Abstract:
The present invention is directed to a biomass gasifier combustor which operates by gasification and combustion of the biomass to produce a clean effluent gas which can be used directly for grain drying or other applications where thermal energy is required. This biomass gasifier combustor burns crop residue clean enough so that the combustion gases can be used directly for grain drying without the need for a heat exchanger to isolate the combustion gases from the drying air. The biomass gasifier combustor includes a screw feeder tube having a screw feeder disposed therein. The screw feeder forces the biomass into a first combustion chamber. Primary combustion of the biomass produces a first combustion gas. A venturi gas pump creates a negative pressure region in the gasifier, drawing the first combustion gas into a second combustion chamber. A secondary combustion takes place, completely oxidizing the organics in the primary combustion gas and producing a clean exhaust gas which can be used directly for grain drying purposes. An improved first chamber includes a manifold section for preventing the biomass from escaping into the secondary combustion chamber, and a variable height grate for allowing the ash product to fall through the holes in the variable height grate. A damper may be provided at the air inlets to control the flow rates or primary and secondary air. A damper may be placed on the exhaust eductor or venturi pump for regulating the thermal output of the system. The level of biomass in the first combustion chamber may also be monitored and automatically controlled.

Description:
This application is a divisional of copending application Ser. No. 113,339, filed on Jan. 18, 1981, now U.S. Pat. No. 4,334,484. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to biomass gasifier combustors for burning crop residue so that the resultant combustion gases can be used for grain drying or other applications where thermal energy is required. 
     2. Description of the Prior Art 
     In the prior art, it was required to use a heat exchanger to isolate the combustion gases from the drying air so that the drying air could then be used for grain drying or other applications where thermal energy is required. This heat exchanger, in the prior art device, was required because the combustion gases contained excessive particulate matter and unburned combustables. The presence of this particulate matter and unburned combustables in the gases eliminated the possible use of these combustion gases for grain drying purposes. Consequently, the heat exchanger was required in order to produce a clean flow of drying air. 
     U.S. Pat. No. 3,201,329 issued to Bert discloses a device for transforming carbonaceous vegetable matter into charcoal. This device includes a screw feeder 28 positioned within a fire chamber. However, the screw feeder 28 does not act to partially seal the fire chamber or gasification chamber. Furthermore, the Bert reference was not directed to a gasifier combustor, rather, to a means for carbonizing a waster material. 
     SUMMARY OF THE INVENTION 
     It is a primary object of the present invention to provide a biomass gasifier combustor which burns crop residue or other biomasses clean enough so that the combustion gases can be used directly for grain drying purposes without the need for a heat exchanger to isolate the combustion gases from the drying air. 
     Another object of the present invention is to provide a biomass gasifier combustor which includes a screw feeder tube and a screw feeder disposed therein, the screw feeder tube being disposed horizontally to provide a mechanical force for forcing the biomass into a horizontally disposed gasification chamber thereby not relying on gravity to feed the gasifier. The screw feeder also provides a uniform fire bed depth which does not have compacted zones which result in non-uniform burning. 
     A further object of the present invention is to provide a biomass gasifier combustor which includes a screw feeder tube, and a screw feeder disposed therein for providing a partial seal at the feed end of the gasifier. 
     Another object of the present invention is to provide a biomass gasifier combustor having an improved gasification chamber which permits controlled combustion of the biomass and allows the rate of burning to be adjusted to the required output. The gasification chamber includes a manifold section for preventing the biomass from escaping into the combustion chamber and a variable height grate for allowing the ash product, the results of the combustion of the biomass in the gasification chamber, to fall through the holes in the variable height grate thereby falling out of the gasification chamber. 
     These and other objects of the present invention are accomplished by providing a gasifier combustor wherein the biomass is forced into the gasification chamber by a screw feeder. The gasification chamber does not require a mechanical seal since the screw feeder tube together with the screw feeder functions as a partial seal at the feed end of the gasifier. In addition, the biomass is horizontally forced into the fire zone by a mechanical force instead of the conventional gravity feed. As a result, the biomass is gasified (undergoes a primary combustion) in the gasification chamber without excessive compaction by gravity and loss of porosity. A venturi pump is provided which creates a negative pressure region within the entire system. Primary air is drawn through and passes through the fire zone generating a gas which is exhausted into the secondary combustion chamber as a low BTU gas where it undergoes a secondary combustion. Consequently, the gasifier combustor of the present invention produces a clean combustion gas (exhaust) which can be used directly for grain drying purposes without the need to resort to the use of a heat exchanger for isolating the combustion gases from the drying air. 
     Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein: 
     FIG. 1 is a perspective view of a first embodiment of the biomass gasifier combustor of the present invention illustrating the biomass feeder including the screw feeder, the gasification chamber, the gas combustion chamber, and the venturi gas pump creating the negative pressure region; 
     FIG. 1A is a simplified perspective view of the damper for the secondary air inlet; 
     FIG. 1B is a larger view of the pressure blower of FIG. 1 having a damper thereon; 
     FIG. 2 is a perspective view of the gasification chamber taken along section lines 2--2 of FIG. 1; 
     FIG. 3 is a perspective view of another embodiment of the gasification chamber with the present invention; 
     FIG. 4 is a schematic view of the operation of the biomass gasifier combustor of FIG. 1; 
     FIG. 5 is a sectional view of an automatic controller in controlling biomass feeding into the gasification chamber of FIG. 1; 
     FIG. 6 is a sectional view of another, improved embodiment of the biomass gasifier combustor of the present invention; 
     FIG. 7A is a detailed view of the primary combustion chamber and associated peripheral equipment for the biomass gasifier combustor of FIG. 6; 
     FIG. 7B is a detailed view of the secondary combustion chamber and associated peripheral equipment for the biomass gasifier combustor of FIG. 6. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1, a biomass gasifier combustor 2 is shown which includes a biomass feeder 4 integrally connected to a gasification chamber 6. The gasification chamber 6 communicates with the gas combustion chamber 8. The gas combustion chamber 8 further communicates with a venturi gas pump 10. The venturi gas pump 10 creates a negative pressure region within the combustor 2. 
     The biomass feeder 4 includes a gear motor drive screw 12 which rotatably drives a screw feeder 14 disposed within a hopper 16. 
     The screw feeder 14 rotates through a feeder tube 18. As the screw feeder 14 rotates, the blades of the screw feeder 14 travel through the feeder tube 18 and into the gasification chamber 6. 
     Referring to FIG. 2, there is shown a sectional view of the gasification chamber 6, shown in a half-section. The gasification chamber 6 includes an area generally denoted as a fire zone 20. The gasification chamber 6 further includes a plurality of holes 22 utilized as an air entrance for primary air communicating with the fire zone 20. A gas exit tube 24 is disposed on a top portion of the gasification chamber, communicating with the fire zone 20 on one end and with the gas combustion chamber 8 on the other end. 
     Referring to FIG. 1, positioned below the gasification chamber 6 are primary air inlet openings 17. Primary air is drawn through openings 17 in response to the negative pressure region created by the venturi gas pump 10. As combustion gases are created in the gasification chamber 6, these gases exit through the gas exit tube 24 and into the gas combustion chamber 8. The purpose of the gas (or secondary) combustion chamber 8 is to provide an insulated chamber with sufficient oxygen, temperature, residence time and turbulence to completely oxidize the organics to CO 2  and H 2  O. The gas combustion chamber 8 includes a secondary air inlet 26 which permits the flow of air through the air inlet 26 to the gas combustion chamber 8. Covering the secondary air inlet 26, a damper 27 is rotatably engaged thereto to control the amount of secondary air being drawn into the secondary air inlet 26. See FIG. 1A. The damper 27 can be rotated to cover all or a portion of the air inlet opening of the secondary air inlet 26. The ratio of the secondary air to the primary air entering the system is controlled by the damper 27 on the secondary air inlet 26. The amount of secondary air may be increased to a level where no smoke is evident in the exhaust. Typically, between 50-200% excess air is used. 
     The gas combustion chamber 8 also includes insulating firebrick 28 and a castable insulating refractory 30. A sheet metal enclosure 32 encloses the entire gas combustion chamber around the outer portion thereof. 
     Referring to FIG. 4, the biomass gasifier combustor 2 also includes a grate 13. The primary air is drawn through openings 17 in response to the creation of the negative pressure region by the action by the venturi gas pump 10. An ash pan 19 collects the ashes of the hot glowing coals 15. The primary air is drawn through the hot glowing coals 15 as a result of the negative pressure region created by the venturi pump 10. 
