to be attached by a
screwing action.
In some embodiments of the present invention, new electrodes can be added to
the
existing electrodes during operation, which can effectively make the process
in the
system a continuous operation. In alternative embodiments, the electrodes are
only
attached after shutdown of the system and the system is therefore a batch
process.

In operation, the electrodes 224 may be required to be moved into and possibly
out of
the FRG reactor 114. In particular, the electrodes 224 may need to be advanced
into
the FRG reactor 114 in order to have the arc struck and may need to
subsequently be
slowly extracted until a stable are within the FRG reactor 114 is achieved.
Further,
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the electrodes 224 may need to be incrementally advanced into the FRG reactor
114
as the electrodes 224 are consumed by the heat of the arc in operation. In
order to
move the electrodes 224 into and/or out of the FRG reactor 114 and to maintain
the
electrodes 224 in a horizontal position a number of structures/mechanisms may
be
used.

Figure 15A is an angled top view of an electrode support structure using
wheels
according to one embodiment of the present invention. Figure 15B is a zoomed
in
view of the wheel structure of Figure 15A with the support structure removed
for
clarity. As depicted, a set of three wheels 1502 can be used to move each of
the
electrodes 224 into or out of the FRG reactor 114 (not shown in Figures 15A,
15B).
In this implementation, a frame 1504 supports the wheels 1502 and, through the
wheels 1502, supports the electrode 224. As shown, the three wheels 1502 are
spread
out around the outer circumference of the electrode 224 such that each wheel
is
approximately 1200 from each of the other two wheels. Springs 1508 integrated
within the frame 1504 are used to keep the wheels 1502 loaded against the
electrode
224 and motors 1506 are used to rotate the wheels 1502 and move the electrode
224
into or out of the FRG reactor 114. In alternative implementations, more or
less than
three wheels 1502 may be used to move the electrodes 224.
Figure 16 is an angled top view of an alternative electrode support structure
using belt
systems that provide more contact surface with the electrodes 224 compared
with the
wheels of Figure 15. In this embodiment, two belt systems 1602 are used to
support
and move the electrodes 224, one belt system on the upper side of the
electrode 224
and one on the lower side. Each of the belt systems 1602 comprises one driven
wheel
1604, a plurality of bogey wheels 1606 (two in the example of Figure 16), an
idle
wheel 1610 and a belt 1608. The driven wheel 1604 and the idle wheel 1610 are
at
opposite ends of the belt 1608 within each belt system 1602 and have
sufficient
distance between them to tighten the belt 1608 around them. The bogey wheels
1606
are inside the belts 1608 between the driven wheels 1604 and the idle wheels
1610.
Each of the wheels 1604,1606,1610 are implemented with springs (not shown) or
another force generating device to continuously keep the belt 1608 in
frictional
contact with the electrode 224. In operation, the driven wheels 1604 are
rotated by a
motor (not shown) and this force is transferred into a linear motion within
the
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electrode 224 as the belt 1608 turns. The belt systems 1602 may be mounted on
a
frame similar to the frame 1502 depicted in Figure 15A or may be mounted on
another suitable frame to support the belt systems 1602 and the electrodes
224. In
alternative implementations, more or less than two belt systems 1602 may be
used to
move the electrodes 224.

Figures 17A and 17B are a top angled view and a zoomed in view of a further
alternative electrode support structure 1700 using a clamp/rail arrangement.
Figure
17C is a top angled zoomed in view of the clamp/rail arrangement of Figures
17A and
17B with the support structure removed for clarity. As shown, in this case,
the
electrode 224 is supported by a frame 1702 that comprises two parallel guide
rails
1704, a clamping element 1706 and a plurality of alignment elements 1708. The
clamping element 1706 encircles the electrode 224 and comprises two clamps
1710.
When the clamps 1710 are actuated, the clamping element 1706 is in a clamped
state
in which it is tight to the electrode 224 and effectively integrated with the
electrode
224. When the clamps 1710 are not actuated, the clamping element 1706 is in an
unclamped state and the electrode 224 may move linearly through the clamping
element 1706. In one implementation, the clamps may be pneumatic toggle
clamps,
though it should be understood that other types (ex. hydraulic, etc.) and/or
numbers of
clamps and/or clamping elements may be used.

