Basic tutorial of key process steps of a Concord Blue Reformer©
Six Core Processing Units. A CBR© consists of six smaller processing units (PU), each with a different purpose in the production of hydrogen. The first station “PU1000” prepares the feedstocks for reforming.
The second unit “PU2000” receives the prepared feedstock reforming into clean energy—It’s this stage where the magic happens and is at the heart of our waste to hydrogen technology decomposing and reforming a wide range of feedstocks into hydrogen-rich syngas.
Multi-stage Reforming Process. Our reforming process uses not one but three separate stages. As such, there are three key components for each stage. This includes the Preheater, the Reformer and the Pyrolyzer. These three components are special containers or vessels in which the multi-stage reforming process takes place. These three vessels are arranged sequentially in one line from top to bottom.
The Preheater Vessel located on top of the line contains ceramic beads (“the Heat Carrier”), which are heated to over 1,000 degrees Celsius. The ceramic beads then flow downwards due to gravity through the middle vessel, the Reformer, to the Pyrolyzer Vessel at the bottom of the line. This vessel mixes the heated ceramic beads with the prepared feedstock received from PU1000 and is specially treated to ensure this high heat environment is free of oxygen.
Production of Hydrogen-rich Syngas. As the high temperatures start to breakdown and decompose the feedstocks in this oxygen-starved Pyrolyzer Vessel—a process known as “Thermolysis”, Pyrogas is released. As all gas naturally rises, the Pyrogas starts to flow upwards through our specially designed, double clap values into the middle vessel, the Reformer. Steam is injected to act as a catalyst to facilitate the chemical reactions to assist in reforming the Pyrogas into our core product gas—hydrogen-rich Syngas.
Biochar Used as Heat Source. In addition to the Pyrogas, three additional outputs also exit the Pyrolyzer. These are ceramic beads, ash and biochar. Ceramic beads are separated from the ash and biochar then returned to the Preheater Vessel by elevator to begin the cycle anew. Ash and Biochar, a charcoal-like substance is a byproduct of our Thermolysis process, are sent to “PU3000”, the Oxidizer, where it is oxidized producing the heat source for the Preheater Vessel used to heat the ceramic beads. Leftover ash is moved to storage bins for either use in other products such as fertilizers and construction materials or alternatively landfilled. Therefore, post-startup the Concord Blue Reformer© is self-powered and requires no external energy to reform feedstocks into hydrogen.
From Raw Syngas to Commercial Grade Hydrogen. The Raw Syngas produced in the Reformer Vessel is sent to “PU4000” for cleaning, processing, storage and transport. Technologies used for decades in the chemical, oil and gas industries are leveraged to complete these tasks. A Partial Oxidation Reactor (POX) is used to help clean and enrich the hydrogen content of our Syngas. Water Gas Shift Reactor (WGS) further enriches the product gas by catalytically converting carbon into additional hydrogen. Pressure Swing Adsorption (PSA) is then used to separate out the hydrogen from other gases to produce a high quality 5.0 hydrogen product gas ready for commercial usage in a wide range of applications. This commercial grade hydrogen is then moved to storage tanks and prepared for transport to the customer.
Additional Process Steps. To support the clean production of our hydrogen, “PU5000” cleans flue gas produced from the plant to remove pollutants before being released into the atmosphere. Likewise, “PU10400” treats the facility’s wastewater in accordance with local standards and regulations.