WO2007079133A2

WO2007079133A2 - System and method for recycling waste into energy

Info

Publication number: WO2007079133A2
Application number: PCT/US2006/049407
Authority: WO
Inventors: Phillip L. Cauley; Tracy L. Edwards
Original assignee: Natural Resource Recovery, Inc.
Priority date: 2005-12-29
Filing date: 2006-12-28
Publication date: 2007-07-12
Also published as: WO2007079133B1; WO2007079133A3

Abstract

A system for recycling solid waste into energy or tar sands into hydrocarbons includes a heated enclosure (66), one or more input conveyors (60, 67) move waste materials through the heated enclosure, and mechanically move the waste particles and the residual solids along the flow line. A heated rotary drum (74) is in fluid communication with the flow line, and condenser unit (94, 98) receive vapors from the flow line and the rotary drum and output hydrocarbons. Control valves (80, 82) seal a vacuum downstream from the discharge conveyors, and control valves (34, 46) seal vacuum upstream from the one or more input conveyors. The solvent produced from rubber tire feedstock contains a high percent by weight of both limonene and naphthalene.

Description

SYSTEM AND METHOD FOR RECYCLING WASTE INTO ENERGY

RELATED CASES

This application claims priority from U.S. Serial No. 11/320,936 filed December 29, 2005; U.S. Serial No. 11/512,791 filed August 30, 2006; and U.S. Serial No. 11/585,708 filed October 24, 2006.

FIELD OF THE INVENTION

The present invention relates to equipment and techniques for recycling waste, such as rubber tires, into energy, or for recovering hydrocarbons from tar sands. A heated enclosure and a condenser operate under a selected vacuum maintained by a vacuum pump. Waste material or tar sands are moved through the heated enclosure in a first direction, while hydrocarbon vapors are drawn toward the condenser in an opposing second direction. The present invention also relates to solvents and methods of making a solvent, and more particularly to solvents of the type commonly used to dissolve paraffin waxes, asphaltenes, sludges and similar deposits in oilfield operations, pipelines, and tanks.

BACKGROUND OF THE INVENTION

Various types of devices have been experimentally used for recycling waste into energy. Some devices are particularly intended for disposing of solid waste, such as rubber particles from used tires. One type of experimental device utilized a heated enclosure with an interior chamber and a conveyor for inputting waste particles to the heated enclosure. A condenser received vapors from the heated enclosure and output liquid hydrocarbons and gas hydrocarbons. Vacuum pumps have been used in some experimental units to maintain a selected vacuum within the heated enclosure, such that hydrocarbon vapors are drawn from the heated enclosure to the condenser. The prior art systems known to Applicants do not provide a mechanism for metering the amount of waste material input to the heated enclosure, and contain no effective way of monitoring the vacuum within the system at potential leak sites. Conventional packing was used on the end of auger tube shafts to maintain a vacuum.

Other prior art systems for recycling waste into energy include U.S. Patents 4,624,417; 4,769,149; 4,857,458; 4,882,903; 5,429,645; 5,996,512; 6,938,562; and 6,848,375, as well as Patent Application Publications 2004/0103831 and 2004/0192980.

Various types of devices have also been experimentally and commercially used for recovering hydrocarbons from tar sands. Other devices are particularly intended for disposing of solid waste, such as rubber particles from used tires. One type of experimental device utilized a heated enclosure with an interior chamber and a conveyor for inputting tar sands to the heated enclosure. A condenser received vapors from the heated enclosure and output liquid hydrocarbons and gas hydrocarbons. Vacuum pumps have been used in some experimental units to maintain a selected vacuum within the heated enclosure, such that hydrocarbon vapors are drawn from the heated enclosure to the condenser. The prior art systems known to Applicants contain no effective way of monitoring the vacuum within the system at potential leak sites. Conventional packing was used on the end of auger tube shafts to maintain a vacuum.

Prior art systems for recovering hydrocarbons from tar sands include U.S. Patents 4,624,417; 4,769,149; 4,857,458; 4,882,903; 5,429,645; 5,996,512; 6,938,562; and 6,848,375, as well as Patent Application Publications 2004/0103831 and 2004/0192980.

Paraffin and asphaltene deposition in the oilfiield has long been a serious problem in terms of production cost. Treating paraffin/asphaltene deposits with solvents has proved to be successful. Typical solvents used are xylene, toluene, limonene, condensate, petroleum distillates, and various mixtures of solvents. In most cases, no single solvent will dissolve all paraffin wax deposits due to the wide spectrum of waxes present.

Many current solvents are formulated in combination via blending techniques. Limonene, produced via citrus by-products, xylenes and toluenes are blended in ratios to satisfy various desired characteristics. Since limonene produced as a citrus by-product is relatively expensive, typically a small percent of limonene by weight is used in a solvent.

Publication US2004/0192980 discloses a process for converting organic waste material into useful byproducts. U.S. Patent 6,149,881 discloses a method of increasing the limonene production during pyrolysis of scrap tires. A liquid fraction of the pyrolysis byproduct allegedly has about 51% limonene. The process disclosed in this patent is a batch process which is quite different than a continuous process. An article entitled "Formation of dl-limonene in used tire vacuum pyrolysis oils" discloses pulling off condensate at select locations within the system to enhance the amount of limonene in the liquid. Neither of these systems are well suited for operating on a continuous basis to utilize a high volume of tire material to produce a significant amount of solvent.

SUMMARY OF THE INVENTION

In one embodiment, a system for recycling solid waste into energy utilizes solid waste particles having a cross-sectional size less than 1 inch in length. The system comprises a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber, one or more input conveyors for inputting waste particles to the heated enclosure, and a flow line within the heated enclosure in fluid communication with the one or more input conveyors for receiving waste particles and positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150F", thereby producing hydrocarbon vapors and residual solids. A heated conveyor within the flow line mechanically moves the waste particles and the residual solids along the flow line. A heated rotary drum is provided in fluid communication with the flow line for receiving the waste particles and the residual solids, with the rotary drum having an interior temperature of from 730⁰F to 800⁰F for generating hydrocarbon vapors and carbon black solids. A condenser is in fluid communication with the flow line and the rotary drum for receiving the vapors from the flow line and the rotary drum and outputting liquids including hydrocarbons and gas including hydrocarbons. One or more discharge conveyors are provided for discharging the carbon black solids from the rotary drum. Two or more input control valves are each positioned along the one or more input conveyors for sealing vacuum downstream from the one or more input conveyors, with each input control valve having two or more axially spaced closure gates. Similarly, two or more discharge control valves are positioned along the one or more discharge conveyors for sealing vacuum upstream from the one or more discharge conveyors, with each discharge control valve having two or more axially spaced closure gates. A vacuum pump maintains a selective vacuum of less than 5 inches of water between the two or more input valves and the two or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser.

In another embodiment, the system for recycling waste energy includes a heated enclosure, one or more input conveyors, a flow line within the heated enclosure, a heated conveyor within the flow line, a rotary drum, a condenser, one or more discharge conveyors, one or more input control valves, and one or more discharge control valves. Each of the one or more input conveyors, the one or more discharge conveyors, and the conveyor within the flow line includes a rotary auger. Each rotary auger is rotated by a drive motor and a gearbox, with a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a back-up sealed enclosure downstream from the seal for sealing the auger seal from atmosphere. A vacuum pump maintains a selective vacuum of less than 5 inches of water within the condenser, such that hydrocarbon vapors are drawn from the flow line into the condenser.

In yet another embodiment, the system includes a heated enclosure, one or more input conveyors, a heated conveyor within the flow line, a condenser, one or more discharge conveyors, one or more input control valves, one or more discharge control valves, a vacuum pump, and a plurality of leak detector sensors for detecting a leak within the vacuum system between the one or more input control valves and the one or more discharge control valves. A flow meter is provided for measuring a flow rate of hydrocarbon vapors to the condenser, and each of the one or more input conveyors, the one or more discharge conveyors, and the heated conveyor within the flow line includes a rotary auger. A processor is provided for controlling the rotational rate of each rotary auger in response to the flow meter and the plurality of leak detector sensors.