The clamping element 1706 is coupled to two linear bearings 1712 that
interlock with
the parallel guide rails 1704 and a linear actuator 1714. The linear actuator
1714 is
operable to move the clamping element 1706 linearly as the linear bearings
1712 slide
along the length of the guide rails 1704. The stationary end of the linear
actuator
1714 is secured from movement by means of attachment to a bracket 1716. The
electrode 224, as shown, stretches the length of the frame 1702 through the
clamping
element 1706 and through the alignment elements 1708. In this case there are
two
alignment elements 1708 that ensure that the electrode 224 is supported and is
positioned properly to enter the FRG reactor 114, though other numbers of
alignment
elements may be used. When the clamping element 1706 is in the clamped state,
if
the clamping element 1706 is moved along the guide rails 1704 by the linear
actuator
1714, the electrode 224 will move with the clamping element 1706.

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In one sample operation using the electrode support structure 1700 of Figures
17A
and 17B, the clamps 1710 may be engaged by opening a valve to feed compressed
air
to the clamps 1710, thus forcing the clamping element 1706 downward and into a
clamped state with the electrode 224. The linear actuator 1714 may then move
the
clamping element 1706, and as a result the electrode 224, towards or away from
the
FRG reactor 114 along the guide rails 1704. If the clamping element 1706
reaches the
end of the guide rails 1704, the clamps 1710 may be disengaged, thus loosening
the
clamping element 1706 on the electrode 224, and the linear actuator 1714 can
move
the clamping element 1706 back to the other end of the guide rails 1704. After
the
clamping element 1706 is repositioned, the clamps 1710 can be re-engaged, thus
forcing the clamping element 1706 back into a clamped state with the electrode
224.
The engaging of the clamps 1710 and/or the control of the linear actuator 1714
may
be controlled by a computing apparatus (not shown). In the start-up of the FRG
reactor 114, the computing apparatus could cause the electrodes 224 to advance
within the FRG reactor 114 until the arc has been struck and then retract the
electrodes 224 until a stable arc is achieved. The computing apparatus may
further
advance the electrodes 224 incrementally within the FRG reactor 114 as the
heat of
the arc consumes the electrodes 224.

In each of the embodiments of electrode support structures depicted in Figures
15A,
15B, 16, 17A, 17B and 17C, the frame and structure may be designed to be
insulated
from the electricity that will pass through the electrodes 224. In one
embodiment, a
brush assembly as will be described with reference to Figures 18A, 18B, 18C
and 18D
may be used to transfer current to the electrodes 224 from power cables while,
in
another embodiment, a contact clamp assembly as described with reference to
Figures
19A, 19B, 19C and 19D may be used. In either case, an electrode support
structure
1700 similar to that described with respect to Figures 17A, 17B and 17C or
another
support structure (for example, the support structure of Figures 15A/15B or
Figure
16) may be used to provide support to the electrodes 224 and control linear
movement
of the electrodes 224 as may be required. The additional brush assembly or
contact
clamp assembly may be added between the support structure and the FRG reactor
114.



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Figure 18A is a top angled view of a brush assembly 1800 for electrifying an
electrode 224 according to an embodiment of the present invention. Figures 18B
and
18C are a top angled view and a zoomed in view respectively of the brush
assembly
1800 of Figure 18A with cooling lines and fittings removed for clarity. As
shown, the
brush assembly 1800 comprises a back plate 1816; four insulated standoffs 1818
coupled to one side of the back plate 1816; four brush supports 1814 coupled
to the
other side of the back plate 1816; and four brushes 1806. In this example, the
back
plate 1816 comprises a square metal plate with a circular hole in the center,
though in
alternative implementations, other shapes may be used. The insulated standoffs
1818
are made of electrically insulating material and are used to mount the brush
assembly
1800 to the electrode support structure (such as support structure 1700 of
Figure
17A).

Each of the brushes 1806 comprises a flat edge on one side which is coupled to
the
corresponding brush support 1814 and a rounded edge on the opposite side that
with
the other three brushes forms the perimeter of a circle or portions thereof.
In
operation, the electrode 224 is mounted inside the perimeter of the circle
formed by
the four brushes 1806 and through the hole within the back plate 1816. Each of
the
brush supports 1814 comprises electrical lugs 1812 that electrically couple to
shunts
extending from their respective brushes 1806. The brushes 1806 comprise
sufficient
shunts to conduct the current from the brush supports 1814 through the lugs
1812.

