Gasification Reactor for the Production of Synthesis Gases from Solid Gasification Materials Using Oxygen-Containing Gasification Agents

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The invention describes a novel gasification reactor and method for producing synthesis gas (syngas) from solid carbon-containing materials—such as coal, biomass, or waste—using oxygen-containing agents at high temperatures and pressures. The reactor integrates several gasification principles (fixed-bed, fluidized-bed, spouted-bed, and entrained-flow gasification) in a vertically structured, connected chamber setup, enabling efficient, nearly complete conversion of carbon to syngas and deponable ash. This design overcomes limitations of traditional fluidized-bed and fixed-bed gasifiers, especially in terms of process temperature, pressure, and management of residues, and can utilize a variety of carbon sources including waste streams.

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• Industrial production of synthesis gas (syngas) for use in chemical synthesis, fuel, or reducing gas applications.
• Conversion of coal, lignite, biomass, municipal solid waste, or industrial waste (including dried sewage sludge, plastics, or shredder residues) into valuable syngas and minimal residues.
• Integration into integrated gasification combined cycle (IGCC) plants for cleaner power generation.
• Hydrogen production for fuel cells or industrial processes via downstream processing of syngas.
• Generation of feedstock for Fischer-Tropsch synthesis, methanol production, or ammonia plants.

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• Enables high syngas yield with near-complete conversion of carbon from various solid feedstocks, including wastes.
• Operates at higher pressures and temperatures, allowing for more flexible process control and improved gas quality (e.g., lower methane and tars in product gas).
• Minimizes problematic residues: produces deponable (landfill-ready) ash with very low carbon content, reducing landfill burden and post-treatment requirements.
• Reduces oxygen demand and lowering process energy requirements compared to traditional gasifiers.
• Allows flexible feedstock input—including high-ash or mixed fuel streams—without extensive pretreatment or feedstock limitations.
• Improves overall efficiency and reduces emissions (e.g., CO2, tars) compared to conventional systems.

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Patent Abstract

The invention relates to a method and to a gasification reactor for generating synthesis gases from solid gasification materials with the aid of oxygen-containing gasification agents at elevated temperatures using fluidized bed gasification (primary gasification), by means of a gasification reactor (v) having a gasification reaction chamber (v1) which comprises, from bottom to top, a post-oxidation fixed bed gasifier (a), a connection to a connecting reaction chamber, and a primary gasification fluidized bed gasifier (b), a) wherein the reaction chamber of the primary gasification fluidized bed gasifier (b) is uninterruptedly connected directly or via a connector pipe (c) to the reaction chamber of the post-oxidation fixed bed gasifier (a) and both form a joint pressure chamber, b) wherein the connection between the primary gasification fluidized bed gasifier (b) and the post-oxidation fixed bed gasifier (a) has a smaller cross-section by comparison with the reaction chambers of the primary gasification fluidised bed gasifier (b) and the post-oxidation fixed bed gasifier (a), c) wherein in the post-oxidation reaction chamber (a2) in a post-oxidation moving bed the reactor principle of fixed bed gasification is applied, in the connecting reaction chamber the reactor principle of entrained flow gasification is predominantly applied, and in the primary gasification reaction chamber (b1) the reactor principle of central fluidized spouted bed gasification, merging into that of the jet fluidized bed gasification, is applied, and in the secondary gasification reaction chamber (b2) the reactor principle of fluidized bed gasification is applied, d) wherein the primary gasification of the introduced solid gasification materials (25) is carried out using primary gasification agents (primary gasification agents (27) in the stationary fluidized bed, circulating fluidized bed, jet fluidized bed or spouted bed, e) and wherein the C-containing primary gasification bottom products (30) extracted from the primary gasification are post-oxidized with post-oxidation gasification agents (36) in the post-oxidation moving bed (a22) in counter-current and are partially gasified (post-oxidation).