     The venturi gas pump 10 includes a pressure blower 34 for providing the forced air necessary to create the negative pressure region within the combustor 2. 
     Referring to FIG. 1B, the pressure blower 34 is shown. The blower 34 includes a fan inlet 35 for allowing air to enter the blower 34. Covering the fan inlet 35 is a damper 37. The damper 37 is rotatably engaged to the fan inlet 35 to cover all or a portion of the fan inlet 35. The damper 37 controls the amount of heat generated within the gasification chamber 6 and the gas combustion chamber 8. 
     The gasifier combustor of the present invention permits controlled burning of the biomass. The rate of burning is controlled by adjusting the damper 37 on the intake of the pressure blower 34. Opening the damper will increase the suction pressure on the gasifier combustor and consequently increase the primary and secondary air rates. The increase in primary air will increase the rate of biomass conversion and consequently the rate of heat generation. Closing the damper will have an opposite effect. 
     In operation, the biomass gasifier combustor 2, appearing in FIG. 1, produces a clean combustion gas which can be used directly for grain drying without the need for a heat exchanger to isolate the combustion gases from the drying air. 
     The biomass, which includes materials such as corn stalks, corn cobs, corn grain, wood chips, or other biomasses is placed in the biomass feeder 4, and in particular, in the hopper 16 so that the biomass may be engaged by the blades of the screw feeder 14. When the biomass is engaged by the blades of the screw feeder 14, and as the screw feeder rotates in response to the action of the gear motor screw drive 12, the biomass is forced into the feeder tube 18 and into the gasification chamber 6. 
     The venturi gas pump 10 creates a negative pressure region in the combustor 2 due to the operation of the pressure blower 34 in providing a continuous flow of forced air through the venturi gas pump 10. The negative pressure can be controlled through the use of damper 37 covering the fan inlet 35 of blower 34. Since the venturi gas pump 10 communicates with the internal gas combustion chamber 8, a negative pressure region is created in such a way as to cause the combustion gases present in the gas combustion chamber 8 to exit through an opening 38, eventually being exhausted to the atmosphere in the form of hot exhaust gases. 
     Concurrently with and in response to the creation of the negative pressure region in the combustor 2 due to the action of the venturi gas pump 10, primary air enters the openings 17, and passes through the holes 22 and into the fire zone 20 of the gasification chamber 6. The biomass is present in the fire zone 20 when the primary air is forced through the holes 22. 
     Referring to FIG. 4, when the primary air is drawn through openings 17, in response to the negative pressure created by the venturi pump 10, and when the primary air passes through the grate 13 and through the hot glowing coals 15, hot combustion gases are created as a result of the burning of the biomass in the gas combustion chamber 6. 
     These hot combustion gases exit through the gas exit tube 24, and into the gas combustion chamber 8 in response to the creation of the negative pressure region within the combustor 2. 
     Secondary air is drawn through the secondary air inlet 26, in response to the creation of the negative pressure in the gas combustion chamber 8. The secondary air combines with the hot combustion gases in the gas combustion chamber 8. The reaction of the hot combustion gases with the secondary air in the gas combustion chamber 8 causes the hot combustion gases present in the gas combustion chamber 8 to undergo a complete combustion, or a secondary combustion, which oxidizes all the combustables present in the hot combustion gas. An intense heat is created in the secondary gas combustion chamber 8, typically, 1700° F. CO 2  and H 2  O are the result. This CO 2   and H 2  O is exhausted to the atmosphere by exiting through the opening 38. The venturi gas pump 10 carries and exhausts the hot exhaust gases (CO 2 , H 2  O, and N 2 ), which are the product of the secondary combustion occurring within the gas combustion chamber 8. These hot exhaust gases are clean enough so that the hot exhaust gases can be used directly for grain drying without the need for a heat exchanger to isolate the hot exhaust gases from the drying air. 
     Note that refractory insulation exists between the gasification chamber 6 and the secondary combustion chamber 8. This reduces the amount of heat which is transferred from the secondary combustion chamber 8 to the gasification chamber 6. 