In another embodiment, a system for recovering hydrocarbons from tar sands comprises a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber, one or more input conveyors for inputting tar sands to the heated enclosure, and a flow line within the heated enclosure in fluid communication with the one or more input conveyors for receiving tar sands and positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150F°, thereby producing hydrocarbon vapors and residual solids. A heated conveyor within the flow line mechanically moves the tar sands and the residual solids along the flow line. A heated rotary drum is provided in fluid communication with the flow line for receiving the tar sands and the residual solids, with the rotary drum having an interior temperature of from 73O⁰F to 800⁰F for generating hydrocarbon vapors and stripped sand. A condenser is in fluid communication with the flow line and the rotary drum for receiving the vapors from the flow line and the rotary drum and outputting liquids including hydrocarbons and gas including hydrocarbons. One or more discharge conveyors are provided for discharging the stripped sand from the rotary drum. Two or more input control valves are each positioned along the one or more input conveyors for sealing vacuum downstream from the one or more input conveyors, with each input control valve having two or more axially spaced closure gates. Similarly, two or more discharge control valves are positioned along the one or more discharge conveyors for sealing vacuum upstream from the one or more discharge conveyors, with each discharge control valve having two or more axially spaced closure gates. A vacuum pump maintains a selective vacuum of less than 5 inches of water between the two or more input valves and the two or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser.

In yet another embodiment, the system for recovering hydrocarbons from tar sands includes a heated enclosure, one or more input conveyors, a flow line within the heated enclosure, a heated conveyor within the flow line, a rotary drum, a condenser, one or more discharge conveyors, one or more input control valves, and one or more discharge control valves. Each of the one or more input conveyors, the one or more discharge conveyors, and the conveyor within the flow line includes a rotary auger. Each rotary auger is rotated by a drive motor and a gearbox, with a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a back-up sealed enclosure downstream from the seal for sealing the auger seal from atmosphere. A vacuum pump maintains a selective vacuum of less than 5 inches of water within the condenser, such that hydrocarbon vapors are drawn from the flow line into the condenser. A plurality of leak detector sensors detect a leak within the vacuum system between the one or more input control valves and the one or more discharge control valves. A flow meter is provided for measuring a flow rate of hydrocarbon vapors to the condenser. A processor is provided for controlling the rotational rate of each rotary auger in response to the flow meter and the plurality of leak detector sensors.

In yet another embodiment, the solvent comprises by weight a majority of C10 through C25 hydrocarbon materials (hydrocarbons), including at least 6% by weight limonene and 6% by weight naphthalenes. The solvent may also include at least 3% by weight C7 hydrocarbon chains, at least 6% by weight C8 hydrocarbons, and at least 12% by weight C9 hydrocarbons.

According to the method of the invention, the solvent is formed by a process which utilizes rubber tires as the feed stock. More specifically, the method includes providing an enclosure having an interior chamber and plurality of internal baffles, and inputting the tire particles to the heated enclosure and moving these particles along a flow path positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150⁰F, thereby producing hydrocarbon vapors and residual solids. The method also includes rotating a drum in fluid communication with the flow line for receiving the tire particles and residual solids from the flow line, with the drum having an internal temperature of from 730⁰F to 800⁰F for generating hydrocarbon vapors and carbon black solids. Vapors are condensed from the flow line and the drum. Liquids including hydrocarbons are output from a condenser, while gas including hydrocarbons are also output from the condenser. A selected vacuum of at least 5 inches of water is maintained, such that hydrocarbon vapors are drawn from the flow line into the condenser. The desired solvent is extracted from the liquids output from the condenser. These and further features and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a side view belt of a conveyor and vertical auger for initially feeding waste material into a heated enclosure.

Figure 2 is a side view of additional conveyors, a portion of a heated enclosure and a condensing column.

Figure 3 is a side view of another portion of the condensing column and heated enclosure, as well as a discharge conveyor and a flare stack.

Figure 4 is a top view of the equipment shown in Figure 2.

Figure 5 is a top view of the equipment shown in Figure 3.

Figure 6 is a schematic representation of a suitable system according to the present invention.

Figure 7 illustrates a powered end and a driven end of an auger shaft, an auger seal dynamically sealing with an auger shaft, and an enclosure for fluidly isolating the auger seal from atmosphere.

Figure 8 illustrates in greater detail a roto-disk valve assembly, and Figure 9 illustrates a double dump valve assembly.

Figure 10 is an alternate embodiment of some of the equipment shown in Figure 2.

Figure 11 is a block diagram of a suitable system for producing the solvent.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Rubber Tire Feedstock

A system according to the present invention is well suited for converting various types of waste materials into energy, and for the purposes of explanation as discussed below is used to convert waste rubber particles of a type formed from worn tires into energy. Those skilled in the art will appreciate, however, that the system and method disclosed herein may be used to convert various other types of waste materials into energy as discussed below.

Figure 1 illustrates a belt conveyor 12 which may be used to convey rubber particles from an initial dump hopper 14 into a staging hopper 16. The conveyor 12 may be supported on a suitable frame structure 18, with a motor and gearbox assembly 20 used to power the conveyor 12. A magnetic drum 22 is provided adjacent a discharge end of the conveyor 12 for minimizing the amount of metal input to the hopper 16.

The hopper 16 may be provided with a support structure 24 which includes a plurality of load cells 26 for measuring the weight of the material in the hopper. Since the conveyor 12 may be powered only intermittently as need to maintain material in hopper 16, periodic measurements from the load cells 26 may thus be used to calculate the amount of material being input to the system over time. Material from the hopper 16 is input to the vertical auger conveyor 30, which is powered by a drive unit 28. Waste material is discharged from the upper end of the auger conveyor 30 to discharge pipe 32, which flows into the double-dump valve 34 (see Figure 2) which includes a pair of axially spaced gates 36, 38. One of the gates 36, 38 is normally closed when the other gate is open, thereby providing a seal for the vacuum downstream from the valve 34.

Waste material passing through the valve 34 is input to auger conveyor 40, which houses a conventional screw-type auger 42 rotated by drive motor and gearbox assembly 44. Material discharged from conveyor 40 passes through a roto disc valve 46, which also has a pair of axially spaced gates 48, 50. Material passing through the valve 46 is input to another conveyor 52 having an internal auger 54 powered by a motor and gearbox assembly 56. A suitable double dump valve 34 is the Model H-0822-11 valve manufactured by Plattco, and a suitable roto disc valve is the Model RD-5402-1 valve manufactured by Roto-Disc. Figures 8 and 9 show the roto disk valve 46 in greater detail, with the pair of gates 48, 50. Figure 9 illustrates the double dump valve 36 with the pair of gates 36, 38.

The Roto-Disc valve 46 is in series with the double-dump valve 34, which in turn is in series with the substantially vertical auger conveyor 30. This system provides three separate mechanisms for maintaining a vacuum within the system while allowing waste material to pass into the system, with the valves 46 and 34 each including a pair of axially spaced gates. Any gas which bypasses the valves 46 and 34 is thus substantially plugged within the system by the waste material within the vertical auger 30. The plugging effect of the materials in the vertical auger conveyor 30 along with the valves 34, 46 thus provide at least a triple redundancy to maintain vacuum within the system.

Referring still to Figure 2, waste material is discharged from the auger conveyor 52 into the conduit 58, where it drops by gravity into the horizontal conveyor 60 with an auger 62 powered by motor and gearbox assembly 63 (see Figure 3). Conveyor 60 and the auger 62 in turn are received within the interior chamber 64 of the heated enclosure 66, which includes a plurality of baffles 68 for maintaining a desired temperature profile within the heated enclosure. Material passing through the conveyor 60 is thus heated to produce hydrocarbon vapors and residual solids. More particularly, material passes through the conveyor 60 to the left as shown in Figure 2, and then drops to a similar conveyor 67 which includes an auger 65 for moving material to the right, as shown in Figure 2. If desired, another conveyor may be in parallel with conveyor 67 to increase the surface area of exposed material. Conveyor auger 65 may be powered by motor and gearbox assembly 63. Conveyors 60 and 67 form a flow line positioned with respect to the plurality of baffles to provide a temperature gradient along the low line of at least 150F°, while the augers mechanically move the waste material and residual solids through the flow line. Material discharged from the conveyor 67 drops by conduit 68 to yet another horizontal conveyor 70, which similarly has an auger 72 powered by motor and a similar gearbox assembly 63. Conveyor 70 reintroduces the material into the^' heated enclosure 66, and more particularly into rotary drum 74 which may be rotated by drive unit 75. The heated rotary drum 74 is thus in fluid communication with the flow line formed by the conveyors 60 and 67, and receives waste particles and residual solids from the flow line. Accordingly to the present invention, the interior temperature within the rotary drum 74 is maintained at from 730⁰F to 800⁰F for generating hydrocarbon vapors and carbon black solids. As shown in Figure 3, material discharged from the rotary drum 74 is input to the conveyor 76, which also includes an auger 78 powered by motor and gearbox assembly 79. Carbon black solids discharged from the conveyor 76 are passed downward through a roto disc valve 82, then upward through a vertical conveyor 84, where the carbon black within the conveyor 84 acts as a plug to assist in maintaining vacuum in the system. The auger 83 in the vertical conveyor 84 is powered by motor and gearbox assembly 85. Material discharged from the conveyor 84 passes downward through a double pump valve 80, and is finally discharged through conveyor 88 with auger 87 powered by a similar drive. A nitrogen supply system 89 supplies nitrogen to the carbon black solids discharged from the conveyor 88. Dry cooled nitrogen may thus be fed through the carbon exit assembly on the conveyor 88 to provide an inert atmosphere for neutralizing the volatility of the hot hydrocarbons and to cool these solids. A bag type dust collecting filtration system (not shown) may be used to reduce dust from the discharge carbon block solids. Any remaining gases may exit the conveyor 88 through the vertical stack 91, and be burned in flare chamber 90, although flaring may only be necessary in the event of an emergency.

