Granted Patent B2

US 8,105,401 · App. 12/170,421 · Granted Jan 31, 2012

Assignee: Refill Energy, Inc.

Abstract

Claims (40)

1. A method comprising:

selecting a downdraft gasifier comprising:

a housing,

a refractory stack contained within the housing and comprising a plurality of sections formed of refractory, the plurality of sections comprising a lower manifold, at least one intermediate section resting on and extending upward from the lower manifold, and an upper manifold resting on and extending upward from the at least one intermediate section, and

the refractory stack wherein the upper manifold and the at least one intermediate section each comprise a plurality of apertures extending vertically therethrough, the plurality of apertures of the upper manifold aligning with the plurality of apertures of the at least one intermediate section to form a plurality of columnar cavities, each extending from the upper manifold to the lower manifold and placing the upper manifold in communication with the lower manifold;

placing a feedstock into the upper manifold;

measuring the temperature of each columnar cavity of the plurality of columnar cavities; and

adjusting the flow of at least one gas selected from the group consisting of oxygen, oxygen enriched air, and air to a particular columnar cavity to maintain the temperature of the particular columnar cavity within a particular range.

2. The method of claim 1 , wherein adjusting comprises increasing the flow of the at least one gas to raise the temperature of the particular columnar cavity and decreasing the flow of the at least one gas to lower the temperature of the particular columnar cavity.

3. The method of claim 1 , wherein the downdraft gasifier further comprises a shaft system comprising at least one motor and a shaft, the shaft extending vertically through the housing, the at least one motor connected to rotate the shaft about an axis extending vertically.

4. The method of claim 3 , further comprising rotating, by the at least one motor, the shaft about the axis extending vertically.

5. The method of claim 4 , wherein the downdraft gasifier further comprises a mixing blade connected to rotate with the shaft and mix the contents of the upper manifold.

6. The method of claim 5 , further comprising scraping, by the mixing blade, the contents of the upper manifold away from an interior surface of the upper manifold.

7. The method of claim 4 , wherein the downdraft gasifier further comprises at least one wiper blade connected to rotate with the shaft.

8. The method of claim 7 , further comprising urging, by the at least one wiper blade, the contents of the lower section toward the ash outlet.

9. The method of claim 4 , wherein the lower manifold comprises an aperture extending vertically therethrough, the aperture having an undulating perimeter.

10. The method of claim 9 , wherein the downdraft gasifier further comprises a grate connected to rotate with the shaft and positioned adjacent the lower manifold.

11. The method of claim 10 , wherein the downdraft gasifier further comprises a plurality of balls supported by the grate and held by the grate within the aperture of the lower manifold.

12. The method of claim 11 , further comprising agitating, by the undulating perimeter, the plurality of balls as the grate rotates with the shaft.

13. The method of claim 1 , wherein the housing further comprises a base, a lower section resting on and extending upward from the base, an intermediate section resting on and extending upward from the lower section, and an upper section resting on and extending upward from the intermediate section, the lower section comprising a gas outlet and a waste outlet, the upper section comprising a feedstock inlet.

14. The method of claim 13 , wherein the refractory stack is housed with the intermediate section.

15. The method of claim 14 , wherein placing the feedstock further comprises passing the feedstock into the upper section through the feedstock inlet.

16. The method of claim 15 , further comprising extracting syn-gas out of the lower section through the gas outlet.

17. The method of claim 1 , wherein the downdraft gasifier further comprises:

a plurality of electrical resistance heaters, each delivering heat to at least one columnar cavity of the plurality of columnar cavities;

a plurality of temperature sensors, each outputting a signal corresponding to the temperature of at least one columnar cavity of the plurality of columnar cavities; and

a plurality of ports, each delivering at least one gas selected from the group consisting of oxygen, oxygen enriched air, and air to at least one columnar cavity of the plurality of columnar cavities.

18. The method of claim 17 , wherein the downdraft gasifier further comprises:

a coolant system comprising coolant passing through a cooling jacket encircling the lower section;

a feed system controlling passage of feedstock into the upper section;

an extraction system pulling gas out of the lower section through the gas outlet; and

a control system monitoring the output of each sensor of the plurality of temperature sensors and performing the adjusting.

19. The method of claim 1 , further comprising:

grinding municipal solid waste to produce a first output;

mixing into the first output at least one of a quantity of zeolite and a quantity of dolomite to produce a second output;

pelletizing the second output to form the feedstock.

20. The method of claim 1 , further comprising:

starting the gasifier;

wherein the downdraft gasifier further comprises a plurality of electrical resistance heaters, each delivering heat to at least one columnar cavity of the plurality of columnar cavities; and

wherein starting comprises delivering, before the placing, sufficient current to each heater of the plurality of electrical resistance heaters to raise the temperate of each columnar cavity of the plurality of columnar cavities into the particular range.

Assignments (9)

Continuity (2)