In operation, power cables (not shown) are connected to the back plate 1816
and
current flows through the back plate 1816 to the brush supports 1814 and via
the
electrical lugs 1812 to the brushes 1806 where the current is applied to the
electrode
224 through electrical contact between the brushes 1806 and the electrode 224.
Each
of the brush supports 1814 further has a respective pusher plate 1808 mounted
with a
spring 1810 on the outer side. The spring 1810 and pusher plate 1808 together
work
to exert a force on the brush supports 1814, which in turn apply an inward
force on
the brushes 1806. The spring 1810 and pusher plate 1808 work together to
provide a
predetermined contact force between the brushes 1806 and the electrode 224.
This
ensures electrical contact and accommodates minor surface variations along the
length
of the electrode 224.

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The brush supports 1814 are coupled to a set of cooling lines 1803 that allow
cooling
media to flow from an inflow pipe 1802 through a series of cooling lines
within the
brush assembly 1800 to an outflow pipe 1804. The cooling lines 1803 wind
around
the entire brush assembly 1800 with particular cooling focus on the areas in
which
current is being conducted such as the brushes 1806, the brush supports 1814
and the
back plate 1816. In other embodiments, less than all of these elements (ex.
only the
brush supports 1814) may be cooled or alternatively more elements may also be
cooled.

Although shown in Figures 18A, 18B, 18C and 18D as four individual brushes,
other
implementations can be used. For instance, more or less than four brushes 1806
could
be utilized to form the circular opening for the electrode 224. Further, each
individual
brush 1806 may comprise a plurality of segments, individually spring loaded to
maximize the contact between the brushes 1806 and the electrode 224 surface
area.
The brushes 1806 may be comprised of graphite or another material that
provides
strong current transfer or a blend of materials that may maximize current
transfer to
the electrode 224.

Figure 18D is a top angled view of the brush assembly of Figure 18A as
installed on
the electrode support structure of Figure 17A. As shown, the insulated
standoffs 1818
are used to mount the brush assembly 1800 to an electrode support structure
such as
support structure 1700 of Figure 17A. In operation, the electrode 224 can
freely pass
through the brush assembly 1800 while the brush assembly remains stationary
and the
brushes 1806 apply the electrical current to the electrodes 224. This
eliminates the
need to continually adjust a fixed mechanical clamping of power cables on the
electrodes 224 in operation, which can be dangerous for operators and/or
require a
stoppage in the operation.

Figure 19A is a top angled view of a contact clamp assembly 1900 for
electrifying an
electrode 224 according to an embodiment of the present invention. Figures 19B
and
19C are a side view and a top angled view respectively of the contact clamp
assembly
of Figure 19A with cooling lines and fittings removed for clarity. As shown,
the
contact clamp assembly 1900 comprises two contact plates 1904 and a plurality
of
contact segments 1902 each coupled between the two contact plates 1904. The
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contact plates 1904, in this example, each comprise a circular metal plate
with a
circular hole in the center, though other shapes may be used in alternative
designs.
The contact segments 1902 are arranged around the circumference of a circle
such
that a gap exists between adjacent segments. In operation, the contact
segments 1902
will encircle the electrode 224. Each of the segments 1902 is electrically
coupled to
the contact plate 1904 such that current can be transferred from the contact
plate 1904
to the contact segments 1902. Further, each of the contact segments may be
provided
with cooling capability through cooling lines 1911. Cooling lines 1911 allow
cooling
media to flow from an inflow pipe 1910 through a series of cooling lines
within the
contact clamp assembly 1900 to an outflow pipe 1912. The cooling lines 1911
wind
around the entire contact clamp assembly 1900 with particular cooling focus on
the
contact segments 1902.

Further, as depicted in Figures 19B and 19C, the contact clamp assembly 1900
further
comprises a spring loaded T-bolt clamp 1908 which surrounds the ring of
contact
segments 1902 and a pneumatic toggle clamp 1906 operable to control the clamp
1908. When the toggle 1906 is activated, it exerts a tension force to the T-
bolt portion
of the T-bolt clamp 1908, in some embodiments using a spring (not shown),
resulting
in the clamp band portion of the T-bolt clamp 1908 to apply relatively equal
force to
the contact segments 1902. This clamping mechanism ensures that the contact
segments 1902 maintain a tight contact with the electrode 224. When the toggle
1906
is released, the T-bolt clamp 1908 loosens and allows movement between the
contact
segments 1902 and the electrode 224. As shown in Figure 19A, 19B and 19C, the
contact clamp assembly 1900 further comprises a mounting bracket 1922 coupled
between the two contact plates 1904 and to one end of the T-bolt clamp 1908,
the
mounting bracket supporting the toggle 1906.

