NZ762264B2 - Waste processing system - Google Patents
Waste processing system Download PDFInfo
- Publication number
- NZ762264B2 NZ762264B2 NZ762264A NZ76226418A NZ762264B2 NZ 762264 B2 NZ762264 B2 NZ 762264B2 NZ 762264 A NZ762264 A NZ 762264A NZ 76226418 A NZ76226418 A NZ 76226418A NZ 762264 B2 NZ762264 B2 NZ 762264B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- chamber
- heating
- primary chamber
- primary
- waste
- Prior art date
Links
- 239000002699 waste material Substances 0.000 title claims abstract description 60
- 238000012545 processing Methods 0.000 title claims abstract description 23
- 238000010438 heat treatment Methods 0.000 claims abstract description 104
- 238000000034 method Methods 0.000 claims abstract description 37
- 238000001816 cooling Methods 0.000 claims abstract description 17
- 238000011068 loading method Methods 0.000 claims abstract description 17
- 239000012141 concentrate Substances 0.000 claims abstract description 8
- 239000002906 medical waste Substances 0.000 claims description 21
- 238000003672 processing method Methods 0.000 claims description 12
- 239000011261 inert gas Substances 0.000 claims description 9
- 239000000463 material Substances 0.000 abstract description 25
- 239000002910 solid waste Substances 0.000 abstract description 4
- 239000010793 electronic waste Substances 0.000 description 22
- 230000008569 process Effects 0.000 description 18
- 238000002485 combustion reaction Methods 0.000 description 17
- 239000007789 gas Substances 0.000 description 13
- 229910052751 metal Inorganic materials 0.000 description 12
- 239000002184 metal Substances 0.000 description 12
- 238000012546 transfer Methods 0.000 description 12
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- 229910052500 inorganic mineral Inorganic materials 0.000 description 6
- 239000011707 mineral Substances 0.000 description 6
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 5
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- 238000002309 gasification Methods 0.000 description 4
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- 239000004332 silver Substances 0.000 description 2
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- 239000003053 toxin Substances 0.000 description 2
- 231100000765 toxin Toxicity 0.000 description 2
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- 241000894006 Bacteria Species 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910052691 Erbium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 241000700605 Viruses Species 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052785 arsenic Inorganic materials 0.000 description 1
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000031018 biological processes and functions Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- KYKAJFCTULSVSH-UHFFFAOYSA-N chloro(fluoro)methane Chemical compound F[C]Cl KYKAJFCTULSVSH-UHFFFAOYSA-N 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
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- 238000006073 displacement reaction Methods 0.000 description 1
- 239000010791 domestic waste Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
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- 239000003063 flame retardant Substances 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- ZZUFCTLCJUWOSV-UHFFFAOYSA-N furosemide Chemical compound C1=C(Cl)C(S(=O)(=O)N)=CC(C(O)=O)=C1NCC1=CC=CO1 ZZUFCTLCJUWOSV-UHFFFAOYSA-N 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 239000010800 human waste Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 150000002611 lead compounds Chemical class 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000007726 management method Methods 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000010813 municipal solid waste Substances 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 235000019645 odor Nutrition 0.000 description 1
- 230000009340 pathogen transmission Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000002062 proliferating effect Effects 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- WQGWDDDVZFFDIG-UHFFFAOYSA-N pyrogallol Chemical compound OC1=CC=CC(O)=C1O WQGWDDDVZFFDIG-UHFFFAOYSA-N 0.000 description 1
- 238000009853 pyrometallurgy Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
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- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- XTQHKBHJIVJGKJ-UHFFFAOYSA-N sulfur monoxide Chemical class S=O XTQHKBHJIVJGKJ-UHFFFAOYSA-N 0.000 description 1
- 230000036962 time dependent Effects 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 238000013022 venting Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/0075—Disposal of medical waste
-
- B09B3/0083—
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B1/00—Retorts
- C10B1/10—Rotary retorts
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B21/00—Heating of coke ovens with combustible gases
- C10B21/10—Regulating and controlling the combustion
- C10B21/18—Recirculating the flue gases
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B27/00—Arrangements for withdrawal of the distillation gases
- C10B27/06—Conduit details, e.g. valves
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B47/00—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion
- C10B47/28—Other processes
- C10B47/30—Other processes in rotary ovens or retorts
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
- C10B53/07—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of solid raw materials consisting of synthetic polymeric materials, e.g. tyres
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2202/00—Combustion
- F23G2202/10—Combustion in two or more stages
- F23G2202/103—Combustion in two or more stages in separate chambers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2203/00—Furnace arrangements
- F23G2203/20—Rotary drum furnace
- F23G2203/209—Rotary drum furnace with variable inclination of rotation axis
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2204/00—Supplementary heating arrangements
- F23G2204/10—Supplementary heating arrangements using auxiliary fuel
- F23G2204/103—Supplementary heating arrangements using auxiliary fuel gaseous or liquid fuel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2209/00—Specific waste
- F23G2209/20—Medical materials
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2900/00—Special features of, or arrangements for incinerators
- F23G2900/50201—Waste pyrolysis, gasification or cracking by indirect heat transfer
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
- F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
- F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
- F23G5/0273—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage using indirect heating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
- F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
- F23G5/033—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment comminuting or crushing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
- F23G5/20—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having rotating or oscillating drums
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/10—Biofuels, e.g. bio-diesel
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/141—Feedstock
- Y02P20/143—Feedstock the feedstock being recycled material, e.g. plastics
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/20—Waste processing or separation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
Abstract
disposal system and method of use for the processing of solid waste devices to recycle materials located within the devices and recover, reuse and recycle such materials. Such system may include a primary chamber and secondary chamber, attached preferably by use of one or more exhaust ducts, and a secondary chamber exhaust duct. The solid waste devices may include any type of waste, such as electronics waste, medical device waste, and the like. The waste disposal system having a heating chamber, a primary chamber disposed within the heating chamber, a secondary chamber, and lid. The method comprising loading feedstock into the primary chamber, heating the secondary chamber, heating the heating chamber with the feedstock inside, rotating the primary chamber while the primary chamber is being heated, cooling the heating chamber after the heating chamber is heated for a predetermined amount of time, and removing leftover concentrate after heating the heating chamber for the predetermined amount of time. secondary chamber exhaust duct. The solid waste devices may include any type of waste, such as electronics waste, medical device waste, and the like. The waste disposal system having a heating chamber, a primary chamber disposed within the heating chamber, a secondary chamber, and lid. The method comprising loading feedstock into the primary chamber, heating the secondary chamber, heating the heating chamber with the feedstock inside, rotating the primary chamber while the primary chamber is being heated, cooling the heating chamber after the heating chamber is heated for a predetermined amount of time, and removing leftover concentrate after heating the heating chamber for the predetermined amount of time.