Returning again to Figure 2, hydrocarbon vapors from the conveyors 62 and 67 may pass by conduit 92 into the condensing column 94, which may then pass uncondensed vapors via line 96 to condenser 98. Accordingly to the present invention, the condensing column 94 may be provided upstream from the condenser 98 for initially separating liquids and gases, and hydrocarbon vapors are input into a lower portion of the condensing column. Hydrocarbon vapors thus travel by vacuum in an opposite direction of the feed material through the conveyor 62. The condensing column 94 may utilize stainless steel pall rings to provide the surface area desired to start the first step of condensing.

Hydrocarbon vapors leaving the condenser 98 may be passed to a demister 106, and then to a vacuum liquid ring or gas scrubber 108. A majority of the hydrocarbon vapors are liquefied in condensing column 94, and further vapors are condensed in condenser 98. The demister 106 and the liquid ring 108 remove substantially the remaining portion of the gas vapors, so that any gas discharged from the gas chiller 109 may serve as a feedstock to the burner 104, or may be passed to a pipeline or storage tank. The gas chiller may be provided with a vacuum pump for dropping remaining heavy hydrocarbons to a liquid form. The remaining gas may be directed to the burner of the heated enclosure. A water/oil separator 102 may be provided for separating liquid carbons from water, with most of the water occurring as a result of the steam input to the heated enclosure. The reflux pump 110 may be provided for inputting a relatively low volume of oit to the top of the column 98 through the flux line 112, with this oil acting as a quenching material to enhance the condensing process. A blower 114 (see Figure 3) may be provided for inputting air to the burner 104 within the heated enclosure 66, and may be passed through the air to air heat exchanger 115 to warm the air before entering the heat enclosure, thereby increasing efficiency.

A boiler 116 (see Figure 4) preferably powered by the hydrocarbons produced by the system may receive treated water and produce a relatively low volume, high temperature steam, which is preferably at a temperature greater than 800⁰F into the rotary drum 74 for stripping remaining hydrocarbons from the material. Figure 4 is a top view of the equipment shown in Figure 2, and more particularly illustrates a heated flowline 117 from the enclosure 66 to a boiler 116, which produces steam which is input to the enclosure. Low pressure high temperature steam input to the heated enclosure.

A refrigeration unit 124 as shown in Figure 3 may be provided for gas and water cooling. A separate water chiller 126 (see Figure 5) may also be provided, and a gas accumulator tank 128 is also shown in Figure 4.

Temperature and/or vacuum sensors 130 may be provided at the various locations in the system to quickly identify leaks, and to quickly locate a leak, and to provide a temperature of the material at this stage of the process. Signals from each of the signals may thus be input to a master control station 132 shown in Figures 2 and 4, which includes one or more conventional computers. One or more digital flow meters 134 and digital pressure switches 136 may be provided for measuring the flow rate of gas to the condenser column or the flow rate of gas to various other pieces of the system, with the pressure switches providing an accurate reading of the pressure at selected locations within the system. The system may include digital flow meters and digital pressure gauges that will communicate with the computer.

The conveyors within the heated enclosure may thus be operated with a level of one third material or less within each auger conveyor to increase the surface area of exposed material. The material may be retained within the enclosure 66 during a retention time of less than 15 minutes, and typically more than 8 minutes. The retention time of from 10 to 12 minutes will be appropriate for many materials.

Figure 6 illustrates many of the primary components of the system in schematic form. Material from the conveyor 12 thus passes upward through the vertical auger 30, through the double-dump valve 34, and through the conveyor 62 into the heated enclosure 66. Carbon black discharged from the enclosure is passed through the vertical auger 84 and may then be packaged.

Hydrocarbons discharged from the heated enclosure 66 pass to the condensing column 94, with gas continuing to the water tube condenser 98, and are then input by a cyclone pump to a demister, and finally to a gas chiller. A liquid ring with a vacuum pump may be spaced fluidly between the fragmentator and the gas chiller. Other than the gas released through an emergency flare, gas from the chiller may be input to a gas accumulator, and to a gas electrical generator. Some of the gas may be returned to the heated enclosure, and other gas may pass to the boiler. Produced hydrocarbons may thus be recovered in holding tank 102, and may be passed to a burner 104 within the heated enclosure 66 to generate heat. The system may thus primarily run on its own produced gas once the reaction starts to occur.

A water condenser is provided with internal coils preferably fabricated from stainless steel. Water may be treated with a water softening system and will be continuously circulated through a water chiller while flowing through the condenser to maintain a constant temperature and reduce the rate of corrosion. The water softener may be used to input water to the liquid isolation chamber, and also the waste heat boiler. Steam from the boiler may be input to the heated enclosure 66, as discussed above. The oil and water separator 102 may receive oil and water from various locations in the system, but primarily from the condensing column 94.

Each of the conveyors with augers therein may include a machine shaft seal, a shaft housing, a direct drive motor, and a gearbox. Figure 7 depicts an auger shaft with a shaft seal 140 and an enclosure 142 which fluidly isolates the shaft seal from the environment for redundancy. The motor may be a hydraulic, pneumatic or electrically powered motor 144, and may drive a gearbox 146 or another transmission device. The auger motor may include a programmable drive which monitors amperage and rpms of the auger, and may thus be tied to a master computer.

The present invention may sufficiently convert various materials, including but not limited to waste materials, and to energy and non-energy byproducts. In addition to rubber particles from tires as disclosed herein, the invention may be used to convert solid waste, sewage sludge, animal waste, trash and refuge, solid industrial waste, coal or other solid fossil fuels into energy. Waste plastics and waste fat from animals, fryer oils and other food processing wastes may also be converted into useful products according to the present invention. The system avoids many of the problems of prior attempts to efficiently convert waste material into energy by avoiding the requirement of a fluidized bed or other special reactions. Solid material need not be specially treated or prepared into a slurry before being heated to release hydrocarbons. The system of the present invention is relatively compact and can be placed in a small location, with the emissions from the system being relatively clean and non-hazardous. By providing a system which is essentially operating under a vacuum, the likelihood of inadvertent release of gases is minimized, while the vacuum pump draws the hydrocarbon vapors, preferably in a counter flow direction from the particles moving through the system, toward the condenser units.

A particular feature of the invention is that, in addition to or in some cases separate from producing energy, the equipment of the present invention may be used to produce valuable byproducts from waste materials including cleaners, solvents, and other valuable chemicals used in various industrial, oilfield, and pipeline operations. Another significant advantage of the invention is that the system does not require specialized equipment, but rather utilizes components which are generally readily available from a variety of sources. Tar Sands Feedstock

A system according to the present invention is well suited for recovering hydrocarbons from tar sands. Those skilled in the art will appreciate, however, that the system and method disclosed herein may be used to convert various other types of materials, including waste materials, into energy. Tar sands may be feedstock to the equipment discussed above to replace the rubber tire feedstock.

