Description:TECHNICAL FIELD OF THE INVENTION
[0001] The embodiments of the present disclosure generally relate to waste management and energy generation systems. In particularly, relates to a gasification system with multiple injection ports for syngas recirculation and automated process control for converting municipal solid waste into clean energy.

BACKGROUND OF THE DISCLOSURE
[0002] The following description of related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section be used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of prior art.
[0003] Waste management represents a critical global challenge, with the World Bank reporting annual municipal solid waste generation of 2 billion tonnes. The municipal solid waste generation is expected to reach 3.4 billion tonnes by 2050, significantly outpacing population growth. In India alone, 62 million tonnes of solid waste are generated annually, of which only 43 million tonnes are collected and merely 11.9 million tonnes undergo treatment, leaving 31 million tonnes in legacy landfills.
[0004] Traditional waste treatment methods like incineration present significant environmental concerns due to high oxygen consumption and harmful emissions. The incineration process requires excess air for combustion, leading to increased formation of dioxins and furans. The excess air requirement in incineration also results in higher operational costs and reduced energy efficiency.
[0005] Existing gasification systems attempt to address these issues but face several limitations. The existing gasification systems typically operate at lower temperatures around 500 degrees centigrade, resulting in incomplete waste conversion and tar formation. The incomplete waste conversion in existing gasification systems leads to reduced syngas quality and increased maintenance requirements. The tar formation in existing gasification systems causes clogging of equipment and reduced operational efficiency.
[0006] Current gasification technologies lack effective temperature control across different reactor zones. The ineffective temperature control in current gasification technologies results in non-uniform gasification and reduced process efficiency. The non-uniform gasification leads to variation in syngas composition and reduced energy output.
[0007] Existing systems also struggle with syngas recirculation control. The inadequate syngas recirculation control results in unstable operating conditions and reduced process efficiency. The unstable operating conditions lead to variation in product quality and increased environmental emissions.
[0008] Most conventional gasification systems lack integrated process control capabilities. The absence of integrated process control in conventional gasification systems results in manual interventions and reduced operational reliability. The manual interventions lead to process inconsistencies and increase operational costs.
[0009] Additionally, current systems face challenges in maintaining optimal oxygen-to-fuel ratios. The sub-optimal oxygen-to-fuel ratios in current systems result in inefficient gasification and increased pollutant formation. The inefficient gasification leads to reduced energy recovery and increases environmental impact.
[00010] Conventional systems and methods face difficulty in maintaining consistent temperature profiles, controlling syngas recirculation, ensuring optimal oxygen-to-fuel ratios, and providing automated process control for efficient waste-to-energy conversion. There is, therefore, a need in the art to provide a gasification system that can overcome the shortcomings of the existing prior arts.

SUMMARY OF THE DISCLOSURE
[00011] This summary may be provided to introduce concepts related to a gasification system for waste-to-energy conversion; the concepts are further described below in the detailed description. This summary may be not intended to identify essential features of the claimed subject matter nor maybe it intended for use in determining or limiting the scope of the claimed subject matter.
[00012] In an exemplary embodiment, a gasification system for waste-to-energy conversion is described. The gasification system comprises a gasification reactor configured with a combustion zone and a syngas outlet. The combustion zone is operated under sub-stoichiometric oxygen conditions. A syngas distribution system is fluidly connected to the syngas outlet of the gasification reactor. The syngas distribution system comprises a primary flow path configured for directing syngas to an electricity generation unit and a recirculation flow path configured for returning syngas to the combustion zone of the gasification reactor. A sensor assembly is integrated within the gasification reactor and the syngas distribution system. The sensor assembly comprises temperature sensors disposed within the combustion zone, oxygen sensors positioned along the recirculation flow path, and pressure sensors monitoring reactor pressure. A flow control assembly is disposed within the syngas distribution system. The flow control assembly comprises a recirculation control valve disposed within the recirculation flow path and a power generation control valve disposed within the primary flow path, wherein each control valve comprises a modulating actuator configured to respond to control signals. A process control unit is operatively connected to the sensor assembly and the flow control assembly. The process control unit is configured for receiving continuous data signals from the sensor assembly indicating combustion zone temperature, oxygen concentration, and reactor pressure. The process control unit processes the received continuous data signals against predetermined operating parameters. The process control unit generates control signals to modulate the recirculation control valve and the power generation control valve. The process control unit maintains auto-thermal operation of the gasification reactor by adjusting proportion of syngas flowing through the recirculation flow path relative to the primary flow path based on the processed continuous data signals.