Description
WASTE PROCESSING SYSTEM
CROSS REFERENCE TO RELATED APPLICATION
This application is related to and claims the priority of U.S. Provisional Patent
Application No. 62/552,080, filed August 30, 2017, which is hereby incorporated
herein by reference in its entirety.
FIELD OF THE INVENTION
Certain embodiments may generally relate to the processing of waste. More
specifically, certain embodiments may relate to a controlled combined pyrolysis and
gasification method for processing waste to safely dispose of harmful components in
the waste while enabling efficient recovery of precious metals and rare earth elements.
BACKGROUND OF THE INVENTION
The current most common way to dispose of waste is by use of a landfill.
Landfill operators attempt to make sanitary landfills by filling a land area with
successive layers of solid waste, principally household waste, and layers of earth or
soil are well known. The uncontrolled landfill depends upon natural biological action,
precipitation and climate to effect decomposition. As the waste decomposes, toxic
materials in the waste may enter into the natural precipitation draining out of the
landfill, thereby allowing highly toxic contaminated water to potentially contaminate
underground water supplies, surface streams and wells. Due to the very slow
stabilization, the uncontrolled landfill is not usable for other purposes for long periods
of time and thus, particularly near metropolitan areas, represents a large waste of land
resources.
Despite efforts to recycle materials in the waste, certain types of waste are
difficult to recycle by use of the current standard methods.
For instance, electronic waste, otherwise known as e-scrap and e-waste, is
trash generated from surplus, broken, and obsolete electronic devices. E-waste is
prolific and toxic. It is well researched that only approximately 13% of e-waste is
processed for materials recovery. In addition, e-waste volumes are increasing at a
compounding 8% per annum. As such, landfills are usually not a permitted option
due to long term leaching of heavy metals.
When disposed in landfills, e-waste contributes approximately 70% of the
overall hazardous waste components despite by volume being a relatively small
fraction of materials placed in the landfills. Further, e-waste equates to a material
percentage of metals and minerals mined annually. For example, e-waste gold content
equates to approximately 10% of the gold mined annually. Disposal of e-waste
without the recovery of minerals and metals is inefficient and unsustainable long term.
E-waste can also be particularly detrimental to the environment since such waste
includes harmful lead compounds, mercury, cadmium, chromium, and
chlorofluorocarbon (CFC) gases. Thus, the hazardous content of e-waste requires
special management.
In years past, finding efficient and effective ways of disposing of such waste
has been, and continues to be a challenge. For instance, incineration has not been a
viable option due to nitrogen oxides (NOx) and sulfur oxides (SOx), acidity, arsenic,
and heavy metals and other toxins that have detrimental effects on the atmosphere.
Most other solutions require manual deconstruction of feedstock, and are labor
intensive. In addition, typical extraction of previous metals use high temperature
refining methods, which produce emissions that require scrubber systems and high
levels of energy. Other alternatives tend to require large-scale operations that are
centralized and logistically less efficient. Moreover, other processes are per gram of
metals recovered are more expensive to build and to operate. In addition, other
developments of hydro digesters take a small percentage of electronic waste, such as
ground up printed circuit boards and dissolve them. Further, post processing disposal
of toxic residue concentrates is then required (i.e., hydrocarbon, flame-retardants, and
other residues).
However, a majority of electronic products usually end up in landfills, and just
a small percentage come back to be used in new electronic devices. In addition,
recycling e-waste can be challenging because certain electronics are sophisticated
devices manufactured from varying proportions of glass, metals, and plastics.
Electronic devices generally contain valuable materials including copper, tin, iron,
aluminum, palladium, titanium, gold, and silver. Therefore, there is a need to be able
to find effective and safe ways to recover, reuse, and recycle such materials. This
may be especially true when considering that recycling e-waste can help save energy
and resources, reduce pollution, conserve landfill space, and ultimately provide
environmentally safe methods of processing e-waste. There is also a need for smaller
scale easy to deploy processing at the core of efficient e-waste processing.
Like e-waste, medical waste such as needles, syringes, glassware, and
bandages, also has challenges in disposal. Current medical waste systems do not
sanitize, sort or recycle the medical waste. Given that certain bacteria and viruses can
be transmitted via biologically contaminated waste, care should be taken to destroy
pathogens and thus minimize possible pathogen transmission. Instead, biologically
contaminated medical waste is often disposed in landfills, which can be detrimental
to the environment.
