The EERC operates a 1- to 4-lb/hr continuous fluid-bed reactor (CFBR) bench-scale test unit previously used to pyrolyze/gasify coal, plastics, automotive shredder residue, and wood chips. The unit has also been used in combustion tests and in the processing of lunar soil simulant. The system is rated at 815°C (1500°F) and 170 psi. Various process gases can be used for reactants. To date, ten gases have been used, including CO, CO₂, NO, NO₂, H₂, N₂, air, O₂, HCl, and C₄H₁₀. Two liquids were also used as reactants: water and ethanol. Products have included solids, liquids, and gases, including coal char, ash, basaltic rock, diesel fuel, water, and various proprietary compounds. Various catalysts have also been used to accelerate chemical reactions. Procedures exist to handle hazardous materials such as H₂S, HCN, and HCl.

The reactor consists of a 33-in.-high bed, having a nominal 3-in. i.d. The freeboard section is 17-in. high, with a nominal 4-in. i.d. Any liquid used in the fluidization gas mix is first preheated and vaporized, then mixed with heated fluidization gas and, finally, heated to reaction temperature in a superheater. Some feedstocks may have a very low density so an inert bed material may be used to facilitate adequate fluidization. Solids are fed into the reactor through a dual-auger arrangement. The first auger, horizontally situated, meters out the feed material.

The metered feed drops to the second auger. This second auger, at a 30° angle from horizontal, delivers the feed material quickly into the hot reactor. Because feedstocks may soften, get sticky, or begin to react at low temperatures, it is important to keep the feed at a low temperature until it enters the reactor.

Spent solids are collected from the reactor through a top bed drain leg, lock hopper-type system. Gas, volatiles, and fines leave the top of the reactor and enter a 3-in.-i.d. cyclone where fines are removed. The cyclone is heated with a ceramic filter heater capable of operating at a temperature of 1650°F and 200 psig. Gases leaving the cyclone can pass through a reactor vessel designed for testing of sulfur and chlorine sorbents. A hydrogen separation membrane has also been installed and tested on this unit. The gas stream then enters one of two condensation trains. The two condensation trains are identical, each consisting of a water-cooled indirect heat exchanger, followed by two glycol-cooled indirect heat exchangers. The stream is then depressurized, sampled, and metered.

A fixed-bed filter cartridge may be located prior to one of the condensation trains. The cartridge is made of 3-in. Schedule 10, 304 SS pipe. Two cartridges were available for use: one 4 in. long and one 8 in. long. The cartridges and the lines leading to it are externally heated.

Data collection and process control are achieved with a Genesis^© process control software package. Sixty-two data points are stored on disk every 30 seconds and are updated on the screen every 2 seconds. The data are stored in a Lotus format that can be downloaded or replayed graphically using the Genesis^© software.