[00013] In some embodiments, the combustion zone comprises multiple syngas injection ports positioned at different heights. Each syngas injection port comprises an associated temperature sensor configured for providing localized temperature data to the process control unit. The recirculation flow path includes multiple branch conduits connected to the syngas injection ports. Each branch conduit comprises an individual flow control valve responsive to the localized temperature data from its associated temperature sensor.
[00014] In some embodiments, the process control unit is further configured for executing a control algorithm. The control algorithm compares real-time combustion zone temperature data against a predetermined temperature range. The control algorithm calculates required syngas recirculation flow based on temperature deviation. The control algorithm adjusts the recirculation control valve position to maintain combustion zone temperature within the predetermined temperature range while ensuring sufficient syngas flow through the primary flow path for continuous power generation. The control algorithm maintains negative draft pressure between 0.5- and 2.0-inches water column within the gasification reactor by coordinated control of the recirculation control valve and the power generation control valve.
[00015] In some embodiments, the gasification system further comprises a syngas composition analyzer positioned in the syngas outlet. The syngas composition analyzer is configured for monitoring hydrogen-to-carbon monoxide ratio. The process control unit is further configured for adjusting the proportion of recirculated syngas based on measured syngas composition to optimize gasification conditions and minimize pollutant formation. The process control unit maintains the hydrogen-to-carbon monoxide ratio between 1.5 and 2.0 through automated adjustment of recirculation flow rate.
[00016] In some embodiments, the gasification reactor operates under the sub-stoichiometric oxygen conditions with an oxygen-to-fuel ratio between 0.2 and 0.33. The process control unit is configured for maintaining the oxygen-to-fuel ratio by modulating the recirculation control valve based on data from the oxygen sensors.
[00017] In some embodiments, the gasification system further comprises a superheated steam injection system coupled to the combustion zone. The process control unit is configured for coordinating steam injection with syngas recirculation to maintain combustion zone temperature between 1000 and 1200 degrees centigrade.
[00018] In some embodiments, the gasification system further comprises auxiliary burners disposed within the combustion zone and a thermal recirculation loop having a counter-current heat exchanger. The counter-current heat exchanger is configured for preheating recirculated syngas using combustion zone exhaust heat. The process control unit is configured for activating the auxiliary burners when the combustion zone temperature falls below a predetermined threshold despite maximum syngas recirculation.
[00019] In some embodiments, the gasification system further comprises a feedstock preparation system. The feedstock preparation system is configured for receiving and storing waste materials, shredding the received waste materials into smaller sizes, and drying the shredded waste materials to reduce moisture content. The process control unit is further configured for adjusting the syngas recirculation based on calorific value of the prepared feedstock.
[00020] In some embodiments, the gasification system further comprises a syngas cleaning system positioned between the syngas outlet and the syngas distribution system. The syngas cleaning system comprises a cyclone separator configured for removing larger particulates, a tar filter system configured for capturing tar compounds, a water jet filter configured for removing dust and particulates, and a water condenser system configured for removing excess moisture from the syngas.
[00021] In some embodiments, the process control unit is further configured for implementing an automated startup sequence coordinating syngas recirculation with auxiliary heating, real-time adjustment of recirculation rates based on feedstock calorific value, emergency shutdown protocols triggered by sensor data deviations, and continuous monitoring and control of emissions to maintain compliance with environmental regulations.