Figure 19D is a top angled view of the contact clamp assembly of Figure 19A as
installed on the electrode support structure of Figure 17A. As shown in Figure
19A,
one of the contact plates 1904 comprises two brackets 1918 on one outer face
opposite to the face coupled to the contact segments 1902. These brackets 1918
are
used to connect the contact clamp assembly 1900 to linkages 1920, shown in
Figure
19D, that are further connected to the actuator 1714 within the electrode
support
structure 1700 of Figure 17A. The linkages 1920 connect the contact clamp
assembly
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1900 to the actuator 1714 so that the contact clamp assembly 1900 moves with
the
actuator 1714.

In operation, power cables (not shown) are attached to the contact plates 1904
and
current is passed from the power supply (not shown) via the cables (not shown)
to the
contact plates 1904, through lugs 1914 and jumpers 1916, to each of the
contact
segments 1902 and then directly to the electrode 224. The contact clamp
assembly
moves with the actuator 1714 and the electrode 224 until the actuator 1714
reaches
the end of a stroke. At this point, the current is turned off and the toggles
1710 of
Figure 17A for the electrode 224 and toggle 1906 for the contact clamp
assembly
1900 are deactivated. The actuator 1714 can then be retracted to its start
position and
all toggles 1710 and 1906 can be re-activated. Once the toggles are activated,
the
current can be re-applied to the electrode 224 through the contact clamp
assembly
1900 and both the electrode 224 and the contact clamp assembly 1900 will move
again with the actuator 1714. In operation, this cycle can be repeated
continuously as
the electrode 224 is consumed in the FRG reactor 114.

Figures 11A, 11B and 11C are an angled top view, a top view and a cross-
sectional
side view respectively of the bottom portion of the FRG reactor 114 of Figures
2A
and 2B according to an alternative embodiment in which six electrodes 224 are
used.
In this configuration, the electrodes 224 are matched together in pairs and
each pair
enters the base section 206 of the FRG reactor 114 at 180 angles from each
other and
come close to meeting in the center, creating a small gap between the tips of
the
electrodes. Each of the pairs of electrodes is approximately 120 horizontally
displaced from the other two pairs and is on a different horizontal plane from
the
other two pairs (one upper pair, one middle pair and one lower pair). Each
pair of
electrodes has a center line that is offset from a central axis in the FRG
reactor 114
and together the center of the three pairs of electrodes create a triangle in
the center of
the base section 206 of the FRG reactor 114.
By using sets of electrodes, a plurality of arc zones can be created within
the FRG
reactor 114. This can allow the current being carried in each electrode to be
lower
than in the embodiment depicted in Figures 10A to 10C. In some embodiments,
the
power level over the three pairs of electrodes is the same as the power level
across the
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three individual electrodes of Figures 10A to 10C. In some cases, the use of
the
plurality of arc zones may allow for a higher energy efficiency within the FRG
reactor
114 compared to an implementation that utilizes only a single arc zone.

As material drops to the arc formed by the pair at the highest horizontal
plane (the
upper pair), a first portion of the material may be molecularly broken down by
the
upper arc and a second portion may drop to the arc formed by the pair at the
middle
horizontal plane (the middle pair). At the arc formed by the middle pair, a
portion of
the material may be molecularly broken down by the arc formed by the middle
pair
and a finally a final portion of the material may drop to the arc formed by
the pair at
the lowest horizontal plane (the lower pair) and be molecularly broken down by
the
lower arc. In one embodiment, a third of the input material may be broken down
at
each of the three arcs, though in other embodiments a different proportion may
be
implemented.
Figures 12A, 12B and 12C are an angled top view, a top view and a cross-
sectional
side view respectively of the bottom portion of the FRG reactor 114 of Figures
2A
and 2B according to an alternative embodiment in which six parallel pairs of
electrodes 224 are used. In this configuration, each parallel pair of
electrodes is
matched with another parallel pair of electrodes at the same horizontal plane
but
entering the base section 206 of the FRG reactor 114 at 180 angles from each
other.
The matched pairs of parallel electrodes come close to meeting in the center
of the
bottom of the FRG reactor 114, creating a small gap between the tips of the
electrodes. The matched pairs of parallel electrodes are 120 horizontally
displaced
from the other two matched pairs of parallel electrodes and vertically
displaced on
different horizontal planes from the other matched pairs of parallel
electrodes. In
some embodiments, as depicted in Figures 12A, 12B and 12C, the distance
between
the parallel electrodes may be larger for the parallel electrodes vertically
higher on the
base section 206 of the FRG reactor 114.
The implementation of the electrodes 224 depicted in Figures 12A to 12C allow
for
six small arc zones to be formed, two on each of the three different
horizontal planes.
The two arc zones on each horizontal plane together effectively form a single
larger
arc zone that is wider than a single arc zone. The two pairs of parallel
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the lowest horizontal plane have their center lines relatively close together
while the
two pairs of parallel electrodes on the middle horizontal plane have their
center lines
slightly further apart and the two pairs of parallel electrodes on the highest
horizontal
plane have their center lines furthest apart. The net effect of the formation
of the six
arc zones is to create a rather large arc zone beginning at the lowest
horizontal plane
and extending above the highest horizontal plane.