Current systems of disposing of medical waste include use of on-site
incinerators. Incinerators may be effective in decontaminating and reducing the size
of the medical waste materials, but are not satisfactory because they often have the
danger of toxic gas emissions. In addition, on-site incinerators in large hospitals
cannot be outfitted with adequate pollution control devices and run by highly trained
technicians on a financially feasible basis. As a consequence, these incinerators may
operate at pollution levels in excess of the legal limit or be run by less than adequately
trained technicians. Other methods include use of disinfectant solutions, which can
take up a large amount of space and risk contaminating the operator.
In all cases, the operators must remove the medical waste from its waste
container, which is a rigid, container used by medical professionals to protect others
from the pathogens residing on the medical waste. This process can be labor intensive,
and expose the operators to the sharp objects contained within, such as needles and
broken glass, and expose the operators to the pathogens contained within, including
liquid and solid materials. There, therefore, is also a need for a system to process
medical waste in a way that minimizes manual labor, destroys and disinfects medical
waste products, while minimizing contact of the medical waste to the operator of the
medical waste disposal system. It may also be desirable to recover metals and other
materials from such medical waste, which current systems fail to address in any way.
For these, among other reasons, the inventors developed the currently
presented system. Certain embodiments of present invention provide a system to
effectively and safely process waste, such as e-waste, medical waste, and other
types of waste, to recover, reuse, and recycle such materials. As a result, it may be
possible to reduce pollution, conserve landfill space, and provide environmentally
safe methods of processing and recycling waste materials.
Additional features, advantages, and embodiments of the invention
are set forth or apparent from consideration of the following detailed description,
drawings and claims. Moreover, it is to be understood that both the foregoing
summary of the invention and the following detailed description are exemplary and
intended to provide further explanation without limiting the scope of the invention
as claimed.
SUMMARY
According to certain embodiments, a waste processing method for a waste
processing system may be provided. The waste processing system may have a
heating chamber, a primary chamber disposed within the heating chamber, a
secondary chamber, and a lid. The method may include loading feedstock into the
primary chamber, heating the secondary chamber during the loading of the
feedstock, and heating the heating chamber with the feedstock inside. The method
may also include rotating the primary chamber while the primary chamber is being
heated, cooling the heating chamber after the heating chamber is heated for a
predetermined amount of time, and removing leftover concentrate after heating the
heating chamber for the predetermined amount of time. The method may also
include collecting, in the lid, syngas produced while heating the heating chamber;
sending the syngas from the primary chamber to the secondary chamber via a
primary chamber exhaust duct connecting the primary chamber to the secondary
chamber; burning the syngas in the secondary chamber; and exhausting the burned
syngas out of the waste processing system via a secondary chamber exhaust duct
connected to the secondary chamber. In an embodiment, loading the feedstock may
include rotating the primary chamber and the heating chamber to an operating
position, securing the lid to an open end of the primary chamber, loading the
primary chamber with an inert gas, and tilting the heating chamber and the primary
chamber to a predetermined angle to facilitate processing of the feedstock.
In an embodiment, the method may also include heating the secondary
chamber to a temperature range of about 1000 °C to about 1100 °C, collecting, in
the lid, syngas produced while heating the heating chamber, sending the syngas to
the secondary chamber, burning the syngas in the secondary chamber, and
exhausting the burned syngas out of the waste processing system. According to an
embodiment, the temperature of the primary chamber and a timing of the rotation
of the heating chamber may be controlled based on feedstock type and feedstock
volume.
In another embodiment, the method may include heating the feedstock to a
temperature of about 500 °C to about 600 °C tilting the heating chamber and the
primary chamber to an angle of about 45°, and cooling the heating chamber with a
cooling air fan. According to an embodiment, the rotation of the primary chamber
may be performed by driving a drive motor, which is attached to a bottom surface
of the primary chamber and the heating chamber. In an embodiment, the feedstock
may include computer or electrical equipment, or medical waste items.
According to certain embodiments, a waste processing system may include a
primary chamber section, and a secondary chamber section connected to the primary
chamber section via an exhaust duct. The primary chamber section may include a
heating chamber, a primary chamber disposed within the heating chamber, the
primary chamber being configured to receive feedstock, and a burner configured to
heat the heating chamber and the primary chamber. The secondary chamber section
may include a secondary chamber, and a secondary chamber exhaust duct connected
to the secondary chamber.
In an embodiment, the primary chamber may be loaded with an inert gas.
According to another embodiment, the primary chamber section may include a lid
that is configured to collect syngas produced while heating the heating chamber
and the primary chamber. In another embodiment, the primary chamber section
may include a cooling fan configured to cool the heating chamber.
In a further embodiment, the primary chamber comprises a plurality of heat
transfer fins that are configured to transfer heat from the primary chamber to the
heating chamber, and the plurality of heat transfer fins may be attached to an
exterior surface of the primary chamber. According to an embodiment, the plurality
of heat transfer fins may be made of the same material as the primary chamber.
According to an embodiment, the primary chamber section may include a
drive motor configured to rotate the primary chamber, and the drive motor may be
attached to a bottom surface of the primary chamber and the heating chamber. In
an embodiment, the feedstock may include computer or electrical equipment, or
medical waste items. In another embodiment, the secondary chamber section may
include a syngas combustion air fan configured to supply combustion air to the
secondary chamber. According to an embodiment, the secondary chamber section
may include a syngas combustion air diffuser connected to the syngas combustion
air fan and the secondary chamber exhaust duct.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further
understanding of the invention and are incorporated in and constitute a part of this
specification, illustrate preferred embodiments of the invention and together with
the detailed description serve to explain the principles of the invention. In the
drawings:
Figure 1(A) illustrates a gasifier system according to certain embodiments.