[00022] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF DRAWINGS
[00023] The accompanying drawings, which are incorporated herein, and constitute a part of this disclosure, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that disclosure of such drawings includes the disclosure of electrical components, electronic components or circuitry commonly used to implement such components.
[00024] FIG. 1 illustrates an exemplary system architecture of a gasification system for waste-to-energy conversion, in accordance with embodiments of the present disclosure.
[00025] FIG. 2 illustrates an exemplary block diagram of a system, in accordance with embodiments of the present disclosure.
[00026] FIG. 3 illustrates an exemplary flow process chart, in accordance with embodiments of the present disclosure.
[00027] The foregoing shall be more apparent from the following more detailed description of the disclosure.
LIST OF REFERENCE NUMERALS
102 - Feedstock System
104 - Gasification Reactor
106 - Upper Port
108 - Middle Port
110 - Lower Port
112 - Temperature Sensor T1
114 - Temperature Sensor T2
116 - Temperature Sensor T3
118 - Syngas Cleaning System
120 - Process Control Unit
122 - Distribution System
124 - Electricity Generation Unit
202 - Feeding Hopper
204 - Water Jet Filter
206 - Water Condenser System
208 - Tar Filter System
210 - Syngas Blower
212 - Reactor Cooling System
214 - Ash Collecting System
DETAILED DESCRIPTION OF THE DISCLOSURE
[00028] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
[00029] The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.
[00030] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[00031] Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.
[00032] The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising” as an open transition word without precluding any additional or other elements.
[00033] Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[00034] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[00035] The aspects of the present disclosure are directed to a gasification system with multi-port syngas recirculation control for waste-to-energy conversion. The gasification system aims to provide an advanced, intelligent method for converting municipal solid waste into clean energy through controlled gasification processes and automated syngas management. The multi-port system offers improved efficiency and process optimization by utilizing strategically positioned injection ports, comprehensive sensor arrays, and adaptive control strategies to maintain optimal combustion conditions. The process control unit monitors and manages temperature profiles, oxygen levels, and syngas composition in real-time, enabling automatic adjustment of recirculation rates and operating parameters. This innovative approach combines sophisticated process control, multi-point syngas recirculation, and advanced cleaning technologies to deliver a more efficient, environmentally friendly, and reliable waste-to-energy solution that can adapt to varying feedstock characteristics while maintaining stable operating conditions and minimizing pollutant formation.
[00036] The various embodiments throughout the disclosure will be explained in more detail with reference to FIG. 1, FIG. 2 and FIG 3.
[00037] FIG. 1 illustrates an exemplary system architecture of a gasification system for waste-to-energy conversion, in accordance with embodiments of the present disclosure.
[00038] FIG. 1 may illustrate a gasification system for waste-to-energy conversion. The gasification system may comprise a feedstock system (102) which may be configured to prepare and supply waste materials. The feedstock system (102) may include storage facilities, size reduction equipment, and moisture control mechanisms. The feedstock system (102) may process various types of waste materials including, but not limited to, municipal solid waste, agricultural waste, industrial waste, and biomass materials.
[00039] The gasification system may further comprise a gasification reactor (104) which may be configured with a combustion zone and a syngas outlet. The gasification reactor (104) may be designed to operate under sub-stoichiometric oxygen conditions. The sub-stoichiometric oxygen conditions may refer to operating conditions where the oxygen supply is maintained below the stoichiometric requirement for complete combustion, typically between 20% to 33% of the theoretical oxygen requirement. The gasification reactor (104) may be constructed using high-temperature resistant materials capable of withstanding operating temperatures between 1000 and 1200 degrees centigrade.
[00040] The combustion zone of the gasification reactor (104) may comprise multiple syngas injection ports including an upper port (106), a middle port (108), and a lower port (110). The upper port (106) may be positioned in the high-temperature zone of the reactor and may serve as the primary syngas injection point. The middle port (108) may be located in the main reaction zone and may facilitate temperature control and process stabilization. The lower port (110) may be situated in the reduction zone and may assist in maintaining process stability and complete gasification. Each injection port may be equipped with independent flow control mechanisms to regulate syngas distribution.