At a volume of about 2,000 pounds of tar sands per hour, the desired reaction time of the tar sands in the auger is about 15 minutes. When tar sands or oil shale is the feedstock, the interior temperature within the rotary drum 74 is maintained at from 760⁰F to 840⁰F, and preferably from 780°F to 820⁰F, for generating hydrocarbon vapors and stripped sand or shale. This reactor temperature is the result of input steam and heat generated by burner 104. A boiler 116 (see Figure 4) preferably powered by the hydrocarbons produced by the system may receive treated water and produce a relatively low volume, high temperature steam, which is preferably at a temperature at from 300⁰F to 500⁰F into the rotary drum 74 for stripping remaining hydrocarbons from the material. For processing 2,000 pounds of tar sands per hour, from 0.2 to 0.4 pounds of steam per minute may be input to the reactor at a pressure of from 3 to 5 PSI. Figure 4 is a top view of the equipment shown in Figure 2, and more particularly illustrates a heated flowline 117 from the enclosure 66 to a boiler 116, which produces steam which is input to the enclosure. Relatively low pressure, high temperature steam is thus input to the heated enclosure.

The introduction of high temperature steam to the tar sands results in a steam reformation or "gasification" of hydrocarbons from the tar sands. Most importantly, however, the steam reformation preferably occurs for tar sands in a reactor operating in the range of from 780-820⁰F, which is substantially lower than temperatures conventionally used for steam reformation operations. Also, the present invention does not rely upon a nickel catalyst to perform the steam reformation, and instead uses T1 high carbon steel material for a substantial portion if not all the material contacting the tar sands while within the heated enclosure. The reaction chamber housing and the auger flights are thus fabricated from the T1 material. The T1 material enhances ion transfer, which allows the steam reformation to efficiently occur at a desired lower temperature. During long term operation of the reactor, the reaction chamber housing changes its metallic makeup into a magnetic ferrite as a result of the ion transfer. The retention time of from 10 to 12 minutes will be appropriate for many materials, including oil shale and tar sands. Stripped sand or shale discharged from the enclosure is passed through the vertical auger 84 and may then be shipped to a land fill.

Figure 10 illustrates an alternate embodiment of a portion of the equipment discussed above. A pack column 94 and oil-water separator 102, and a vacuum liquid ring or gas scrubber 108 are provided. Another mister 152 may be provided in the pack column 94, and may be in communication with the liquid ring 108 to provide for a vapor exit. Tar sands or other input material may then be input to the mister 152.

Figure 10 also illustrates a velocity reduction box 154 which is provided upstream of the pack column 94. The velocity reduction box provides a large cross section flow chamber so that the velocity of the vapors entering the pack column are reduced, thereby allowing particles to drop out by gravity and reducing the likelihood of plugging the pack column.

The present invention may sufficiently convert various materials, including but not limited to tar sands, energy and non-energy byproducts. In addition to tar sands as disclosed herein, the invention may be used to convert solid waste, sewage sludge, animal waste, trash and refuge, solid industrial waste, coal or other solid fossil fuels into energy. Waste plastics and waste fat from animals, fryer oils and other food processing wastes may also be converted into useful products according to the present invention. The system avoids many of the probtems of prior attempts to efficiently convert tar sands into energy by avoiding the requirement of a fluidized bed or other special reactions. The stripped sand is much cleaner than sand produced in prior art systems, and little or no further effort need be expended prior to disposal of the stripped sand according to this invention. The system of the present invention is relatively compact and may be placed in a small location, with the emissions from the system being relatively clean and non- hazardous. By providing a system which is essentially operating under a vacuum, the likelihood of inadvertent release of gases is minimized, while the vacuum pump draws the hydrocarbon vapors, preferably in a counter flow direction from the particles moving through the system, toward the condenser units.

The term "tar sands" as used herein refers to subterranean soil, e.g., sand or shale, which contains heavy oil or other hydrocarbons therein. Tar sands can be mined and the useful hydrocarbon products extracted, and then the stripped sands returned for landfill. Most importantly, extracted hydrocarbons may be substantially reformed, so that the resultant product is substantially thinner and has a significantly higher viscosity than the oil contained in the sands. This allows the product to be more easily pumped or otherwise transported, and requires less chemical operations to crack the hydrocarbons to obtain commercially useful products. Also, the stripped sands are free, or substantially free, of hydrocarbons once passed through the equipment, so that the environmental impact of returning the stripped sands to landfills is more positive.

A particular feature of the invention is that, in addition to or in some cases separate from producing oil, the equipment of the present invention may be used to produce valuable hydrocarbon byproducts from tar sands including cleaners, solvents, and other valuable chemicals used in various industrial, oilfield, and pipeline operations. Another significant advantage of the invention is that the system does not require specialized equipment, but rather utilizes components which are generally readily available from a variety of sources. Solvent

A process as described above produces a multi-component solvent from tire scrap rubber. The liquid product or solvent is produced along with carbon black solids and gas. The gas may be used in the process to heat the reactor and/or may be sold. The solvent is a complex component mixture compared to competitive products produced from petroleum. The process thermatically and metallurgically reforms the constituents and binders of rubber and reforms them into the solvent. The high percentage of limonene and naphthalene in the solvent is the result of reformation of the rubber constituents.

The following detailed analysis of the solvent shows over 290 components with significant levels of limonene, napthalenes, toluene and xylenes. The solvent may be further refined to produce a wide range of valuable commodity products. The multi-component and heavy aromatic composition of the product is unique. The solvent has a vast potential for treating paraffin and asphaltene problems in oilfield production, pipeline and tank bottom stimulation applications.

Compound MW CAS No. % Range

Propylene 42.1 115-07-1 <1

Propane 44.1 74-98-6 <1

Isobutyleπe 56.1 115-11-7 <1

Butane 58.1 106-97-8 <1

Methyl Mercaptan 48.2 74-93-1 <1

3-Methyl-l-butene 70.1 563-45-1 <1

Isopentane 72.1 78-78-4 <1

2-Methyl-l-butene 70.1 563-46-2 <1

Isoprene 68.1 78-79-5 <1 t-2-Pentene 70.1 627-20-3 <1 Cyclopentadiene 66.1 542-92-7 <1

C5H8 68.1 18631-83-9 <1

C6H12 84.1 558-37-2 <1

3-Methylpentane 86.1 96-14-0 <1

1-Hexene 84.1 592-41-6 <1

C6H12 84.1 760-21-4 <1 t-4-Methyt-2-pentene 84.1 674-76-0 < 1 t-3-Methyl-2-pentene 84.1 616-12-6 <1