Figure 1(B) illustrates a backside view of the gasifier system of Figure 1(A)
according to certain embodiments.
Figure 2(A) illustrates a perspective view of the primary chamber of Figures
1(A) and 1(B) including a cut-out interior view of the primary chamber according to
certain embodiments.
Figure 2(B) illustrates a plan view of the primary chamber according to certain
embodiments.
Figure 2(C) illustrates a side view of the primary chamber according to certain
embodiments.
Figure 3(A) illustrates an internal cross-sectional view of the primary chamber
of Figures 1(A) – 2(C) according to certain embodiments.
Figure 3(B) illustrates an internal cross-sectional view of the primary chamber
along line A-A of Figure 3(A) according to certain embodiments.
Figure 4 illustrates a method to reduce waste according to certain
embodiments.
Figure 5 illustrates an alternative view of the gas flow for pyrolosis control
within the primary chamber.
DETAILED DESCRIPTION
In the following detailed description of the illustrative embodiments,
reference is made to the accompanying drawings that form a part hereof. These
embodiments are described in sufficient detail to enable those skilled in the art to
practice the invention, and it is understood that other embodiments may be utilized
and that logical or structural changes may be made to the invention without
departing from the spirit or scope of this disclosure. To avoid detail not necessary
to enable those skilled in the art to practice the embodiments described herein, the
description may omit certain information known to those skilled in the art. The
following detailed description is, therefore, not to be taken in a limiting sense.
The features, structures, or characteristics of the invention described
throughout this specification may be combined in any suitable manner in one or
more embodiments. For example, the usage of the phrases “certain embodiments,”
“some embodiments,” or other similar language, throughout this specification
refers to the fact that a particular feature, structure, or characteristic described in
connection with the embodiment may be included in at least one embodiment of
the present invention.
In the following detailed description of the illustrative embodiments,
reference is made to the accompanying drawings that form a part hereof. These
embodiments are described in sufficient detail to enable those skilled in the art to
practice the invention, and it is understood that other embodiments may be utilized
and that logical or structural changes may be made to the invention without
departing from the spirit or scope of this disclosure. To avoid detail not necessary
to enable those skilled in the art to practice the embodiments described herein, the
description may omit certain information known to those skilled in the art. The
following detailed description is, therefore, not to be taken in a limiting sense.
The examples described herein are for illustrative purposes only. As will be
appreciated by one skilled in the art, certain embodiments described herein,
including, for example, but not limited to, those shown in Figures 1(A) – 4, may be
embodied as a system, apparatus, or method.
Certain embodiments may provide a gasifier designed and built to process and
efficiently extract metal and minerals from waste. The output obtained may include
a synthetic ore in a format suitable for immediate hydrometallurgical refining.
According to certain embodiments, this may be accomplished by providing precise
control of indirect heat in a gasification (which may also be starved oxygen or no
oxygen at all) atmosphere within a controlled pressure chamber. The pressure
chamber may include internal fins therein such that when the pressure chamber
rotates, the internal fins may provide agitation, and milling media such as grinding
balls for reduction to fines. The pressure chamber may include alternative gas inputs
to adjust a primary chamber atmosphere.
According to certain embodiments, the overall process of processing the waste
may be controlled by a programmable logic control (PLC) system. In certain
embodiments, the PLC system may read the various process measures such as
temperatures, pressures, rotational speeds, atmospheric concentrations, speed of fans,
flows and other process data, and adjust the parameters of the system in ways to
maximize the process as a whole. The PLC system may also measure gaseous
emissions, where the gaseous emissions may be dosed to achieve a particular pH
balance and to control pyrolosis. The PLC system may also adjust the processes and
parameters of the system in response to the waste materials added, in a time dependent
manner, to account for the type of waste added, the volume of waste, the harmful
contaminants in the waste, and the like to maximize the ability to recycle the outputted
materials.
Figure 1(A) illustrates a system 100 according to certain embodiments, and
Figure 1(B) illustrates a backside view of the system 100 of Figure 1(A) according to
certain embodiments. In particular, the system 100 may include a primary chamber
section 105 and a secondary chamber section 110. As illustrated in Figure 1, the
primary chamber section 105 is interconnected with the secondary chamber section
110 via an exhaust duct 12, and secondary chamber exhaust duct 13. Figure 1(A) also
illustrates that the primary chamber section 105 includes a primary chamber 1 that is
disposed within a heating chamber 2. According to certain embodiments, the primary
chamber 1 may be made of various materials including, for example, stainless steel.
Further, the primary chamber 1 is affixed to the heating chamber 2, but may be
separated from the heating chamber 2 for maintenance purposes. During operation,
the primary chamber 1 may be configured to rotate by being driven by a gearbox and
drive motor 9. As illustrated in Figure 1(B), the gearbox 9 may be attached to a
bottom surface of the primary chamber 1 and heating chamber 2. The rotation motion
can be accomplished via a chain drive, hydraulic motor, or other high torque low
speed power transmission means. In certain embodiments, variations in rotation
speed are preferred during operation. Therefore the rotation may be controlled by a
Variable Frequency Drive, which in turn may be controlled by the PLC.
Also illustrated in Figures 1(A) and 1(B) is a burner 5a and 5b respectively.
The burner 5a and 5b is used for heat input to their respective components. Natural
gas or propane are the preferred fuel sources, but liquid fuels or other gaseous fuels
may be utilized. Further, burner 5a is attached to the exterior of heating chamber 2 to
provide heat internally to heating chamber 2, which indirectly heats the primary
chamber 1.