[00041] The gasification system may include a comprehensive sensor assembly comprising temperature sensors (112, 114, 116) disposed within the combustion zone. The temperature sensor (112) may be associated with the upper port (106), the temperature sensor (114) may be associated with the middle port (108), and the temperature sensor (116) may be associated with the lower port (110). Each temperature sensor may provide localized temperature data for its respective zone. The sensor assembly may also include oxygen sensors positioned along the recirculation flow path and pressure sensors for monitoring reactor pressure.
[00042] A syngas cleaning system (118) may be positioned downstream of the gasification reactor (104). The syngas cleaning system (118) may comprise multiple stages of cleaning equipment including cyclone separators, filters, and condensers. The syngas cleaning system (118) may be designed to remove particulates, tar compounds, and moisture from the produced syngas. The syngas cleaning system (118) may ensure the syngas meets required quality specifications for power generation.
[00043] A process control unit (120) may be operatively connected to both the sensor assembly and flow control assembly. The process control unit (120) may receive continuous data signals indicating combustion zone temperatures, oxygen concentrations, and reactor pressure. The process control unit (120) may process these signals against predetermined operating parameters which may include, but are not limited to, temperature ranges, pressure limits, and composition targets. The process control unit (120) may execute control algorithms to maintain optimal operating conditions.
[00044] A syngas distribution system (122) may be fluidly connected to the syngas outlet of the gasification reactor (104). The syngas distribution system (122) may comprise a primary flow path and a recirculation flow path. The primary flow path may direct cleaned syngas to an electricity generation unit (124). The recirculation flow path may return a portion of the syngas to the combustion zone through the multiple injection ports (106, 108, 110). The syngas distribution system (122) may include flow control valves with modulating actuators responsive to control signals from the process control unit (120).
[00045] The electricity generation unit (124) may convert the clean syngas into electrical power. The electricity generation unit (124) may comprise gas engines, turbines, or other power generation equipment suitable for syngas utilization. The electricity generation unit (124) may be sized according to the syngas production capacity of the gasification system.
[00046] The flow control assembly within the syngas distribution system (122) may comprise multiple specialized valves. The recirculation control valve may be designed for precise flow modulation and may be constructed of materials suitable for high-temperature syngas handling. The power generation control valve may be engineered for steady flow control to the electricity generation unit (124). Each control valve may incorporate modulating actuators which may respond to signals from the process control unit (120) within milliseconds to maintain optimal system performance.
[00047] The syngas produced in the gasification reactor (104) may comprise a mixture of combustible gases. The primary components of the syngas may include hydrogen, carbon monoxide, methane, and carbon dioxide. The ratio of hydrogen to carbon monoxide in the syngas may be maintained between 1.5 and 2.0 through automated control of operating conditions. The syngas composition may be continuously monitored by analyzers positioned at strategic locations within the system.
[00048] The temperature profile within the gasification reactor (104) may be maintained through coordinated control of multiple parameters. The upper zone temperature, as monitored by temperature sensor (112), may be maintained between 1000 and 1200 degrees centigrade. The middle zone temperature, monitored by temperature sensor (114), may be controlled between 800 and 1000 degrees centigrade. The lower zone temperature, monitored by temperature sensor (116), may be regulated between 600 and 800 degrees centigrade.
[00049] The process control unit (120) may implement sophisticated control algorithms for system operation. The control algorithms may include proportional-integral-derivative (PID) control loops, feed-forward control strategies, and adaptive control mechanisms. The process control unit (120) may utilize artificial intelligence and machine learning techniques to optimize system performance based on historical operating data.