3-Metylcyclopentene 82.1 1120-62-3 < 1 c-3-Methyl-2-pentene 84.1 922-62-3 <1

Methylcyclopentane 84.1 96-37-7 <1 t-2-Methyl-l,3-pentadiene 82.1 926-54-5 <1

C6H8 80.1 592-57-4 <1

1,3-Cyclohexadien e 80.1 592-48-3 <1

C6H10 82.1 592-48-3 <1

Benzene 78.1 71-43-2 <1

1,4-Cyclohexadiεne 80.1 628-41-1 <1

3-Methylhexane 100.1 589-34-4 <1

Cyclohexene 82.1 110-83-8 <1 t-l,2-Dimethylcyclopentane 98.1 822-50-4 <1

1-Heptene 100.1 142-82-5 <1

C7H12 96.1 999-78-0 <1 c-3-Methyl-2-hexene 98.1 10574-36-4 <1

1,5-Dimethylcyclopentene 96.1 16491-15-9 <1

C7H14 98.1 10574-37-5 <1

5,5-Dimethyl-l,3-cycIopentadiene 94.1 4125-18-2 <1

Methylcyclohexene 96.1 591-49-1 < 1

Ethylcyclopen tane 98.1 1640-89-7 <1

Methyl Isobutyl Ketone (MIBK) 100.1 108-10-1 <1

Methyl-t-l,3,5-hexatriene 94.1 24587-26-6 <1

C7H10 94.1 4313-57-9 <1

1^3-Dimethylcyclopentadiene 94.1 4784-86-5 <1

1,5-Dimethylcyclopentene 96.1 16491-15-9 < 1

3-EthyIcyclopentene 96.1 694-35-9 <1

Methyl-t-l,3,5-hexatriene 94.1 19264-50-7 <1

2-Metliylheptane 114.1 592-27-8 <1

Toluene 92.1 108-88-3 2-6

Methylcyclohexene 96.1 591-49-1 <1

1,3-Cycloheptadiene 94.1 4054-38-0 <1

4-Methyl-l,4-Hexadiene 96.1 1116-90-1 <1

C8H16 112.1 2207-04-7 <1

C7H12O 112.1 4541-32-6 <1

1-Octene 112.1 111-66-0 < 1

Octane 114.1 111-65-9 <1

Vinylcyclohexane 110.1 695-12-5 <1

C8H12 108.1 2809-84-9 <1

C8H16 112.1 2207-03-6 <1

4-EthyIcyclohexen e 110.1 3742-42-5 <1

C8H12 108.1 4430-91-5 <1 c-2-Octene 112.1 7642-04-8 <1

C8H14 110.1 29253-64-3 <1

Isopropylcyclopentene 110.1 1462-07-3 <1 C8H14 110.1 1000142-17-5 <1

Dimethylcyclohexene 110.1 56021-63-7 <1

Dimethylcyclohexene 110.1 70688-47-0 <1

C9H14 122.1 37439-53-5 <1

Trimethylcyclohexane 126.1 3073-66-3 <1

C8H12 108.1 4430-91-5 <1

C9H14 122.1 4249-12-1 <1

C8H12 108.1 83615-96-7 <1

Tetrahydromethylthiophene 102.2 1795-09-1 <1

C9H16 124.1 37050-05-8 <1

C8H12 108.1 818-48-4 <1

C9H16 124.1 61142-34-5 <1

Ethylbenzenc 106.1 100-41-4 1-4

C8H12 108.1 1000192-48-8 <1

C9H16 124.1 20184-89-8 <1 m-Xylene 106.1 108-38-3 1-4 p-Xylene 106.1 106-42-3 <1

C8H12 108.1 1000150-54-4 <1

Dimethy Ith iophen e 112.2 638-00-6 <1

C8H12O 124.1 1767-84-6 <1

Dimethylthiophene 112.2 632-16-6 <1

Styrene 104.1 100-42-5 <1 o-Xylene 106.1 95-47-6 1-2

C9H18 126.1 6434-78-2 <1

C8H10O 122.1 2220-40-8 <1

C8H12 108.1 72347-62-7 <1

C9H14 122.1 1000196-61-0 <1

C9H14 122.1 1000162-25-6 <1

Pentamethylcyclopentadiene 136.1 4045-44-7 <1

C9H16 124.1 4634-87-1 <1

Isopropylbenzene (Cumene) 120.1 98-82-8 <1

C10H18 138.1 3983-03-7 <1

C10H16 136.1 1000163-57-0 <1

Propylcyclohexeπe 124.1 2539-75-5 <1

C10H16 136.1 99-85-4 <1

C10H18 138.1 7712-74-5 <1

C8H12O 124.1 1000196-10-0 <I

C10H18 138.1 5256-65-5 <1

C10H16 136.1 42123-66-0 <1

2-Propenylbenzene 118.1 300-57-2 <1

C9H14O 138.1 100144-30-7 <1

C10H18 138.1 20536-41-8 <1

C10H16 136.1 61141-57-9 <1

Propylbenzene 120.1 103-65-1 <1

1-Decene 140.1 872-05-9 <1

C10H16 136.1 5989-54-8 <1

Ethyltoluene isomer 120.1 622-96-8 1-2

Ethyltoluene isomer 120.1 620-14-4 1-2

1,3,5-Trimethylbenzene 120.1 108-67-8 <1

C10H16 136.1 74663-83-5 <1

Aniline 93.1 62-53-3 <1

Ethyltoluene isomer 120.1 611-14-3 <1 Alpha-Methylstyrene 118.1 98-83-9 < ]

C10H16 136.1 7216-56-0 < 1

C10H18 138.1 33501-88-1 < 1

C10H18 138.1 31222-43-2 < 1

1,2,4-Trimethylbenzene 120.1 95-63-6 1-3

C10H18 138.1 74630-29-8 1 -2

C10H16 136.1 18172-67-3 < 1

C9H14 122.1 37439-53-5 < 1

ClOHlS 138.1 61228-10-2 < 1

C10H16 136.1 33622-26-3 < 1

2-Caren (C10H16) 136.1 1000149-94-6 < 1

1,2,3-Trimethylbenzene 120.1 526-73-8 1-2

Isopropyltoluene isomer 134.1 527-84-4 1-4

Limoπene 136.1 5989-27-5 10-25

Indane 118.1 496-11-7 < 1

Beta-Pinene 136.1 127-91-3 < 1

Indene 116.1 95-13-6 < 1

Diethylbenzene isomer 134.1 141-93-5 < 1

Propyltoluene isomer 134.1 1074-43-7 < 1

2-Methylphenol 108.1 95-48-7 < 1

Diethylbenzene isomer 134.1 135-01-3 1-2 l-Methylpropylbenzene 134.1 135-98-8 < 1

4-Methylphenol 108.1 106-44-5 < 1

Dimethylethylbenzene 134.1 934-80-5 < 1

Isopropyltoluene isomer 134.1 99-87-6 < 1

2-Propenyltoluene 132.1 1587-04-8 < 1

Dimethylethylbenzene 134.1 933-98-2 < 1

4-Carene (C10H16) 136.1 29050-33-7 < 1

Isopropyltoluene isomer .134.1 535-77-3 < 1

Isopropenyltoluene isomer 132.1 1195-32-0 1-2

Dimethylstyrene isomer 132.1 2039-89-6 < 1

Isobutyltoluene isomer 148.1 5161-04-6 < 1 sec-butyltoluene isomer 148.1 1595-16-0 < 1

1,2,4,5-Tetramethylbenzene 134.1 95-93-2 < 1

1,2,3,4-Tetramethylbenzene 134.1 488-23-3 < 1

2-Propenyltoluene 132.1 3333-13-9 < 1

C11H14 146.1 97664-18-1 < 1

Dimethylstyrene isomer 132.1 2234-20-0 <

C11H16 148.1 4706-89-2 < 1

Methylindane isomer 132.1 824-22-6 <

Methylindane isomer 132.1 767-58-8 < "

Methylindene isomer 130.1 2177-47-1

Methylindene isomer 130.1 767-59-9 < '