With the burner 5a, the internal area of the heating chamber 2 is heated to
temperatures necessary to indirectly heat the feedstock which is contained within the
primary chamber 1. Temperature ranges for this internal area can adjusted to account
for the type of waste. In one embodiment, the temperature range would be up to
1000°C. This heating may occur at atmospheric pressure, and may ultimately
generate synthetic gas from heating feedstock contained within the primary chamber
1. As the heating chamber 2 is heated, the heat of the chamber 2 may be preserved
since the heating chamber 2 is made of an insulated shell. The insulated shell of the
heating chamber 2 may include an outer layer and an inner layer. The outer layer of
certain embodiments may be made of carbon steel, and the inner layer may be made
of a high temperature insulating material that may be used in a furnace application.
Such examples include ceramic fibers, refractory monoliths, or refractory brick.
To cool the primary chamber section 105, Figures 1(A) and 1(B) illustrate that
one or more cooling air fans 6 may be provided. In particular, the cooling air fans 6
may supply cool air to the internal area of the heating chamber 2 causing indirect
cooling of the primary chamber 1. As illustrated in Figures 1(A) and 1(B), a cooling
air fan is connected to the internal surface of the heating chamber via a duct. This air
flow to the heating chamber can be controlled by a gate valve. The cooling fans 6
may also serve to provide combustion air or cooling air or other gases into the primary
chamber via duct pipe 17. Duct pipe 17 is ultimately connected to the tuyere pipes
on the primary chamber and passes into the rotating primary by the same means as
the inert gas.
Figures 1(A) and 1B) further illustrate that the primary chamber section 105
includes a support frame 15, which provides support for the primary chamber 1 and
the heating chamber 2. Attached to a trunnion support 22 of the support frame 15 is
a trunnion 20. Furthermore, a hydraulic lifting cylinder 10 is provided and attached
to the trunnion 20 and the trunnion support 22 of the support frame 15. Although only
one hydraulic cylinder 10 is illustrated, in other embodiments, more than one
hydraulic lifting cylinder 10 may be utilized. The combination of the hydraulic lifting
cylinder 10 and the trunnion 20 provides rotational movement of primary chamber 1
and heating chamber 2 so that these structures may be properly positioned for loading
and unloading. That is, the trunnion 20 and hydraulic lifting cylinder 10 may be
configured to provide means for rotational movement of the primary chamber 1 and
heating chamber 2 for the loading of feedstock into the primary chamber 1.
For example, Figure 1(A) and 1(B) illustrate the primary chamber 1 and
heating chamber 2 in an operating position. In one embodiment, the primary chamber
1 and the heating chamber 2 may be rotated from 0º horizontal to a 45° angle from
vertical during operations. However, in other embodiments, the primary chamber 1
and heating chamber 2 may be rotated to other angles as appropriate for loading and/or
unloading, such as, for example to an angle of about 70°. Angling of the primary
chamber 1 and heating chamber 2 may also allow for the contents within the primary
chamber 1 to be conveniently added or removed.
Prior to operating the primary chamber section 105, the primary chamber 1
may be loaded with feedstock or waste through an opening at the top of the primary
chamber 1. To load the feedstock, a lid 11 that covers the opening of the primary
chamber 1 is removed, and feedstock is disposed into the primary chamber 1. In
certain embodiments, the lid 11 may be an exhaust hood. In other embodiments, the
lid 11 may remove combustion products, fumes, smoke, odors, heat, and steam from
inside the primary chamber 1 by evacuation and filtration. According to certain
embodiments, the lid 11 may be formed from conventional materials that are either
identical to or different from the materials that make up the primary chamber 1.
In certain embodiments, the feedstock may include batteries such as lithium
ion batteries, mobile phones, laptops, computers, motherboards, and various other
computer and/or electrical equipment or devices. In other embodiments, the
feedstock may be medical waste items such as human waste contaminated equipment,
hardware, medical devices that contain electrical circuits or other hardware, tubing,
needles, glass, or other waste materials that may contain or be exposed to harmful
pathogens or toxins, or even large hazardous waste boxes that contain medical waste.
In some embodiments, the feedstock does not need to be broken down, and can instead
be directly deposited into the primary chamber 1. However, if desired, the feedstock
may be broken down into smaller parts before being loaded. For larger or heavier
feedstock, a gantry may be used for loading into the primary chamber 1.
Once the feedstock has been loaded into the primary chamber 1, the lid 11 may
be lowered to seal the opening of the primary chamber 1, and thereby maintaining an
inert environment within the primary chamber 1. After sealing the primary chamber
1, residual oxygen within the primary chamber 1 may be removed by displacement
with inert gas. Heat may also then be supplied indirectly to the primary chamber via
the burner 5a. As the primary chamber 1 is heated, the gearbox 9 may drive the
primary chamber 1 causing it to rotate. In addition, as the primary chamber 1 is
heated, the feedstock may start to give off gas and disintegrate. Syngas is generated
from the elemental material within the feedstock.
During the heating, according to certain embodiments, feedstock
disintegration may occur at three different stages depending on the type and volume
of feedstock used. However, in other embodiments, a fourth stage may be observed.
The first stage may be observed at 250 °C, the second stage may be observed at
400 °C, and the third stage may be observed at 550 °C. In addition, the temperatures
at which these stages start and end may vary. The addition of an inert gas into the
primary chamber allows for better control and makes the behavior of the feedstock
more predictable.