[00050] The sensor assembly integrated within the gasification reactor (104) may provide comprehensive monitoring capabilities. The oxygen sensors may be positioned at multiple points along the recirculation flow path. The oxygen sensors may utilize zirconia-based sensing elements capable of operating in high-temperature environments. The pressure sensors may employ various technologies including differential pressure measurement systems for accurate reactor pressure monitoring.
[00051] The auto-thermal operation of the gasification reactor (104) may be achieved through precise control of syngas recirculation. The term "auto-thermal operation" may refer to a self-sustaining process where the heat required for gasification is generated through partial oxidation of the feedstock and recirculated syngas. The process control unit (120) may continuously adjust the proportion of syngas flowing through the recirculation flow path based on real-time temperature measurements.
[00052] The negative draft pressure within the gasification reactor (104) may be maintained between 0.5 and 2.0 inches water column. The term "negative draft pressure" may refer to the sub-atmospheric pressure maintained within the reactor to prevent gas leakage and ensure proper flow patterns. The process control unit (120) may achieve this through coordinated control of the recirculation control valve and power generation control valve positions.
[00053] The syngas flow through multiple injection ports (106, 108, 110) may create distinct reaction zones within the gasification reactor (104). The upper port (106) may inject syngas to maintain the high-temperature oxidation zone. The middle port (108) may support the primary gasification reactions. The lower port (110) may facilitate char reduction and final gas quality optimization. This staged injection approach may enhance overall conversion efficiency.
[00054] The feedstock system (102) may incorporate various mechanisms for waste material preparation. The feedstock preparation may include size reduction to achieve particle sizes typically between 50mm and 150mm. The moisture content of the prepared feedstock may be controlled to remain below 20% by weight. The prepared feedstock characteristics may be communicated to the process control unit (120) for optimization of gasification parameters.
[00055] The process control unit (120) may implement comprehensive safety protocols. The safety protocols may include emergency shutdown sequences, automated pressure relief mechanisms, and temperature limit controls. The process control unit (120) may continuously monitor critical parameters and initiate appropriate responses to any deviations from safe operating ranges. The safety systems may be designed with redundancy and fail-safe mechanisms.
[00056] FIG. 2 may illustrate detailed subsystems of the gasification system. A feeding hopper (202) may be provided at the input section of the gasification reactor. The feeding hopper (202) may comprise a storage section, a metering mechanism, and a sealed feeding system. The feeding hopper (202) may be designed to maintain an air-tight seal while feeding waste materials into the high-temperature reactor environment. The feeding hopper (202) may incorporate level sensors, weight measurement systems, and automated feed rate controls.
[00057] A water jet filter (204) may be positioned within the syngas cleaning system. The water jet filter (204) may utilize high-pressure water sprays to remove particulate matter from the syngas stream. The water jet filter (204) may comprise multiple spray nozzles arranged in a counter-current configuration. The high-pressure water jets may effectively capture particles down to 5 microns in size. The water jet filter (204) may include a water recirculation system to minimize water consumption.
[00058] A water condenser system (206) may be installed downstream of the water jet filter (204). The water condenser system (206) may be designed to cool the syngas and remove moisture content. The water condenser system (206) may utilize shell and tube heat exchangers with cooling water circulation. The condensed water from the syngas may be collected and treated for reuse in the water jet filter (204). The water condenser system (206) may reduce the syngas temperature to approximately 40 degrees centigrade.
[00059] A tar filter system (208) may be incorporated for removing tar compounds from the syngas. The tar filter system (208) may employ multiple filtration stages including activated carbon beds and specialized polymer-based filter elements. The tar filter system (208) may be designed to operate at temperatures above the tar condensation point to prevent system fouling. The tar filter system (208) may achieve tar removal efficiencies exceeding 99%. The captured tar compounds may be returned to the gasification reactor for thermal cracking.
[00060] A syngas blower (210) may be provided to maintain proper gas flow through the system. The syngas blower (210) may be designed for handling high-temperature, corrosive gases. The syngas blower (210) may incorporate variable frequency drives for flow control. The syngas blower (210) may maintain the required negative draft pressure within the gasification reactor while ensuring adequate flow through all cleaning stages. The syngas blower (210) may be constructed with special sealing systems to prevent gas leakage.
