US20070295248A1 - Energy and steel recovery system - Google Patents
Energy and steel recovery system Download PDFInfo
- Publication number
- US20070295248A1 US20070295248A1 US11/850,148 US85014807A US2007295248A1 US 20070295248 A1 US20070295248 A1 US 20070295248A1 US 85014807 A US85014807 A US 85014807A US 2007295248 A1 US2007295248 A1 US 2007295248A1
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- United States
- Prior art keywords
- suspension column
- column
- waste fuel
- suspension
- recovery system
- Prior art date
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- Abandoned
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Classifications
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- 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
- F23G5/24—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having a vertical, substantially cylindrical, combustion chamber
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- 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
- F23G5/44—Details; Accessories
- F23G5/442—Waste feed arrangements
- F23G5/444—Waste feed arrangements for solid waste
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- 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
- F23G5/44—Details; Accessories
- F23G5/46—Recuperation of heat
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
- F23G7/12—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of plastics, e.g. rubber
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES
- F23J1/00—Removing ash, clinker, or slag from combustion chambers
- F23J1/02—Apparatus for removing ash, clinker, or slag from ash-pits, e.g. by employing trucks or conveyors, by employing suction devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23K—FEEDING FUEL TO COMBUSTION APPARATUS
- F23K3/00—Feeding or distributing of lump or pulverulent fuel to combustion apparatus
- F23K3/16—Over-feed arrangements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2209/00—Specific waste
- F23G2209/28—Plastics or rubber like materials
- F23G2209/281—Tyres
Definitions
- This invention relates to improvements in energy and steel recovery systems. More particularly, the invention relates to a system for recovering energy and steel through combustion of tires in suspension in a slipstream of a high energy user.
- This invention allows an efficient use of the heating power of waste materials, preferably solids such as whole vehicle tires, and also other waste materials in bulk or crushed form to reduce fuel consumption expenses in large capacity boiler systems.
- Tires while being suspended in the gas stream by a number of forks that would methodically retract, would combust as they progress down the inside of the column, counter current to the gas stream. The heat generated by the tire combustion would then be recovered in the boiler and the steel and any ash would be removed at the bottom of the column for ultimate recycling or disposal.
- An object of the invention is to improve energy recovery in the combustion of waste fuel.
- Another object is to improve the method of recovery of energy in combustion of waste fuel in a column through gasification and a controlled movement of vaporized and residual byproducts into a combustion zone of a boiler so that the radiant energy of the waste fuel is recovered in the boiler, thereby eliminating ash in the column and providing a higher quality of steel produced.
- a further object is to provide a system and method for waste fuel fractionation.
- Yet another object of the invention is to improve boiler technology.
- Another object is to improve efficiency of boiler technology.
- Still another objective of this invention is to enhance the process in which waste material is burned within a suspension system.
- the invention is directed to an energy and steel recovery system.
- the system has a suspension column and a plurality of suspension burners operably disposed in the suspension column wherein the burners are spaced from one another along the length of the suspension column.
- the suspension column includes means for receiving the combustible material onto one of the burners and feeding, e.g., via gravity feeding, the combustible material to an adjacent downwardly disposed burner to further combust the combustible material.
- a first conduit includes a first end communicably connected to a heated air path of the suspension column and a second end communicably connected to an outflow air path of a boiler wherein air flow passes from the outflow air path of the boiler to heated air flow path of the suspension column.
- a second conduit includes a first end communicably connected to the heated air flow path of the suspension column and a second end communicably connected to a return air flow path of the boiler wherein air flow passes from the heated air flow path of the suspension column to the return air flow path of the boiler.
- the boiler can include a combustion zone and an economizer with dual economizers feeding heat and oxygen to a lower end of the column.
- the system further includes means for removing residual combusted and noncombustible waste materials from the suspension column.
- the suspension column can be equipped with an outer air passage jacket surrounding an inner column wall to which the first and second conduits are communicably connected.
- air or other medium enters the jacket and passes through the jacket being heated from the outer surface of the inner wall without mixing with air from the combustion occurring within the inner wall.
- Each suspension burner includes a plurality of support fingers each having a waste derived fuel support surface which is removably disposed in the suspension column to provide for self cleaning of the support surface of the fingers upon removal from the suspension column.