According to certain embodiments, in addition to adding feedstock into the
primary chamber 1, milling media may also be added. Milling media may be any
used to crush or grind materials, such as balls, beads, cylinders, cut wire, or other
shaped materials, and may be formed of materials such as steel, aluminia oxide, metal
alloys, tungsten carbide, and the like. The mixing of milling media with the feedstock
assists in pulverizing the feedstock into a powder-like concentrate. This grinding
process may be helpful during the combined pyrolysis and gasification process as
well. Moreover, it may help remove the already gasified layers from the feedstock
and expose new layers making the process faster and more uniform.
As illustrated in Figures 1(A) and 1(B), a primary chamber exhaust duct 12 is
connected to the lid 11. During operation of the primary chamber 1 and the heating
chamber 2, toxic gases are produced within the primary chamber 1 from the feedstock.
The toxic gases may be removed via an exhaust system, starting at the lid 11. The
flow of gases then moves through the primary chamber exhaust duct 12, and then into
the secondary chamber 3.
Ultimately, the toxic gases and syngas may be expelled into the atmosphere or
can be captured and put back into the flow after reaching a secondary chamber 3. As
previously noted, the primary chamber section 105 is connected to the secondary
chamber 3 via the primary chamber exhaust duct 12. As illustrated in Figures 1(A)
and 1(B), there may be provided an explosion door 19 which serves as a safety device
in the event that the syngas produced becomes volatile. In certain embodiments the
explosion door 19 is a gravity held hatch that is allowed to freely open in the case of
a sudden increase of pressure inside the system. The explosion door 19 is sized to
allow venting of the rapidly expanding gases. The door can automatically reset itself
so as to minimize loss of gas from within the duct system (11, 12, 4, and 13).
Once the toxic gases and syngas reach the secondary chamber 3, they may
remain within the secondary chamber 3 for a minimum period of time, such as for
example for about 2 seconds. Once the time has elapsed, the gases may be exhausted
out to a heat exchanger or boiler, and then to an emissions filter system (not shown).
As illustrated in Figures 1(A) and 1(B), the secondary chamber 3 may be
provided on the secondary chamber section 110 of the gasifier system 100. The
secondary chamber 3 may include a syngas combustion air fan 7, which is connected
to the secondary chamber exhaust duct 13 by way of a syngas combustion air diffuser
18. The syngas combustion air diffuser 18 may be made of stainless steel. However,
in other embodiments, different materials may be used for forming the syngas
combustion air diffuser 18. During operation of the gasifier system 100, since the
produced syngas is combustible and is burned in the secondary chamber 3, the syngas
combustion air diffuser 18 may be configured to provide combustion air to the
secondary chamber 3 in order to burn the syngas. In particular, the combustion air
may be supplied by the syngas combustion air fan 7. Thus, in certain embodiments,
the secondary chamber 3 is where exothermic reaction of the syngas occurs.
According to certain embodiments, the secondary chamber 3 may have a round
tube shape, and the secondary chamber 3 may be fully insulated. In particular, the
secondary chamber 3 may be made up of a carbon steel outer shell and a high
temperature insulation inner layer. This inner layer may consist of any high
temperature insulation; for example ceramic fiber, refractory monoliths, or refractory
brick. During operation, the temperature within the secondary chamber 3 may be
maintained at a minimum temperature via a natural gas burner, such as burner 5b.
The length and diameter of the secondary chamber 3 may be set to give the syngas a
minimum of two second retention time in the hot environment before exiting. Further,
although Figures 1(A) and 1(B) illustrate only one primary chamber 1 and heating
chamber 2 of the primary chamber section 105, the secondary chamber 3 can be sized
to allow more than one primary chamber 1 and heating chamber 2 embodiment to
operate simultaneously. The sizing for such a secondary chamber may be based upon
the speed of the combined pyrolysis and gasification in the primary chamber 1 and
the expected calorific value of the feedstock. This calorific value can be calculated to
provide an equation of potential air flow through the system. The length and diameter
of the secondary chamber 3 must be such that the minimum 2 second retention time
is maintained at maximum syngas combustion. As illustrated in Figures 1(A) and
1(B) the design of the secondary chamber 3 may be cylindrical. Other shapes may be
utilized as long as the minimum retention time is maintained.
As illustrated in Figures 1(A) and 1(B), the secondary chamber section 110
may also include a draft control device 8. This draft control device 8 may provide a
negative draft to the exhaust system in certain embodiments, more specifically the lid
11. The draft control device 8 may consist of an educator type system, as illustrated
in Figure 1(B). It may also consist of one or more induction fans. In addition, the
secondary chamber section 110 may include another burner 5b disposed on a side face
of the secondary chamber 3, the side face being the same side that the syngas
combustion air fan 7 is disposed, and the side face being opposite another side face of
the secondary chamber 3 where the secondary stack 14 and educator air fan are
disposed. According to certain embodiments, support legs may be provided to
support the secondary chamber 3.
In certain embodiments, the gasifier system 100 as a whole may be transported.
For transportation, the gasifier system 100 may be disassembled into different
components which are then reassembled at a later time for system use.
Figure 2(A) illustrates a perspective view of the primary chamber 1 of Figures
1(A) and 1(B), including a cut-out interior view of the primary chamber 1 according
to certain embodiments. Further, Figure 2(B) illustrates a plan view of the interior of
the primary chamber 1 according to certain embodiments. As illustrated in Figure
2(A), the primary chamber 1 has an opening 201 at a top portion of the chamber. As
described above, the opening 201 provides a means for depositing feedstock into the
primary chamber 1. In addition, the opening 201 can be sealed by attachment of the
lid 11, and the opening 201 may be configured to allow loading and unloading of the
feedstock.
Figure 2(A) also illustrates that the primary chamber 1 has a top cone section
205, which forms a portion of the primary chamber 1 that is sealed by the lid 11.