Methylindene isomer 130.1 767-60-2 <

ClOHlO 130.1 2288-18-8 < 1

Methylbenzyl Alcohol isomer 122.1 89-95-2 < 1

ClOHlO 130.1 15677-15-3 < 1

C11H16 148.1 2049-95-8 < 1

C11H14 146.1 56253-64-6 < 1

C11H14 146.1 6682-71-9 < 1

Naphthalene 128.1 91-20-3 < 1

C11H14 146.1 17059-48-2 < I 1-Dodecene 168.2 112-41-4 <1

Dimethylindane isomer 146.1 17057-82-8 <1

C6-Alkylbenzene 162.1 55669-88-0 <1

C6-Alkylthiophene 168.3 54411-06-2 <1

C6-Alkylbenzene 162.1 102-25-0 <1

C11H14 146.1 53172-84-2 <1

Benzothiazole 135.1 95-16-9 1-2

Methyltetralin 146.1 2809-64-5 <1

Trimethyliπdane isomer 160.1 40650-41-7 <1%

Trimethylindane isomer 160.1 2613-76-5 <1

Ethyliπdene 144.1 17059-50-6 <1

Dimethylindane isomer 146.1 6682-71-9 <1

Dimethylindene isomer 144.1 2177-48-2 <1

Dimethylindeπe isomer 144.1 4773-82-4 <1

Dimethylindene isomer 144.1 18636-55-0 <1

Methyldihydroπaphthalene 144.1 2717-44-4 <1

C12H14 158,1 1605-18-1 <1

1-Tridecene 182.2 2437-56-1 <1

Dimethyltetralin isomer 160.1 25419-33-4 <1

Tridecane 184.2 629-50-5 <1

Methylbenzothiazole 149.1 120-75-2 <1

2-MethylnaphthaIene 142.1 91-57-6 .<1

Trimcthylindene isomer 158.1 4773-83-5 <1

Trimethylindene isomer 158.1 2177-45-9 <1

C13H20 176.2 1595-03-5 <1

1-Methylnaphthalene 142.1 90-12-0 <1

C12H16 160.1 14679-13-1 <1

Dimethyltetralin isomer 160.1 4175-54-6 <1

Trimethylindane isomer 160.1 54340-88-4 <1

Dimethyltetralin isomer 160.1 <1

Trimethylindene isomer 158.1 <1

Biphenyl 154.1 92-52-4 <1

1-Tetradecene 196.2 1120-36-1 <1

Dimethylbenzothiophene 162.3 16587-48-7 <1

Tetradecane 198.2 629-59-4 <1

Ethylnaphthalene 156.1 1127-76-0 <1

Dimethylnaphthalene 156.1 571-61-9 <1

Dimethylnaphthalene 156.1 582-16-1 <1

Dimethylnaphthalene 156.1 575-41-7 <1

Dimethylnaphthalene 156.1 573-98-8 1-2

C9-Alkylthiophene 210.3 5206-09-7 <1

Dimethylquinoline 157.1 877-43-0 <1

C15H24 204.2 470-40-6 <1

C10H18 138.1 74630-29-8 <1

Dimethylnaphthalene 156.1 581-42-0 <1

C15H26 206.2 1000156-14-5 <1

C15H22 202.2 644-30-4 <1

C15H22 202.2 16982-00-6 <1

Methylbiphenyl 168.1 644-08-6 <1 Pentadecane 212.3 629-62-9 <1

Methylbiphenyl 168.1 643-58-3 <1

Trimethylnaphthalene 170.1 2245-38-7 <1

C15H26 206.2 13567-54-9 <1

Trimethylnaphthalene 170.1 829-26-5 <1

Trimethylnaphthalene 170.1 2131-42-2 <1

Trimethylnaphthalene 170.1 2131-41-1 1-2

Trimethylazulene 170.1 941-81-1 <1

Dimethylbiphenyl 182.1 605-39-0 <1

C14H16 184.1 490-65-3 <1

1-Hexadecene 224.3 629-73-2 <1

C3-Alkylbenzothiophene 190.3 18428-05-2 <1

Hexadecane 226.3 544-76-3 <1

Dimethylbiphenyl 182.1 612-75-9 <I

Isopropenylnaphthalene 168.1 1855-47-6 <1

2-Methylthibenzothiazole 181.4 615-22-5 <1

1,1-Diphenylhydrazine 184.1 530-50-7 <1

Tetramethylnaphthalene 184.1 3031-15-0 <1

Triethylacetophcnone 204.2 2715-54-0 <1

1,3-Diphenylpropane 196.1 1081-75-0 <1

Benzothiazolone 151.2 934-34-9 <1

Tetramethylnaphthalene 184.1 <1

CS-Alkylnaphthalene 198.1 483-78-3 <1

C4-Alkylbenzothiophene 190.1 18428-05-2 <1

1-Heptadecene 238.3 6765-39-5 <1

Tetramethylnaphthalene 184.1 < 1

Heptadecane 240.3 629-78-7 <1

C13H20O 184.1 613-37-6 <1

Methylfluorene 180.1 1430-97-3 <1

Methylfluorene 180.1 1556-99-6 <1

Methylfluorene 180.1 1730-37-6 <1

Tetramethylnaphthalene 184.1 <1

Diphenylamine 183.1 552-82-9 <1

Dimethylbiphenyl 182.1 611-43-8 <1

Dimethylbiphenyl 182.1 611-61-0 <1

C3-Alkylbiphenyl 196.1 7116-95-2 <1

Dimethylbiphenyl 182.1 613-33-2 <1

1-Octadeccπe 252.3 112-88-9 <1

Octadecane 254.3 593-45-3 <1

Phenanthrene 178.1 85-01-8 <1

Anthracene 178.1 120-12-7 <1

Methyldihydroanthracene 194.1 948-67-4 <1

Diniethylfluorene 194.1 4612-63-9 <1

Alpha-Methylstilbene 194.1 833-81-8 <1

C14H24 192.2 1000149-59-0 <1

C15H16 196.1 28122-28-3 <1

C15H16 196.1 620-85-9 <1

C15H16 196.1 28122-27-2 <1

Phenylnaphthalene 204.1 605-02-7 <1

C3-Alkylbiphenyl 196.1 20282-30-8 <1

1-Nonadecene 266.3 18435-45-5 <1

Noπadecane 268.3 629-92-5 <1 Methylanthracene 192.1 610-48-0 < 1

Methylanthraceπe 192.1 779-02-2 < 1

C16H16 208.1 2919-20-2 < 1

Methylanthracene 192.1 613-12-7 < 1

Hexadecanoic Acid 256.2 57-10-3 < 1

Phenylnaphthalene 204.1 35465-71-5 < 1

Dimethylphenanthrene 206.1 3674-69-9 < 1

C19H28 256.2 1000197-14-1 < 1

Dimethylanthracene 206.1 781-43-1 < 1

Dimethylphenanthrene 206.1 1576-67-6 < 1

Dimethy Iphen anth rene 206.1 1576-69-8 < 1

Butylatcd Hydroxytoluene 220.2 128-37-0 < 1

Fluoranthene 202.1 206-44-0 < 1

Heneicosane 296.3 629-94-7 < 1

Hexadecanenitrile 251.3 5399-02-0 < 1

2-Propenylan th racene 218.1 23707-65-5 < 1

Diisopropylbiphenyl 238.2 69009-90-1 < 1

Pyreπe 202.1 129-00-0 < 1

Trimethylphenanthrene 220.1 3674-73-5 < 1

Docosane 310.4 629-97-0 < ]

C4-Alkylphenanthrene 234.1 483-65-8 < 1

Tricosane 324.4 638-67-5 < 1

Tetracosane 338.4 646-31-1 < ]

Chrysene 228.1 218-01-9 < 1

Pentacosane 352.4 629-99-2 < 1

Benz[a]anthracene 228.1 56-55-3 < 1

As discussed above, the multi-component mixture of the solvent enables it to dissolve the entire spectrum of waxes and asphaltene deposits. The solvent includes a large percentage of unsaturates and aromatics, which give the solvent the ability to maintain solids in suspension for extended periods of time compared to other solvents. Once a paraffin substance is treated, the paraffins are not likely to recombine due to unsaturates molecular structure that creates an ionic repulsion effect.

The solvent also has the ability to stay bonded to metallic surfaces for extended periods of time. This characteristic further enhances the solvent's ability to be a lubricant as well which further separates the solvent from other produced solvents. A summary of the lab analysis on a solvents manufactured by this technique follows, with percentages expressed as a weight percent.

1. Content of light (gas) non-alkane hydrocarbons (C1 to C5) = 2.5%

The content of these light hydrocarbons may vary from less than 1% to about 4%, depending on operating parameters for the process. Although a low percentage of light hydrocarbons thus will typically be present in a solvent manufactured in this manner, the light hydrocarbons are not considered particularly important in satisfying the solvent's ability to dissolve waxes and paraffins. The C1-C5 hydrocarbon materials are not considered significant to the desired solvent characteristics. These light hydrocarbons could be removed from the solvent by conventional techniques.

2. Total content of C6 to C25 = about 96% to 99.5%

- Of which about 12.8% by weight of the solvent was LIMONENE

- Of which 9.5% by weight of the solvent was NAPHTHALENES

The weight percentage of limonene and the percentage of naphthalenes are particularly significant, and it is believed that their combination increases the effectiveness of the solvent when both the limonene and the naphthalenes have a significant weight percentage. The percentage of limonene may be 6% or more, and preferably in the range of from 8% to 25%. The percentage of naphthalenes may be 6% or more, and in the range of from 8% to 14%. In more preferred embodiments, the weight percentage of limonene in the solvent may be about 10%, and the weight percentage of naphthalenes in the solvent may also be about 10%. The term "limonene" as used herein refers to dl-limonene, which is also referred to as dipentene. The term "naphthalenes" as used herein broadly refers to any of the chemical components having a hydrocarbon chain based upon C10H8 molecules, and includes methyldihydronaphthalene (C11), 2- methylnaphthalene (C11), 1-methylnaphthalene (C11), dimethylnaphthalene (C12), trimethylnaphthalene (C13), isopropenylnaphthalene (C13), tetramethylnaphthalene (C14), C5-alkylnaphthalene (C15), and phenylnaphthalene (C16). The term "C10" as used herein means chemical components with a carbon number of 10, and includes limonene and some of the naphthalenes. Similarly, the terms "C6\ ^UC7", "C8", "C9", "C11" and "C12" mean chemical components with a carbon number of 6, 7, 8, 9, 11 and 12, respectively.