It should be understood that further alternative embodiments are possible that
can
allow for alternative arc zones within the bottom portion of the FRG reactor
114. In
some embodiments, the fewer or more electrodes or electrode pairs are used.
For
instance, there may be more than two electrode pairs in parallel at a single
horizontal
plane, more or less than three horizontal planes with electrodes, and/or
different
combinations of single pairs of electrodes and multiple pairs of parallel
electrodes at
different horizontal planes. Further, in some embodiments, the electrodes may
not be
displaced horizontally by 1200 and instead may be aligned or may be displaced
by a
different angle.

In the plurality of scenarios in which more than one set of electrodes is
utilized, the
main effect is to form a plurality of arc zones in operation. Each are zone
has it's own
input material to arc zone interface area where the heat and light initiate
the molecular
break down of the input material. In some embodiments, the sum of all the
individual
input material to arc zone interface areas allows for an increased amount of
input
material to be converted per unit energy that is input to the system compared
to the
simpler electrode configuration of Figures 10A to 10C in which a single arc
zone is
formed in operation.

Figures 13A, 13B and 13C are an angled top view, a side view and a cross-
sectional
side view of one of the electrodes 224 that may be used within the FRG reactor
114 of
Figures 2A and 2B according to an alternative embodiment in which a tungsten
tip
1300 is used. In this embodiment, an electrode outer jacket 1302 that may be
filled
with a coolant (ex. water) is used to cool the tungsten tip 1300. As shown in
Figures
13A, 13B and 13C, the electrode outer jacket 1302 comprises a coolant inlet
1306 and
a coolant inlet 1304.

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Graphite electrodes are relatively economical and have a high melting point
(3675 C) but they are consumed within the operation of the FRG reactor 114 due
to
the extreme temperatures. This consumption leads to a need for the electrodes
needing to be replaced, thus adding costs in electrode materials, labor and
possibly
downtime during electrode changeover. Further, the energy that is used to
consume
the graphite electrodes is wasted energy that could have been used to
molecularly
break down the input material, which may be MSW or MSS. Yet further, the
relatively high resistance in graphite contributes to I2R losses, wasted
energy and in
some cases heat that may require a method of cooling at the power supply cable
to
electrode interface.

Tungsten electrodes also have a high melting point (3400 C) and will be
consumed
in the high extreme temperatures of the FRG reactor 114 but at a much lower
rate than
graphite electrodes. This will lead to less energy wasted on the consuming of
the
electrodes and more energy available to breakdown the input material, thus
potentially
lower operational costs. Further, an arc formed using tungsten can produce
more UV
light than an arc formed with graphite. The additional UV light in some
embodiments
can increase the production of free radicals within the FRG zone and as a
result
increase the overall energy efficiency of the system. Problems with tungsten
electrodes in the FRG reactor 114 may include difficulty to start and maintain
the arc
created by the electrodes and the relatively high cost of tungsten compared to
graphite. To improve arc characteristics, oxides can be added to the tungsten.

To improve the costs, in some embodiments such as that depicted in Figures 13A
to
13C, only a tungsten tip 1300 is utilized rather than a full electrode of
tungsten. In the
embodiment of Figures 13A to 13C, the tungsten tip 1300 is bonded to the
electrode
outer jacket 1302 that is electrically conductive. The electrode outer jacket
1302 may
be formed with a less expensive metal such as copper and can be cooled by
coolant
running through the electrode outer jacket 1302. In operation, liquid coolant
(such as
water) can be input to the coolant inlet 1306, flow through the electrode
outer jacket
1302 and output from the coolant outlet 1304. The coolant can prevent the
jacket
1302 from melting as well as potentially lower the tungsten tip temperature
and
therefore reduce the consumption of the tungsten tip 1300.