- the suspension burner includes means for automatically retracting the fingers from the column. Further, means for automatically feeding the waste material on to the fingers of the suspension burner are provided.
- a conduit 83 can be connected to the upper portion of the column to remove hot organic vapor and fixed carbon particulate to a cyclone which passes gas and fixed carbon particulate to the combustion zone of the boiler.
- a CO 2 removal apparatus can be operably connected to the cyclone to remove CO 2 from the gas reflux to the column further reducing the emissions of the process.
- the present invention is particularly useful in providing additional heating energy to high energy user systems, such as boilers and using a novel a structure and method and provides an automated feed of waste materials, preferably tires, into a suspension column. Upon burning tires, residual metals from within the tires pass by virtue of their weight and gravity to the residual waste removal means where the metals, i.e., steel wires from tires can be removed.
- waste materials preferably tires
- the alternative waste energy including at least partially combustible organic-containing waste can provide a substantial amount of the heat required for heating high energy user systems, such as a boiler. Novelty of the invention will be apparent hereinafter as discussed more fully below and other objectives and advantages of this invention will be apparent from reading the drawings and description hereinafter.
- FIG. 1 is a side elevation diagrammatic view embodying the invention, especially the suspension column with suspension burners.
- FIG. 2A is a view illustrating a first mode of a burner of the instant invention.
- FIG. 2B is a view illustrating a second mode of the burner of FIG. 2A .
- FIG. 3A is another view illustrating the second mode of the invention.
- FIG. 3B is a view illustrating a third mode of the burner of the instant invention wherein combusted material has moved to a lower burner.
- FIG. 3C is a view illustrating a fourth mode of the burner of the instant invention wherein combusted material has moved to a recovery conveyor.
- FIG. 4 is a perspective view of a burner of the instant invention.
- FIG. 5 is a side elevation diagrammatic view embodying the invention test unit.
- FIG. 6 is a side elevation diagrammatic view embodying another aspect of the invention.
- FIG. 7 is a side elevation diagrammatic view embodying still another aspect of the invention.
- an energy and steel recovery system is generally referred to by the numeral 10 .
- the present invention provides an improved way to recover the energy in the waste fuel, such as a tire(s) 12 , by gasifying the tire and moving both the tire's vaporized organics and fixed carbon into the combustion zone 73 of a boiler 72 . Radiant energy of the tire is recovered in the boiler 72 eliminating ash in a column 14 and a higher quality of steel is produced.
- the column 14 is configured to provide for a number of zones 101 , 102 , 103 , 104 and 105 including heating, drying, volatizing, combusting and ashing, respectively.
- Tires 12 can be fractionated under low oxygen, high velocity and high temperature, i.e., approximately 1,100° F. conditions, producing a gaseous and solid fuel for the boiler 72 while producing no negative effects to the boiler 72 and generating a high quality of residual recyclable steel from the tire 12 .
- the energy and steel recovery system is generally referred to by the numeral 10 .
- the alternative fuel which can preferably be combustible waste tires 12 , is fed to a suspension column 14 by feeding means 16 .
- the suspension column 14 can preferably include and one or more, preferably a plurality of suspension burners 18 A, 18 B, 18 C, 18 D, 18 E, 18 F, 18 G, 18 H, 18 I, 18 J, 18 L, 18 M which are operably disposed in the suspension column 14 wherein the suspension burners 18 A, 18 B, 18 C, 18 D, 18 E, 18 F, 18 G, 18 H, 18 I, 18 J, 18 L, 18 M are spaced from one another along the vertical length of the suspension column 14 .
- the number of suspension burners 18 A, 18 B, 18 C, 18 D, 18 E, 18 F, 18 G, 18 H, 18 I, 18 J, 18 L, 18 M and spacing therebetween can be varied to accommodate the length and size of the suspension column 14 as well as the material to be combusted and to accomplish fractionation.
- spacing can be to provide that the tires 12 be readily removable from an upwardly disposed suspension burner 18 A to burner 18 B and so on.
- Each of the suspension burners 18 A, 18 B, 18 C, 18 D, 18 E, 18 F, 18 G, 18 H, 18 I, 18 J, 18 L, 18 M can be similar in design and operation and like numbers are intended to describe like parts with the exception that burner 18 A is connected to additional components described hereinafter.