3. The breakdown of the C6's through C12's are as follows:

C6 at least 1% (Carbon Number=6)

C7 at least 3% (Carbon Number=7)

C8 at least 6% (Carbon Number=8)

C9 at least 12% (Carbon Number=9)

C10 at least 5% (Carbon Number=10)

C11 at least 6% (Carbon Number=11)

C12 at least 6% (Carbon Number=12)

C13 at least 3% (Carbon Number=13)

C14 at least 1% (Carbon Number=14)

C15 at least 2% (Carbon Number=15)

From the above, it should be understood that each of the C6 hydrocarbon materials, the C7 hydrocarbon materials, the C8 hydrocarbon materials and the C9 hydrocarbon materials comprise at least 25% by weight of the solvent. Also, the C10 hydrocarbon materials also comprise at least 25% by weight of the solvent. The majority of the C10 constituents are from the limonene. C10 hydrocarbons weight percentage is preferably in excess of 20% of the solvent by weight. C6 and C7 hydrocarbons also comprise a significant percent by weight of the solvent, and both the C6 and C7 materials may be by weight at least 2% and 3%, respectively, for most applications.

A relatively low amount of C6 hydrocarbon materials, e.g., from 1-3% by weight of the solvent, may be present, although there may be applications where it is preferred to significantly reduce or eliminate these materials from the solvent, along with the removal of the light C1-C5 hydrocarbon materials, as discussed above.

Percentage by weight of hydrocarbon materials drops significantly after the C10 materials. In a preferred embodiment, the solvent may include from 6-8% by weight C-11 hydrocarbon materials, and may also include from 6-9% by weight C12 hydrocarbon materials. For numbers higher than C12, the percentage by weight again is reduced, and from 3-6% by weight of the solvent may be C13 hydrocarbon materials and from 1-4% by weight may be C14 hydrocarbon materials. The solvent may include from 2-6% by weight C15 hydrocarbon materials, and from 2-6% by weight C16-C25 hydrocarbon materials. In one embodiment, the solvent preferably comprises by weight at least 5% C-10 through C-25 hydrocarbon materials.

The breakout of the C13 and larger carbon chains is more difficult to determine, sin ce many constituents of these larger chains are not easily identifiable with their C-H makeup. From the above, these C13 and larger chains comprise about 15% or less of the solvent..

Physical Properties

Appearance: Brown Liquid

Viscosity @ 100 Degrees F: 2.1 , cSt

Boiling Point Range: 40 Degrees C (IBP) - 200 Degrees C

Specific Gravity @ 60 Degrees F: 0.9195 API Gravity @ 69 Degrees F: 22.3 Degrees F

Flash Point, PM: 69 Degrees F

Freezing Point: < -5 Degrees F

According to the method of manufacturing a solvent from waste tires, an enclosure may be provided having an interior chamber and a plurality of baffles. Tire particles may be input to the heated enclosure and move along a flow line positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150⁰F, thereby producing hydrocarbon vapors and residual solids. The drum in fluid communication with the flow line is rotated for receiving the tire particles and residual solids from the flow line, with the drum having an interior temperature of from 730⁰F to 800⁰F for generating hydrocarbon vapors and carbon black solids. The vapors from the flow line of the drum are condensed, and the output includes liquid hydrocarbons from the condenser and gas including hydrocarbons from the condenser. A selected vacuum of at least 5 inches of water is maintained, such that hydrocarbon vapors are drawn from the flow line into the condenser. Solvent may be extracted from the liquids output from the condenser. In many cases, a useful solvent may be generated simply by separating the hydrocarbon materials from water, so that the water is discharged or returned back to the system, with the remaining solvent serving the highly useful purposes as disclosed herein.

At least a portion of the gas produced may be input into a burner within the enclosure to reduce the fuel cost to the system. Fuel to the burner may specifically be controlled as a function of the measured drum temperature. In a preferred embodiment, the flow line extends in one axial direction, and in a substantially opposing axial direction within the chamber. Carbon black solids may be discharged from the drum.

In a preferred embodiment, steam is input to the drum at a temperature of greater than 800⁰F. The rotary drum is heated to an interior temperature of from 730⁰F to 800⁰F for generating hydrocarbon vapors and carbon black solids. Preferably a drum magnet may be used to remove metal particles from the rubber particles prior to the material entering the heated chamber.

Figure 11 illustrates the primary components of the system in schematic form. Material from the conveyor 12 thus passes upward through the vertical auger 30, through the double-dump valve 34, and through the conveyor 62 into the heated enclosure 66. Carbon black discharged from the enclosure is passed through the vertical auger 84 and may then be packaged for sale. Further detail regarding a suitable system for manufacturing a solvent is discussed with respect to Figures 1-9 above.

A water condenser is provided with internal coils preferably fabricated from stainless steel. Water may be treated with a water softening system and will be continuously circulated through a water chiller while flowing through the condenser to maintain a constant temperature and reduce the rate of corrosion. The water softener may be used to input water to the liquid isolation chamber, and also the waste heat boiler. Steam from the boiler may be input to the heated enclosure 66, as discussed above. The oil and water separator 102 may receive oil and water from various locations in the system, but primarily from the condensing column 94. Separated water may be discharged to waste treatment or input back to the system. The oil, which is termed a solvent in this application, may be separated from the water and selectively output from separator 102 to drums or other containers for sale.

Other oilfield applications may use this solvent for corrosion inhibitors, paraffin inhibitors, asphaltene inhibitors, paraffin dispersing, surfactants, emulsion breakers, anti-sludge agents, inverted drilling mud, friction reducers, frac fluid loss agent, liquid gel concentrates, oil soluble acids, acid corrosion inhibitors, hydrocarbon foaming agents, and emulsified acid systems. Solvent spray may also be produced from other feedstock, including oil shale or tar sands, although its composition will vary from the solvent produced with rubber tires as the feedstock.

Although specific embodiments of the invention have been described herein in some detail, this has been done solely for the purposes of explaining the various aspects of the invention, and is not intended to limit the scope of the invention as defined in the claims which follow. Those skilled in the art will understand that the embodiment shown and described is exemplary, and various other substitutions, alterations, and modifications, including but not limited to those design alternatives specifically discussed herein, may be made in the practice of the invention without departing from its scope.

Claims

WHAT IS CLAIMED IS:

1. A system for recycling solid waste into energy, the solid waste having a cross-sectional particle size less than one inch in length, the system comprising: a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber; one or more input conveyors for inputting waste particles to the heated enclosure and having a flow line positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150F°, thereby producing hydrocarbon vapors and residual solids, the input conveyors mechanically moving the waste particles and the residual solids along the flow line; a heated rotary drum in fluid communication with the flow line for receiving the waste particles and residual solids from the flow line, the rotary drum having an interior temperature of from 730^cF to 800°F for generating hydrocarbon vapors and carbon black solids; a condenser in fluid communication with the flow line and the rotary drum for receiving the vapors from the flow line and the rotary drum and outputting liquids including hydrocarbons and gas including hydrocarbons; one or more discharge conveyors for discharging the carbon black solids from the rotary drum; two or more input control valves for sealing vacuum downstream from the one or more input conveyors, each input control valve having two or more axially spaced closure gates; two or more discharge control valves for sealing vacuum upstream from the one or more discharge conveyors, each discharge control valve having two or more axiaily spaced closure gates; and a vacuum pump for maintaining a selected vacuum of less than 5 inches of water between the two or more input valves and the two or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser.

2. The system as defined in Claim 1 , wherein at least a portion of the one or more gas including hydrocarbons and the liquids including hydrocarbons are input into a burner within the heated enclosure.

3. The system as defined in Claim 2, wherein a drum sensor senses a temperature within the rotating drum; and fuel to the burner is controlled as a function of the measured drum temperature.

4. The system as defined in Claim 1 , further comprising: a substantially vertical input conveyor in fluid communication with the two or more input control valves for providing a plug of waste material for minimizing vacuum loss.

5. The system as defined in Claim 1, further comprising: a substantially vertical waste conveyor in fluid communication with the two or more discharge control valves for providing a plug of carbon block solids for minimizing vacuum loss.

6. The system as defined in Claim 1, wherein each of the one or more input conveyors, the one or more discharge conveyors, and the heated conveyor within the flow line includes a rotary auger.

7. The system as defined in Claim 6, wherein each rotary auger is rotated by a drive motor and gearbox, a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a sealed enclosure downstream from the seal for containing gases which pass by the seal.

8. The system as defined in Claim 6, further comprising: one or more rpm sensors for monitoring a rotational rate of the rotary augers.

9. The system as defined in Claim 6, wherein each auger is driven by the motor and gearbox to rotate at less than 10 rpm.