     Referring to FIG. 3, another embodiment of the present invention is shown which includes an improved modification to the gasification chamber 6 of FIG. 1. The gasification chambr 6 in FIG. 3 includes a manifold section 40 for preventing large pieces of the biomass from being carried into the gas combustion chamber 8. This gasification chamber 6 in FIG. 3 also includes a variable height grate 42. The variable height grate creates a larger volume in the fire zone and is not disrupted by the turning of the screw feeder 14. The ash, which is the product of the primary combustion of the biomass in the gasification chamber 6, falls through the holes 44 in the variable height grate. The screw feeder 14 runs the entire length of the fire zone 20 inside the gasification chamber 6 to spread the biomass over the entire fire zone area. 
     Referring to FIG. 5, an automatic control of biomass feeding into the gasification zone is disclosed. The screw feeder 14 feeds the biomass into the gasification chamber 6 until the biomass blocks and prevents the rotation of the paddle 21. The paddle 21 continuously rotates in response to the action of its controller 23. As the screw feeder feeds the biomass into the gasification chamber 6, the biomass accumulates and eventually interrupts the rotation of the paddle 21. When the paddle rotation is interrupted, a micro switch in the controller 23 is triggered. When the micro switch in the controller 23 is triggered, a controller signal is fed back to the gearmotor drive screw 12 to prevent rotation of the screw feeder 14. Consequently, the rotation of the screw feeder 14 terminates, and the biomass is no longer forced into the gasification chamber 6. As burning proceeds, in the gasification chamber 6, the level of the biomass in the gasification chamber drops. This drop in the level of the biomass in the gasification chamber acts to release the paddle 21. As a result, the rotation of the paddle 21 once again commences. The micro switch in the controller 23 is released, releasing the gearmotor drive screw 12, and commencing rotation of the screw feeder 14. Biomass is then forced back into the gasification chamber 6 for subsequent combustion. 
     Referring to FIG. 6, an alternative embodiment of the present invention is illustrated. The biomass gasifier combustor 46 in FIG. 6 depicts a primary combustion chamber 48 and a secondary combustion chamber 50. The screw feeder rotates, as in the previous embodiment, and forces the biomass into the primary combustion chamber. Primary air is drawn into the primary combustion chamber through the primary air inlet 52. This primary air gasifies the biomass present within the primary combustion chamber. The biomass 56 undergoes a primary combustion in the primary combustion chamber to produce a low BTU gas. Primary combustion gases are released and drawn through a gas exit pipe 58. The gas exit pipe 58 connects with the secondary combustion chamber 50. As the primary combustion gases enter the secondary combustion chamber, a propane torch 61 ignites the primary combustion gas. The primary combustion gases mix with the secondary air being drawn into the secondary air inlet 60 in a mixing zone 80A. When the primary combustion gas is mixed with the secondary air in the secondary combustion chamber 50, a secondary combustion of the primary combustion gases takes place in a combustion zone 80A, thereby producing a clean secondary gas consisting of primarily CO 2 , H 2  O, and N 2 . Sufficient time, temperature and turbulence is caused as a result of the secondary combustion within the secondary combustion chamber 50 in order to completely oxidize the organics present in the primary combustion gas thereby producing the secondary combustion gas in the form of CO 2 , H 2  O and N 2 . Since the secondary air is being drawn into the secondary air inlet 60, the secondary combustion gases exit through the exhaust stack 62 and to the atmosphere. The secondary combustion gas (exhaust) is drawn through the secondary combustion chamber by the negative pressure generated by the educator which performs a function identical to the venturi pump 10 in FIG. 1. 
     A more thorough understanding of the alternative embodiment appearing in FIG. 6 is illustrated in FIGS. 7A and 7B. 
     In FIG. 7A, the primary combustion chamber, and its associated peripheral equipment is shown. The screw feeder 14 forces the biomass into the primary combustion chamber 48. The gearmotor drive screw 12 drives the screw feeder in forcing the biomass into the primary combustion chamber 48. A variable height grate 64 is illustrated wherein the biomass is placed on the variable height grate. The primary air enters the primary air inlet 52 as a result of the operation of the air blower 66. The air blower 66 regulates the primary air flow rate into the primary combustion chamber 48. 