- suspension burner 18 A connects to housing 24 which includes an exterior gate 20 and an interior gate or door 22 which provide an airlock during injection of tire 12 into the suspension column 14 .
- the exterior gate 20 is opened while the interior gate 22 is closed to pass waste derived fuel material into a burner housing 24 .
- the exterior gate 20 is closed while the interior gate 22 is opened to pass tires 12 from burner housing 24 into the suspension column 14 . This is illustrated in FIGS. 2A-4 .
- the suspension burner 18 A includes a plurality of support fingers 26 A each having a waste support surface 28 A which are removably disposed in the suspension column 14 through slotted open surface 32 A to provide for self cleaning of the support surface 28 A of the fingers 26 A upon removal from the column 14 .
- slotted surfaces 32 A can be formed in a face of the column 14 through which the fingers 26 A move back and forth to effect the removal of the residual waste 13 .
- the suspension burner 18 A includes means 30 A for automatically retracting the fingers 26 A from the column 14 .
- the means 30 A can include a motor 31 A and a linear actuator 33 A which is operably interconnected to the movable housing 52 and fingers 26 A.
- the means 30 A sit on a platform 56 .
- Feeding means 16 are provided for automatically feeding the tires 12 to the burner 18 A onto the fingers 26 A of the suspension burner 18 A.
- Feeding means 16 can include an inclined elevator belt 34 wherein the tires 12 are placed and elevated thereby to the housing 24 through gate 20 .
- a truck ramp 36 is operably disposed adjacent a trailer tipper 38 for enabling dumping tires 12 into a hopper 40 .
- a rotating disk tire separator 42 is operably disposed to the hopper 40 and separates tires 12 into an accumulator 44 for inspection. Unsuitable tires can rejected onto a reject conveyor belt (not shown), while accepted tires 12 are fed onto the inclined conveyor belt 34 .
- Such feed is controlled by means of a controller 46 which is operably connected to a sensor 48 located in the suspension column 14 to sense when the conditions are suitable for combustion to take place for the next in line tire 12 .
- a linear actuated ram 50 is partially operably disposed in housing 52 and casing 54 connected to the housing 24 and is controllably moved back and forth through burner housing 24 .
- the controller 46 receives a signal to feed a tire 12 and initiate the ram 50 to push the tire 12 from the burner housing 24 into the suspension column 14 and onto the suspension fingers 26 A.
- the tire 12 is burned within the suspension column 14 .
- Tires 12 may also be introduced mechanically onto the suspension burner 18 A by other means such as a screw feed or other similar device (not shown).
- the boiler 72 can include combustion zone 73 and an economizer zone 75 with dual economizers feeding heat and oxygen to a lower end of the column 14 .
- Boiler 72 can be equipped with one or more slip streams of hot gases taken from economizer zone 75 of boiler 72 and introduced into a lower end of the column 14 as seen in FIG. 7 .
- the tire(s) 12 is exposed to the hot gas stream until the rubber is gasified and subjected to the fractionation process.
- a vent 82 from the column 14 can be routed back to the boiler combustion zone 73 as a fuel supplement.
- conduit 83 which can be connected to the upper portion of the column 14 to remove hot organic vapor and fixed carbon particulate to a cyclone 85 which passes gas and fixed carbon particulate to the combustion zone 73 of the boiler 72 .
- a CO 2 removal apparatus 87 can be operably connected to the cyclone 85 to remove CO 2 from the gas reflux 89 to the column 14 further providing lower emissions for the boiler 72 .
- the fuel stream from the gasification of the tire 12 was sampled and analyzed for flow rate (velocity), temperature, moisture, molecular weight, heat content, gas density, semi-volatile organics speciation, volatile organics speciation, hydrogen sulfide (H 2 S), carbon monoxide (CO), carbon dioxide (CO 2 ), nitrogen oxides (NO x ), total organic carbon (TOC), oxygen (O 2 ), and absolute pressure under varying scenarios.
- the inlet of the chamber was monitored for flow rate (velocity), temperature, and O 2 .
- FIGS. 3A-3C show several of the steps of wherein the tires 12 are burned and residual of tires 12 is further gravity fed, such as to a lower burner 18 B and ultimately dispensed onto a drop-out conveyor 58 which can be a chain drag out assembly operably disposed in a vessel 59 .