Further, this cone section 205 may be insulated. This insulated cone section serves to
protect the seals both on the lid 11 as well as the heating chamber 2. In addition,
surrounding the top cone section 205 is an exhaust end support holder 210. The
exhaust end support holder 210 may serve as a mounting surface. In addition, as
illustrated in Figure 2(A), the primary chamber 1 may include tuyere pipes 215,
disposed on an exterior surface of the primary chamber 1. As further illustrated in
Figure 2(A), the tuyere pipes 215 also extend into the internal space of the primary
chamber 1 through a perimeter sidewall of the primary chamber 1.
As further illustrated in Figures 2(A) and 2(B), the primary chamber 1 may
include one or more heat transfer fins 235 that may transfer heat from the primary
chamber 1 to the heating chamber 2. In certain embodiments, the heat transfer fins
235 may be attached to the exterior surface of the primary chamber 1, and may extend
from the lower portion of the top cone section 205 to beneath a bottom surface of the
primary chamber 1 that is directly opposite the opening 201. The heat transfer fins
235 may also extend in a direction parallel to the length of the primary chamber 1.
The heat transfer fins 235 may further be rectangular flat bar welded to the outside of
the primary chamber 1 to increase the heat transfer surface area. According to certain
embodiments, the heat transfer fins 235 may be made of the same material as the
primary chamber 1. However, in other embodiments, different materials providing
the same or similar structural features may be used.
Further, extending from the bottom surface of the primary chamber 1 is a shaft
230. Attached to the shaft 230 is a lower seal hub 220 and a bottom bearing support
flange 225. In certain embodiments, the shaft 230 may be driven by the gearbox 9,
which in turn causes the primary chamber 1 to rotate. The lower seal hub 220 may
provide a seal between the rotating shaft 230 and the heating chamber 2. The bottom
bearing support flange 225 may consist of a drilled and tapped flange to accept a large
diameter 4-way ball bearing capable of supporting the loading primary chamber 1.
Figure 2(C) illustrates a side view of the primary chamber 1 according to
certain embodiments. As illustrated in Figure 2(C), the length L of the primary
chamber 1 (including the shaft 230 to which the lower seal hub 220 and the bottom
bearing support flange 225 are attached) may be from about 9 ft. Further, a length L
from the lower portion of the top cone section 205 to the bottom face of the primary
chamber may be about 5 ft. In addition, Figure 2(C) illustrate stiffeners 240 located
at a bottom end of the primary chamber 1. According to certain embodiments, the
stiffeners 240 may extend out radially from the shaft 230, and may provide structural
support of the primary chamber 1.
Figure 3(A) illustrates an internal cross-sectional view of the primary chamber
1 of Figures 1(A) – 2(C) according to certain embodiments. As illustrated in Figure
3(A), the primary chamber 1 may include one or more tuyere pipes 301 in the interior
of the primary chamber 1. For instance, in certain embodiments, the primary chamber
1 may include eight tuyere pipes 301. However, in other embodiments, more or less
tuyere pipes 301 may be used. In addition, according to certain embodiments, the
tuyere pipes 301 may be disposed in a circumferential direction of the primary
chamber 1 interior, and may surround a tuyere 305 located in the center of the primary
chamber 1 interior. As illustrated in Figure 3(A), the tuyere 305 may be connected to
the shaft 230 in order to provide means of injecting inert gas or combustion air into
the primary chamber 1.
Figure 3(B) illustrates an internal cross-sectional view of the primary chamber
1 along A-A of Figure 3(A) according to certain embodiments. Similar to Figure
3(A), Figure 3(B) illustrates an internal cross-section of the primary chamber 1 along
line A-A. In particular, Figure 3(B) illustrates heat transfer fins 310 disposed along
an outer circumferential surface of the primary chamber 1. In certain embodiments,
the primary chamber 1 may include sixteen fins, but is not limited to such a number
of fins. Also illustrated in Figure 3(B) are the tuyere pipes 301 disposed along an
interior circumferential surface of the primary chamber 1, and a chamber shell 315
that serves as an exterior surface of the primary chamber 1. Further, Figure 3(B)
illustrates a rotational movement of the primary shell in the direction of arrow 320
during operation, of with rotation direction may be determined by flight placement
and effective direction.
Figure 4 illustrates a method to reduce waste according to certain
embodiments. At 401, feedstock may be loaded into the primary chamber. This may
be done by rotating the heating/primary chamber assembly to its operating position,
and fitting and securing the lid the exhaust to the open end of the primary chamber.
Once the primary chamber has been sealed, the primary chamber may be loaded with
inert gas, and the heating/primary chamber assembly may be tilted at an angle to
facilitate processing of the feedstock. For instance, according to certain embodiments,
the heating/primary chamber assembly may be tilted at an angle of about 45°.
However, in other embodiments, the heating/primary chamber assembly may be tilted
at other useful angles depending on the type of feedstock deposited into the primary
chamber and the volume of feedstock deposited.
At 405, the secondary chamber may be brought up to temperature or heated up
during the loading process. However, in other embodiments, the secondary chamber
may already be at an acceptable temperature from a previous batch. According to
certain embodiments, the secondary chamber may be heated to a temperature range
of about 1000 °C to about 1100 °C.
At 410, the heating chamber may be heated and the primary chamber may be
rotated. As the heating chamber is heated, it indirectly heats the primary chamber.
Moreover, the rise in temperature of the primary chamber and heating chamber is
constantly monitored and may be controlled. Once the feedstock has reached a
temperature of about 500 – 600 °C, at 415, the temperature may be stabilized and the
rotation may commence for a controlled time depending on the type of feedstock and
volume of feedstock. As the primary chamber heats up, the feedstock begins to give
off gas in the form of syngas as it is being broken down.