[00061] A reactor cooling system (212) may be integrated with the gasification reactor. The reactor cooling system (212) may comprise water-cooled jackets surrounding the high-temperature zones. The reactor cooling system (212) may incorporate multiple cooling circuits with independent temperature control. The cooling water temperature may be maintained between 40 and 60 degrees centigrade. The reactor cooling system (212) may include emergency cooling provisions for rapid temperature reduction if required.
[00062] An ash collecting system (214) may be installed at the bottom of the gasification reactor. The ash collecting system (214) may include a water-cooled screw conveyor for continuous ash removal. The ash collecting system (214) may incorporate ash quality monitoring sensors to ensure complete carbon conversion. The removed ash may be cooled and stored in sealed containers. The ash collecting system (214) may be designed to operate without disrupting the negative pressure maintained within the reactor.
[00063] The water jet filter (204), water condenser system (206), and tar filter system (208) may operate in sequence to achieve comprehensive syngas cleaning. The process control unit may monitor pressure drops across each cleaning stage. The cleaning efficiency may be continuously evaluated through syngas quality measurements. The cleaning systems may be equipped with bypass arrangements for maintenance access.
[00064] The reactor cooling system (212) may work in coordination with the temperature control strategy. The cooling water flow rates may be automatically adjusted based on temperature measurements from multiple sensors. The reactor cooling system (212) may incorporate heat recovery mechanisms to improve overall system efficiency. The recovered heat may be utilized for feedstock drying or steam generation.
[00065] The syngas blower (210) speed may be controlled based on multiple parameters. The control parameters may include reactor pressure, cleaning system pressure drops, and required flow rates to the electricity generation unit. The syngas blower (210) may be equipped with acoustic insulation to minimize noise levels. Emergency backup power may be provided to ensure continuous blower operation.
[00066] FIG. 3 may illustrate a comprehensive process flow diagram of the waste-to-energy gasification system. The process may begin at the tipping floor where municipal solid waste (MSW) may be initially received. The tipping floor may be designed to accommodate multiple waste collection vehicles and may include initial waste inspection facilities.
[00067] From the tipping floor, the waste materials may proceed to a recycling and sorting section. This section may comprise a conveyor system with multiple sorting stations. The sorting process may separate out metals, glass, and plastic bottles for recycling. The separation may be achieved through a combination of manual sorting and automated systems including magnetic separators for metals and optical sorters for plastics.
[00068] The remaining waste may proceed to the MSW preparation area. In this area, the feedstock preparation system may process the waste to achieve proper specifications for gasification. The preparation may include size reduction, moisture control, and homogenization of the waste materials. The prepared MSW may then be transferred to the feeding hopper system for controlled introduction into the gasifier.
[00069] The gasifier may operate at temperatures ranging from 750°F to 3,000°F (approximately 400°C to 1,650°C). These elevated temperatures may ensure complete thermal decomposition of the waste materials. The gasification process may occur under controlled sub-stoichiometric conditions, with the multi-port injection system providing precise control of reaction conditions at different heights within the gasifier.
[00070] The gasification process may produce two primary outputs: syngas and inert solids. The syngas may flow upward through the gasifier and exit at the top, while inert solids may be collected at the bottom. The inert solids may be processed for use as construction materials, demonstrating the system's ability to maximize resource recovery.
[00071] The produced syngas may enter the gas cleaning section. The gas cleaning system may employ multiple stages including the water jet filter, tar filter system, and water condenser system. These systems may work in sequence to remove particulates, tar compounds, and excess moisture from the syngas. The cleaning process may ensure the syngas meets the quality requirements for power generation.
[00072] The cleaned syngas may then flow to the electric generator section. The electricity generation unit may convert the chemical energy of the syngas into electrical power. The generator may be connected to power distribution infrastructure, represented by the transmission lines in the figure, for delivering the generated electricity to the grid.