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In other embodiments, tungsten could be utilized to form the entire electrode
and, in
this case, an electrode outer jacket 1302 may not be necessary, though it may
still be
used. Further, in some embodiments, the electrode outer jacket 1302 could be
used
with graphite electrodes or electrodes made of other materials. Some materials
that
could be used to form an arc within the FRG reactor 114, either as a whole
electrode
or as a tip coupled to a hollow tube with an electrode outer jacket, include
molybdenum (melting point: 2610 C) and titanium (melting point: 1775 C). One
skilled in the art may know of other electrode materials that could also allow
for the
formation of an arc within the FRG reactor 114 and the material used in the
electrodes
should not limit the scope of the present invention.

Figure 14A is an angled top view of an electrode system according to an
alternative
embodiment of the present invention, which includes injectors for tar, water
and/or
CO2. Figures 14B and 14C are a cross-sectional side view and a cross-sectional
front
view of the electrode system of Figure 14A. Figure 14D is an assembly diagram
for
the electrode system of Figure 14A. As shown, the electrode 224 is encased in
an
insulator 1400 and both the electrode 224 and the insulator 1400 protrude
through a
portion 1410 of the base section 206 of the FRG reactor 114. The portion 1410
is
illustrated in Figure 14A for clarity. Further within the insulator 1400 are
first,
second and third notches in which a water injector 1402, tar injector 1404 and
CO2
injector 1406 are inserted with sealant 1408 filling in each of the three
notches. It
should be understood that some embodiments of the present invention may have
none,
one, two, three or more injectors such as injectors 1402, 1404, 1406 and
Figures 14A
to 14D are illustrating one particular implementation in which water, tar and
CO2 is
injected adjacent to one or more electrodes.

In embodiments that implement the water injector 1402, water added into the
FRG
reactor 114 at the electrode will be homolysised by the light and heat of the
arc to
produce free radicals. The water injector 1402 could replace or be in
combination
with the water injection pipe 706. In some embodiments, water injected via the
water
injector 1402 may need more pressure than water injected by the water
injection pipe
706 to ensure the water makes it to the arc. In some embodiments, the water
that is
injected by the water injector 1402 may comprise contaminated water such as
condensate loaded with tars or industrial waste from an external source. The
use of
48


CA 02741386 2011-05-27

1014-002 -PCT
this contaminated water in this matter can allow for a safe and efficient
disposal
method.

In embodiments of the present invention, tar may be generated by pyrolysis of
input
material above the arc in the FRG reactor 114. These tars may either be broken
down
by the arc or may exit the FRG reactor 114 in the form of vapors in the
syngas. In
some embodiments, tars may be collected at one or more locations within the
system
of the present invention, potentially during the cleaning of the syngas or, in
some
embodiments, within the FRG reactor 114. Since the tars are a source of
carbon, in
some embodiments, tar can be injected into the FRG reactor 114 adjacent to the
electrodes 224 using the tar injector 1404. The tars can then molecularly
breakdown
within the arc and contribute positively to the syngas being produced in the
FRG
reactor 114. The tar injector 1404 may replace or be in combination with the
attachment 502 in the material injection system 112. The tar that is injected
by the tar
injector 1404 may come from the system of the present invention or could come
from
an external source of tar (ex. another industrial processing plant).

CO2 is a greenhouse gas that is created as waste in many industrial processes.
The
process of the present invention produces some CO2, which would be considered
a
contaminant within the output syngas. The syngas produced by the system of the
present invention in some embodiments can be scrubbed to remove the CO2. This
CO2 as well as the CO2 from other industrial processes, which may include
significant
levels of other impurities, can be injected into the FRG reactor 114 at the
CO2 injector
1406. Within the arc, the CO2 can molecularly breakdown and, when combined
with
an additional carbon atom, can produce two carbon monoxide CO molecules which
are a positive component within syngas due to being combustible.

Although the water injector 1402, the tar injector 1404 and the CO2 injector
1406 are
shown within Figures 14A to 14D integrated with the electrode 224, this should
not
limit the scope of the present invention. In particular, one or more of the
injectors
could be located elsewhere in the FRG reactor 114 and/or could be independent
of
other mechanical elements.