At 420, the heating chamber burner 5a may be turned off, and the cooling fan
may be started. During the cooling process, rotation of the primary chamber may
continue. At 425, the secondary chamber may be turned off. Once the concentrate is
at a low enough temperature for safe handling, at 430, the lid may be pulled away
from the primary chamber, and the heating/primary component may be tipped into a
downward position to dump out the leftover concentrate.
During the process 410 and 415, the produced syngas is collected in the lid 11,
and burned in the secondary chamber 3, after which it is exhausted to the atmosphere
or filtered further in an emissions system.
Figure 5 illustrates an internal cross-sectional view of the primary chamber
including use of gas pipes to insert gases into the feedstock. Such inert gases may be
used for pyrolosis control, and may be hotter or colder than the feedstock contained
in the primary chamber.
The above-described embodiments provide significant improvements and
advantages over conventional methods and systems for processing waste. For
instance, according to certain embodiments, it may be possible to reduce e-waste to a
concentrated ore containing minerals, metals, and carbon. It may also be possible to
remove hydrocarbons and nonmetal and non-mineral components. According to
other embodiments, it may be possible to solve the need for cost effective,
environmentally superior, logistically decentralized capture and processing of a
hazardous waste stream of which currently only a small percentage is being managed.
It may further be possible to remove the negative consequences of e-waste storage,
landfill disposal, incineration, and pyro metallurgical refining. Likewise, the above-
described embodiments may reduce medical waste, killing harmful pathogens and
recycling materials contained in the medical waste.
According to other embodiments, it may be possible to enable the cessation of
the harmful effects on humans in emerging markets where informal dangerous metals
extraction processes are common. That is, use of the system for e-waste ensures
secure auditable data storage media destruction at decentralized locations. According
to certain embodiments, it may be possible to operate in a controlled temperature
environment to maximize the recoverability of more metals and minerals than current
higher temperature refinery solutions.
In yet further embodiments, it is not required to remove lithium ion batteries
from e-waste such as from phones and laptops, and other portable devices. According
to certain embodiments, it may also be possible to recycle lithium ion batteries,
process and digest whole phones, laptops, and other electronic devices, and provide a
process that involves less pre-processing than manual or pyro metallurgical processes
for e-waste.
According to other embodiments, it may be possible to use hydro-
metallurgical extract of previous metals such as gold, silver, and palladium using
small-scale relocatable refineries. It may further be possible to enable a clear, highly
concentrated post previous metals extraction residue to be refined with ease by copper
smelters, and those seeking to recover cobalt, iridium, barium, erbium,
praseodymium, and/or other rare earths.
Although the foregoing description is directed to the preferred embodiments
of the invention, it is noted that other variation and modifications will be apparent
to those skilled in the art, and may be made without departing from the spirit or
scope of the invention. Moreover, features described in connection with one
embodiment of the invention may be used in conjunction with other embodiments,
even if not explicitly stated above.
WE
Claims (11)
1. A waste processing method for a waste processing system, the waste processing system having a heating chamber, a primary chamber disposed within the heating chamber, a secondary chamber, and lid, the method comprising: loading feedstock into the primary chamber; heating the secondary chamber; heating the heating chamber with the feedstock inside; rotating the primary chamber while the primary chamber is being heated; cooling the heating chamber after the heating chamber is heated for a predetermined amount of time; removing leftover concentrate after heating the heating chamber for the predetermined amount of time collecting, in the lid, syngas produced while heating the heating chamber; sending the syngas from the primary chamber to the secondary chamber via a primary chamber exhaust duct connecting the primary chamber to the secondary chamber; burning the syngas in the secondary chamber; and exhausting the burned syngas out of the waste processing system via a secondary chamber exhaust duct connected to the secondary chamber.
2. The waste processing method according to claim 1, wherein loading the feedstock comprises: rotating the primary chamber and the heating chamber to an operating position; securing the lid to an open end of the primary chamber; loading the primary chamber with an inert gas; and tilting the heating chamber and the primary chamber to a predetermined angle to facilitate processing of the feedstock.
3. The waste processing method according to claim 1, wherein the secondary chamber is heated during the loading of the feedstock.
4. The waste processing method according to claim 1, further comprising heating the secondary chamber to a temperature range of about 1000 °C to about 1100 °C.
5. The waste processing method according to claim 1, wherein the temperature of the primary chamber and a timing of the rotation of the heating chamber are controlled based on feedstock type and feedstock volume.
6. The waste processing method according to claim 1, further comprising heating the feedstock to a temperature of about 500 °C to about 600 °C.
7. The waste processing method according to claim 1, wherein the method further comprises tilting the heating chamber and the primary chamber to an angle of about 45°.
8. The waste processing method according to claim 1, wherein the method further comprises cooling the heating chamber with a cooling air fan.
9. The waste processing method according to claim 1, wherein the rotation of the primary chamber is performed by driving a drive motor, which is attached to a bottom surface of the primary chamber and the heating chamber.
10. The waste processing method according to claim 1, wherein the feedstock comprises computer or electrical equipment, or medical waste items.
11. The waste processing method according to claim 1 substantially as herein described with reference to figures 1A – 5 and/or examples.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201762552080P | 2017-08-30 | 2017-08-30 | |
US62/552,080 | 2017-08-30 | ||
PCT/IB2018/056653 WO2019043632A1 (en) | 2017-08-30 | 2018-08-30 | Waste processing system |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ762264A NZ762264A (en) | 2021-01-29 |
NZ762264B2 true NZ762264B2 (en) | 2021-04-30 |
Family
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