[00073] A portion of the cleaned syngas may be recirculated back to the gasifier through the multi-port injection system. The recirculation flow, indicated by the arrows, may help maintain optimal temperature profiles and reaction conditions within the gasifier. The process control unit may continuously monitor and adjust the recirculation rates based on real-time operating parameters.
[00074] The entire process flow may be designed for continuous operation with provisions for maintenance access at key points. The system may incorporate multiple feedback loops for process optimization and environmental compliance. The process control unit may manage all aspects of the operation, from waste feeding to power generation, ensuring efficient and stable performance.

ADVANTAGES OF THE PRESENT DISCLOSURE
[00075] The present disclosure is advantageous in providing multi-port syngas injection that enables precise temperature control across different reactor zones, resulting in more efficient gasification and reduced tar formation compared to single-point injection systems.
[00076] The present disclosure is advantageous in achieving operation under sub-stoichiometric oxygen conditions with an oxygen-to-fuel ratio between 0.2 and 0.33, which significantly reduces dioxin and furan formation compared to conventional incineration processes requiring excess air.
[00077] The present disclosure is advantageous in maintaining auto-thermal operation through intelligent control of syngas recirculation, eliminating the need for continuous external fuel input and improving overall system efficiency.
[00078] The present disclosure is advantageous in utilizing real-time sensor data and adaptive control algorithms to maintain optimal hydrogen-to-carbon monoxide ratios between 1.5 and 2.0, ensuring consistent syngas quality for power generation.
[00079] The present disclosure is advantageous in implementing coordinated control of multiple process parameters through an integrated process control unit, reducing manual intervention and improving operational reliability.
[00080] The present disclosure is advantageous in maintaining negative draft pressure between 0.5 and 2.0 inches water column, preventing gas leakage and ensuring safe operation while optimizing gas flow patterns.
[00081] The present disclosure is advantageous in providing a comprehensive syngas cleaning system with multiple stages, achieving superior gas quality through sequential removal of particulates, tar compounds, and moisture.
[00082] The present disclosure is advantageous in operating at elevated temperatures between 1000 and 1200 degrees centigrade in the primary reaction zone, ensuring complete waste conversion and minimal pollutant formation.
[00083] The present disclosure is advantageous in incorporating automated startup and shutdown sequences, reducing operational risks and ensuring consistent performance during transitional phases. , Claims:WE Claim:
1. A gasification system for waste-to-energy conversion, comprising:
- a gasification reactor (104) configured with a combustion zone and a syngas outlet, wherein the combustion zone is operated under sub-stoichiometric oxygen conditions;
- a syngas distribution system (122) fluidly connected to the syngas outlet of the gasification reactor (104), wherein the syngas distribution system (122) comprises:
- a primary flow path configured for directing syngas to an electricity generation unit (124); and
- a recirculation flow path configured for returning syngas to the combustion zone of the gasification reactor (104);
- a sensor assembly integrated within the gasification reactor (104) and the syngas distribution system (122), wherein the sensor assembly comprises:
- temperature sensors (112, 114, 116) disposed within the combustion zone;
- oxygen sensors positioned along the recirculation flow path; and
- pressure sensors monitoring reactor pressure;
- a flow control assembly disposed within the syngas distribution system (122), wherein the flow control assembly comprises:
- a recirculation control valve disposed within the recirculation flow path; and
- a power generation control valve disposed within the primary flow path,
wherein each control valve comprises a modulating actuator configured to respond to control signals;
- a process control unit (120) operatively connected to the sensor assembly and the flow control assembly, wherein the process control unit (120) is configured for:
- receiving continuous data signals from the sensor assembly indicating combustion zone temperature, oxygen concentration, and reactor pressure;
- processing the received continuous data signals against predetermined operating parameters;
- generating control signals to modulate the recirculation control valve and the power generation control valve; and
- maintaining auto-thermal operation of the gasification reactor (104) by adjusting proportion of syngas flowing through the recirculation flow path relative to the primary flow path based on the processed continuous data signals.