49


CA 02741386 2011-05-27

1014-002 -PCT
In some embodiments of the present invention, a control system may be
implemented
to control one or more aspects of the system described above with reference to
Figures 1 through 14. In particular, in some embodiments, the control system
may
monitor the syngas extracted from the FRG reactor 114 and control an element
within
the system in response to one or more monitored aspects of the syngas. Changes
may
need to be needed for a variety of reasons including the variability of the
material
input to the system.

In one embodiment, moisture content (level of gaseous water) within the syngas
may
be monitored and the amount of water injected into the FRG chamber may be
controlled in response. Water injected to the FRG reactor 114 is used to
create free
radicals that can improve the generation of syngas from the input material but
it is not
desirable to have high moisture content within the extracted syngas. If the
moisture
content in the material is high, water may not have to be injected into the
FRG reactor
114 to generate sufficient free radicals and any additional water may simply
increase
the moisture content within the extracted syngas. By monitoring the moisture
content
within the extracted syngas, a high moisture level can be adjusted by reducing
or
stopping the water injection into the FRG reactor 114 from the water injection
pipe
706, the water attachment 500 and/or the water injector 1402. On the other
hand, if
the moisture content in the material is low, monitoring the moisture content
within the
extracted syngas can allow for an adjustment in the water injected to the FRG
reactor
114 to compensate and ensure sufficient free radicals are formed.

In other embodiments, carbon compound content within extracted syngas may be
monitored and the rate of speed of input of material into the FRG reactor 114
from the
material injection system 112 and/or the rate of speed of movement of material
within
the FRG reactor 114 may be controlled. In particular, the rate of rotation of
the MIS
400 and/or MFS 220 may be controlled in response to the carbon compound
content
within the extracted syngas. Further, the content of the material input to the
FRG
reactor 114, the level of tar injected into the FRG reactor 114 and/or the
level of CO2
injected into the FRG reactor 114 may be adjusted in response to the monitored
level
of carbon compound content within the extracted syngas.



CA 02741386 2011-05-27

1014-002 -PCT
In yet other embodiments, in response to monitored aspects of the extracted
syngas,
the location of extraction of the syngas, the location of injection of water,
the
positioning of the electrodes and/or the level of electrical current flowing
through the
electrodes may be adjusted.
The embodiments of the present invention as described herein above provide a
number of advantages over prior architectures. In particular, embodiments of
the
present invention may provide improved flow of material through the system and
therefore more efficient generation of syngas. Further, embodiments of the
present
invention may allow for improved control of the output syngas through the
ability to
adjust many variables including the amount of water input (and therefore the
generation of additional free radicals), the rate of input of material, the
level of
electrical current applied to the electrodes 224, the location of extraction
of the
syngas, the location of injection of water, the injection of tar, the
injection of CO2, the
positioning of the electrodes 224 etc. This control is especially useful when
the
material input to the system is significantly variable in terms of moisture
content,
carbon content, substances, etc, as it typically may be with MSW or MSS.

As described, embodiments of the present invention allow for an area of free
radicals
within the FRG chamber 114 which can be enhanced through the injection of a
controlled amount of water. The FRG zone initiates breakdown of the input
material
within the FRG reactor 114 to generate syngas. Since the water injection is
controlled, sufficient free radicals can be formed within the FRG chamber 114
while
not adding unacceptable levels of moisture content (i.e. gaseous water) within
the
resulting syngas extracted from the FRG reactor 114. The free radicals
combined
with the high intensity light and high heat from the arc within the FRG
reactor 114
can break down the input material in an efficient manner, reducing the energy
required for each kilogram of input material processed. In the case of MSW
being the
input material, the resulting syngas can have a stored energy (in various
forms: heat in
gas, water vapor, heating value of gas), greater than the energy used in the
electricity
to create the arc within the FRG reactor 114 combined with the typical energy
that
could have been generated through heating and combusting of the input
material.

51


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1014-002 -PCT
An advantage of particular embodiments of the present invention is the ability
within
the system to reuse the waste materials from the system. In particular, as
described,
contaminants extracted from the syngas during a cleaning process can be re-
injected
into the FRG reactor 114 for processing and can be broken down in the arc.
Further,
CO2 and contaminated water that may be generated in the processing of the
input
material both could be re-injected to the FRG reactor 114 and/or the material
injection
system 112 to be processed and broken down. Yet further, in some embodiments
of
the present invention, the system may be a net producer of water as water is
one of the
products of the molecular reductions that will occur in the arc of the FRG
reactor 114.
Although various embodiments of the present invention have been described and
illustrated, it will be apparent to those skilled in the art that numerous
modifications
and variations can be made without departing from the scope of the invention.