     A controller 68 is shown which maintains a constant level of biomass in the primary combustion chamber 48. This controller 68 is similar to the controller appearing in FIG. 5. The controller 68 maintains the constant level of biomass in the primary combustion chamber by monitoring the rotational conditions of the paddle 70. When the biomass in the gasifier reaches a predetermined level, the paddle 70 is prevented from rotating. A micro switch in the controller housing 72 is activated or triggered as a result of the termination of the rotation of paddle 70. The activation of the micro switch in the controller housing 72 deenergized the gearmotor drive screw 12 such that the screw feeder 14 stops rotating. As a result, the biomass then is no longer forced into the primary combustion chamber 48. 
     The variable height grate 64 controls the temperature of the primary combustion gas exiting the gasifier 48. The temperature of the primary air flowing up through the biomass will drop from approximately 1200° C. at the grate 64 to approximately 300° C. at the screw feeder 14. As a result of this drop in temperature, a steel screw feeder 14 can be used for the feeder screw in forcing the biomass into the primary combustion chamber. As a result, it is no longer necessary to utilize expensive alloys high in chrome and nickle as materials for the screw feeder 14, which will withstand high temperatures. 
     Referring to FIG. 7B, the secondary combustion chamber 50 and its associated peripheral equipment is shown. An igniter 74 is illustrated for the purpose of maintaining a flame 76 in the mixing zone to prevent gas explosions during start up and to add stability to gas burning when high moisture fuels or biomass are the energy source being gasified. The secondary air inlet 60 is shown which includes a fan or air blower 77 which controls the amount of excess secondary air being pumped into the secondary combustion chamber 50. Excess secondary air is needed to complete the combustion of the primary combustion gas in the secondary combustion chamber and is used to keep temperatures in the secondary combustion chamber lower than the temperature limit of the materials used in construction of the secondary combustion chamber. 
     The secondary air inlet 60 further includes a damper 78 which controls the amount of excess air being pumped into the secondary combustion chamber. The incoming primary combustion gas from the primary combustion chamber is mixed with the incoming secondary air being pumped into the secondary air inlet 60 in the mixing zone 80A. The mixing zone 80A provides the necessary turbulence to thoroughly mix the incoming secondary air with the incoming primary combustion gas. Thorough mixing of the incoming secondary air and the incoming primary combustion gas enhances the complete combustion of the combustibles present in the primary combustion gas and provides for a clean exhaust consisting primarily of CO 2 , H 2  O and N 2 . 
     The eductor exhaust pump 82, located at the top portion of the exhaust stack 62, creates a negative pressure region in the secondary combustion chamber and the gasifier. By regulating the rate at which the exhaust is pulled through the system in the eductor 82, the rate of burning and consequently the thermal output is also regulated. 
     A damper 84 regulates the rate at which the exhaust is pulled through the exhaust stack 62 from the system. The damper 84 also regulates the thermal output of the system. 
     In the secondary combustion chamber 50, the secondary combustion gas is produced in response to the mixture of the incoming secondary air and the incoming primary combustion gas, and in response to the resultant combustion of the incoming primary combustion gas. The secondary combustion chamber 50 provides a zone with sufficient time, temperature and turbulence to completely oxidize the combustables present in the incoming primary combustion gas. Consequently, the secondary combustion gas includes primarily CO 2 , H 2  O and N 2 . The refractory insulation 86 in insulating the secondary combustion chamber, maintains the temperature in the secondary combustion chamber at a high level such that chemical reactions will proceed to completion in a short time. No heat is extracted from the secondary combustion gas or exhaust gases until the organics present have been completely oxidized. 
     Some of the typical applications for use of the present invention include grain drying, tobacco curing, disposal of peanut shells, disposal of woodchips and use of a thermal energy for kiln drying, disposal of cotton gin wastes and utilization of heat for drying and disposal of wastes to generate boiler steam. 
     The gasification chamber of the present invention does not require a mechanical seal since the screw feeder tube 18 together with the screw feeder 14 functions as a partial seal at the feed end of the gasifier. In addition, the biomass is horizontally forced into the fire zone by a mechanical force (the action of the screw feeder 14) instead of the conventional gravity feed. As a result, the present invention enables the biomass to be gasified in a uniform fire bed which results in uniform burning. 
     The biomass gasifier combustor 2 of the present invention produces a clean combustion gas which can be used directly for grain drying without the need for a heat exchanger to isolate the combustion gases from the drying air. 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art, are intended to be included within the scope of the following claims.