2. The gasification system as claimed in claim 1, wherein:
- the combustion zone comprises multiple syngas injection ports (106, 108, 110) positioned at different heights;
- each syngas injection port comprises an associated temperature sensor (112, 114, 116) configured for providing localized temperature data to the process control unit (120);
- the recirculation flow path includes multiple branch conduits connected to the syngas injection ports (106, 108, 110); and
- each branch conduit comprises an individual flow control valve responsive to the localized temperature data from its associated temperature sensor.

3. The gasification system as claimed in claim 1, wherein the process control unit (120) is further configured for executing a control algorithm comprising:
- comparing real-time combustion zone temperature data against a predetermined temperature range;
- calculating required syngas recirculation flow based on temperature deviation;
- adjusting the recirculation control valve position to maintain combustion zone temperature within the predetermined temperature range while ensuring sufficient syngas flow through the primary flow path for continuous power generation; and
- maintaining negative draft pressure between 0.5 and 2.0 inches water column within the gasification reactor (104) by coordinated control of the recirculation control valve and the power generation control valve.

4. The gasification system as claimed in claim 1 is further configured for comprising:
- a syngas composition analyzer positioned in the syngas outlet;
wherein:
- the syngas composition analyzer is configured for monitoring hydrogen-to-carbon monoxide ratio; and
- the process control unit (120) is further configured for:
- adjusting the proportion of recirculated syngas based on measured syngas composition to optimize gasification conditions and minimize pollutant formation; and
- maintaining the hydrogen-to-carbon monoxide ratio between 1.5 and 2.0 through automated adjustment of recirculation flow rate.

5. The gasification system as claimed in claim 1, wherein:
- the gasification reactor (104) operates under the sub-stoichiometric oxygen conditions with an oxygen-to-fuel ratio between 0.2 and 0.33; and
- the process control unit (120) is configured for maintaining the oxygen-to-fuel ratio by modulating the recirculation control valve based on data from the oxygen sensors.

6. The gasification system as claimed in claim 1 is further configured for comprising:
- a superheated steam injection system coupled to the combustion zone;
wherein the process control unit (120) is configured for coordinating steam injection with syngas recirculation to maintain combustion zone temperature between 1000 and 1200 degrees centigrade.
7. The gasification system as claimed in claim 1 is further configured for comprising:
- auxiliary burners disposed within the combustion zone;
- a thermal recirculation loop having a counter-current heat exchanger configured for preheating recirculated syngas using combustion zone exhaust heat;
wherein the process control unit (120) is configured for activating the auxiliary burners when the combustion zone temperature falls below a predetermined threshold despite maximum syngas recirculation.

8. The gasification system as claimed in claim 1 is further configured for comprising:
- a feedstock preparation system (102) configured for:
- receiving and storing waste materials;
- shredding the received waste materials into smaller sizes; and
- drying the shredded waste materials to reduce moisture content;
wherein the process control unit (120) is further configured for adjusting the syngas recirculation based on calorific value of the prepared feedstock.
9. The gasification system as claimed in claim 1 is further configured for comprising:
- a syngas cleaning system (118) positioned between the syngas outlet and the syngas distribution system (122), wherein the syngas cleaning system (118) comprises:
- a cyclone separator configured for removing larger particulates;
- a tar filter system configured for capturing tar compounds;
- a water jet filter configured for removing dust and particulates; and
- a water condenser system configured for removing excess moisture from the syngas.
10. The gasification system as claimed in claim 1, wherein the process control unit (120) is further configured for implementing:
- an automated startup sequence coordinating syngas recirculation with auxiliary heating;
- real-time adjustment of recirculation rates based on feedstock calorific value;
- emergency shutdown protocols triggered by sensor data deviations; and
- continuous monitoring and control of emissions to maintain compliance with environmental regulations.