10. The system as defined in Claim 1 , wherein the flow line extends in one axial direction and in a substantially opposing axial direction within the heated chamber.

11. The system as defined in Claim 1 , wherein the recycled waste are rubber tires, and a drum magnet is provided upstream from the one or more input conveyors for removing metal particles from rubber particles.

12. The system as defined in Claim 1, further comprising: a nitrogen supply system to supply nitrogen to carbon black solids discharged from the one or more discharge conveyors.

13. The system as defined in Claim 1, further comprising: a water chiller for cooling hydrocarbon vapors passing through the condenser.

14. The system as defined in Claim 1, further comprising: a condensing column upstream of the condenser for separating liquids and gases, hydrocarbon vapors being input into a lower portion of the condensing column.

15. The system as defined in Claim 1, further comprising: a plurality of sensors for detecting a leak within a vacuum system between the two or more input control valves and the two or more discharge control valves.

16. The system as defined in Claim 1 , further comprising: a flow meter for measuring a flow rate of hydrocarbon vapors to the condenser.

17. The system as defined in Claim 1 , further comprising: one or more load cells for measuring a weight of recycling waste in a hopper upstream from the one or more input conveyors, thereby providing an input weight of waste material as a function of time.

18. The system as defined in Claim 1 , further comprising: a steam line for inputting steam at a temperature of greater than 800⁰F into the rotary drum.

19. The system as defined in Claim 18, further comprising: a boiler heated by at least one of the gas including hydrocarbons and the liquids including hydrocarbon to provide steam to the steam lines.

20. The system as defined in Claim 1 , wherein a vacuum pump maintains a selected vacuum between the two or more input valves and the two or more discharge valves of from 0.5 inches to 2.5 inches of water.

21. A system for recovering hydrocarbons from tar sands, the system comprising: a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber; one or more input conveyors for inputting tar sands to the heated enclosure, the heated enclosure having a flow line positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150F°, thereby producing hydrocarbon vapors and stripped sands, the input conveyors mechanically moving the tar sands and the stripped sands along the flow line; a heated rotary drum in fluid communication with the flow line for receiving the tar sands from the flow line, the rotary drum having an interior temperature of from _.760⁰F to 840⁰F for generating hydrocarbon vapors and stripped sands; a condenser in fluid communication with the flow line and the rotary drum for receiving the vapors from the flow line and the rotary drum and outputting liquids including hydrocarbons; one or more discharge conveyors for discharging the stripped sands from the rotary drum; two or more input control valves for sealing vacuum downstream from the one or more input conveyors, each input control valve having two or more axially spaced closure gates; two or more discharge control valves for sealing vacuum upstream from the one or more discharge conveyors, each discharge control valve having two or more axially spaced closure gates; and a vacuum pump for maintaining a selected vacuum of less than 5 inches of water between the two or more input valves and the two or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser.

22. The system as defined in Claim 21, wherein a portion of the hydrocarbons are input into a burner within the heated enclosure.

23. The system as defined in Claim 22, wherein a drum sensor senses a temperature within the rotating drum; and tar sands movement to the burner is controlled as a function of the measured drum temperature.

24. The system as defined in Claim 21 , further comprising: a substantially vertical input conveyor in fluid communication with the two or more input control valves for providing a plug of tar sands for minimizing vacuum loss.

25. The system as defined in Claim 21 , further comprising: a substantially vertical waste conveyor in fluid communication with the two or more discharge control valves for providing a plug of stripped sands for minimizing vacuum loss.

26. The system as defined in Claim 21, wherein each of the one or more input conveyors, the one or more discharge conveyors, and the heated conveyor within the flow line includes a rotary auger.

27. The system as defined in Claim 26, wherein each rotary auger is rotated by a drive motor and gearbox, a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a sealed enclosure downstream from the seal for containing gases which pass by the seal.

28. The system as defined in Claim 26, further comprising: one or more rpm sensors for monitoring a rotational rate of the rotary augers.

29. The system as defined in Claim 26, wherein each auger is driven by the motor and gearbox to rotate at less than 10 rpm.

30. The system as defined in Claim 21, wherein the flow line extends in one axial direction and in a substantially opposing axial direction within the heated chamber.

31. The system as defined in Claim 21 , further comprising: a nitrogen supply system to supply nitrogen to stripped sands discharged from the one or more discharge conveyors.

32. The system as defined in Claim 21 , further comprising: a water chiller for cooling hydrocarbon vapors passing through the condenser.

33. The system as defined in Claim 21 , further comprising: a condensing column upstream of the condenser for separating liquids and gases, hydrocarbon vapors being input into a lower portion of the condensing column.

34. The system as defined in Claim 21 , further comprising: a plurality of sensors for detecting a leak within a vacuum system between the two or more input control valves and the two or more discharge control valves.

35. The system as defined in Claim 21 , further comprising: a flow meter for measuring a flow rate of hydrocarbon vapors to the condenser.

36. The system as defined in Claim 21 , further comprising: a steam line for inputting steam at a temperature of greater than 800⁰F into the rotary drum.

37. The system as defined in Claim 26, further comprising: a boiler heated by at least one of gas including hydrocarbons and the liquids including hydrocarbon to provide steam to the steam lines.

38. The system as defined in Claim 21, wherein a vacuum pump maintains a selected vacuum between the two or more input valves and the two or more discharge valves of from 0.5 inches to 2.5 inches of water.

39. A solvent, comprising: at least 3% by weight C7 hydrocarbon materials; at least 6% by weight C8 hydrocarbon materials; at least 12% by weight C9 hydrocarbon materials; at least 6% by weight limonene; and at least 6% by weight naphthalenes.

40. A solvent as defined in Claim 39, wherein the limonene is from 8-25% by weight.

41. A solvent as defined in Claim 39, wherein the naphthalenes are from 8-14% by weight.

42. A solvent as defined in Claim 39, wherein the C7 hydrocarbon materials are at least 5% by weight of the solvent.

43. A solvent as defined in Claim 39, wherein C-1 to C-5 hydrocarbon materials comprise from 2-5% by weight of the solvent.

44. A solvent as defined in Claim 39, wherein the solvent comprises at least 2% by weight C6 hydrocarbon materials.

45. A solvent as defined in Claim 44, wherein the C6 hydrocarbon materials comprise at least 4% by weight of the solvent.

46. A solvent as defined in Claim 39, wherein C10 hydrocarbons comprise at least 25% by weight of the solvent.

47. A solvent as defined in Claim 39, wherein C-13 and higher hydrocarbon materials comprise less than 9% by weight of the solvent.

48. A solvent comprising: from 4%-8% by weight C7 hydrocarbon materials; from 8%-12% by weight C8 hydrocarbon materials; from 14%-20% by weight C9 hydrocarbon materials; and from 25%-40% by weight C10 hydrocarbon materials.

49. A solvent as defined in Claim 48, wherein the solvent further comprises: from 6%-8% by weight C11 hydrocarbon materials.

50. A solvent as defined in Claim 48, wherein the solvent further comprises: from 6%-9% by weight C12 hydrocarbon materials.

51. A solvent as defined in Claim 48, wherein the solvent further comprises: from 3%-6% by weight C13 hydrocarbon materials.

52. A solvent as defined in Claim 48, wherein the solvent further comprises: from 1%-4% by weight C14 hydrocarbon materials.

53. A method of manufacturing a solvent from waste tires, the method comprising: providing an enclosure having an interior chamber and a plurality of internal baffles; inputting the tire particles to the heated enclosure and moveable along a flow line positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150F°, thereby producing hydrocarbon vapors and residual solids; rotating a drum in fluid communication with the flow line for receiving the tire particles and residual solids from the flow line, the drum having an interior temperature of from 730⁰F to 800⁰F for generating hydrocarbon vapors and carbon black solids; condensing vapors from the flow line and the drum and outputting liquids including hydrocarbons from condenser and gas including hydrocarbons from the condenser; maintaining a selected vacuum of less than 5 inches of water, such that hydrocarbon vapors are drawn from the flow line into the condenser; extracting the solvent from the liquids output from the condenser.

54. A method as defined in Claim 53, wherein at least a portion of the one or more gas including hydrocarbons are input into a burner within the enclosure.

55. The system as defined in Claim 53, wherein fuel to the burner is controlled as a function of measured drum temperature.

56. A method as defined in Claim 53, wherein the flow line extends in one axial direction and in a substantially opposing axial direction within the chamber.