52

Dessin représentatif
Une figure unique qui représente un dessin illustrant l'invention.
États administratifs

Pour une meilleure compréhension de l'état de la demande ou brevet qui figure sur cette page, la rubrique Mise en garde , et les descriptions de Brevet , États administratifs , Taxes périodiques et Historique des paiements devraient être consultées.

États administratifs

Titre Date
Date de délivrance prévu 2013-01-08
(86) Date de dépôt PCT 2010-10-22
(85) Entrée nationale 2011-05-27
Requête d'examen 2011-05-27
(87) Date de publication PCT 2012-04-22
(45) Délivré 2013-01-08

Historique d'abandonnement

Il n'y a pas d'historique d'abandonnement

Taxes périodiques

Dernier paiement au montant de 125,00 $ a été reçu le 2023-10-10


 Montants des taxes pour le maintien en état à venir

Description Date Montant
Prochain paiement si taxe générale 2024-10-22 347,00 $
Prochain paiement si taxe applicable aux petites entités 2024-10-22 125,00 $

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  • taxe de rétablissement ;
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Historique des paiements

Type de taxes Anniversaire Échéance Montant payé Date payée
Requête d'examen 200,00 $ 2011-05-27
Enregistrement de documents 100,00 $ 2011-05-27
Le dépôt d'une demande de brevet 400,00 $ 2011-05-27
Taxe finale 318,00 $ 2012-09-17
Taxe de maintien en état - Demande - nouvelle loi 2 2012-10-22 100,00 $ 2012-10-18
Taxe de maintien en état - brevet - nouvelle loi 3 2013-10-22 300,00 $ 2013-10-23
Taxe de maintien en état - brevet - nouvelle loi 4 2014-10-22 100,00 $ 2014-10-21
Taxe de maintien en état - brevet - nouvelle loi 5 2015-10-22 200,00 $ 2015-10-19
Taxe de maintien en état - brevet - nouvelle loi 6 2016-10-24 200,00 $ 2016-10-11
Taxe de maintien en état - brevet - nouvelle loi 7 2017-10-23 200,00 $ 2017-10-02
Taxe de maintien en état - brevet - nouvelle loi 8 2018-10-22 100,00 $ 2018-10-22
Taxe de maintien en état - brevet - nouvelle loi 9 2019-10-22 100,00 $ 2019-10-21
Taxe de maintien en état - brevet - nouvelle loi 10 2020-10-22 125,00 $ 2020-10-09
Taxe de maintien en état - brevet - nouvelle loi 11 2021-10-22 125,00 $ 2021-10-22
Taxe de maintien en état - brevet - nouvelle loi 12 2022-10-24 125,00 $ 2022-10-24
Taxe de maintien en état - brevet - nouvelle loi 13 2023-10-23 125,00 $ 2023-10-10
Titulaires au dossier

Les titulaires actuels et antérieures au dossier sont affichés en ordre alphabétique.

Titulaires actuels au dossier
RESPONSIBLE ENERGY INC.
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Description du
Document 
Date
(yyyy-mm-dd) 
Nombre de pages   Taille de l'image (Ko) 
Paiement de taxe périodique 2021-10-22 2 56
Abrégé 2011-05-27 1 27
Description 2011-05-27 52 2 556
Revendications 2011-05-27 20 793
Dessins 2011-05-27 45 751
Page couverture 2012-12-27 2 60
Description 2012-06-28 52 2 556
Revendications 2012-06-28 6 228
Dessins représentatifs 2012-06-27 1 14
Page couverture 2012-06-27 2 59
Abrégé 2012-08-02 1 27
Déclaration de petite entité 2018-10-22 1 100
Paiement de taxe périodique 2018-10-22 2 140
Cession 2011-05-27 7 274
PCT 2011-05-27 12 866
Poursuite-Amendment 2012-02-10 2 62
Poursuite-Amendment 2012-04-23 1 19
Poursuite-Amendment 2012-06-14 3 115
Poursuite-Amendment 2012-06-28 19 669
Correspondance 2012-08-29 4 194
Correspondance 2012-09-17 1 35