- a water seal 61 can be provided by virtue of inner column wall 80 of column 14 extending below water level. In this way, the introduction of tramp air is isolated from entering the combustion zone and the system 10 only introduces slip stream air from boiler 72 as is apparent herein.
- a steel or metal roll-off container 60 and residual ash roll-off container 62 are provided wherein the conveyor 58 can be equipped to automatically separate the residual ash and metal, such as via incorporating a magnetic conveyor.
- first conduit 64 includes a first end 66 which can be communicably connected to a heated air flow path defined by an annular jacket 68 of the suspension column 14 and a second end 70 communicably connected to an outflow air path of a high energy consumption device, such as a boiler 72 , wherein air flow passes from the boiler 72 to the jacket 68 .
- a second conduit 74 includes a first end 76 communicably connected to the heated air flow path of the jacket 68 and a second end 78 communicably connected to a return air flow path of the boiler 72 wherein air flow passes from the jacket 68 to the boiler 72 . It is contemplated that the column 14 and jacket 68 can be used for hot air, steam or hot oil to recover heat generated.
- the embodiment shown in FIG. 1 shows that the suspension column 14 can be equipped with the outer air passage jacket 68 surrounding an inner column wall 80 , although it is envisioned that other air channels can be configured. In this way, the air enters the jacket 68 and passes therethrough being heated from the outer surface of the inner wall 80 without mixing air from combustion occurring within the inner wall 80 .
- the system 10 includes air blowers 81 of the type known to circulate air through the described air flow path. Also, vent 82 is provided on the column 14 and conduit 83 connects through jacket 68 to column 14 . In this regard, a slip stream of the boiler 72 combustion gases can be fed through conduit 83 and fed back to the boiler 72 as described. Thus, heat is recovered from the jacket 68 as well as boiler 72 through reintroduction of combustion gases and there provides a heat recovery boiler.
- the first condition consisted of the introduction of a quarter tire into the gasification unit under a high temperature, low oxygen and high velocity condition.
- the second condition consisted of the introduction of a whole tire into the tire gasification unit under the same high temperature, low oxygen and high velocity settings conducted during the first condition.
- the third test condition consisted of the introduction of one whole tire into the unit under high temperature, low oxygen and low airflow conditions. After the first tire was gasified, a second tire was immediately introduced into the unit.
- the tire gasification inlet stack was sampled for stack gas velocity, temperature, O 2 and CO 2 content.
- the tire gasification outlet stack was sampled for stack gas velocity, temperature, semi-volatile organic compounds, volatile organic compounds, hydrogen sulfide, fuel density, heat content, and gaseous pollutants (O 2 , CO 2 , NO x , CO, VOC). Results of the test are as follows.
- the invention thus provides for recovery the energy in the tire via gasification of the tire under low oxygen, high velocity and approximately 1,100° F. conditions.
- the present system 10 can extract the slip stream gas from the boiler's economizers 75 at one or more points in order to be able to temper the inlet temperature and use the waste heat and low oxygen of the existing process to supply the operating conditions desired.
- An induced draft fan 77 can be installed where needed, e.g., on the exit side of the single tire column, to pull the hot gasses through the column and force the fuel gas and fixed carbon into the combustion zone 73 of the boiler 72 .
- tires 12 can be fractionated under low oxygen and high temperature, approximately 1,100° F. conditions, producing a gaseous and solid fuel for the boiler while producing no negative effects to the boiler and generating a high quality of recyclable steel.
- the gasses generated from the tires 12 are concentrated by refluxing a portion of the overhead stream back into the vaporization zone 102 of the column 14 .
- the fixed carbon fraction is separated from the overhead stream by an inline cyclone 85 and then reintroduced into the fuel feed duct 92 to the boiler 72 .
- a delumper or grinder 94 will be located at the bottom of the cyclone 85 in order to size the solids before they are sent to the boiler 72 for optimum combustion.
- Tire Derived Fuel (TDF) is being successfully utilized worldwide as a supplemental fuel in coal burning operations.
Abstract
Description
- This is a continuation-in-part of U.S. Ser. No. 10/908,525 filed May 16, 2005.
- This invention relates to improvements in energy and steel recovery systems. More particularly, the invention relates to a system for recovering energy and steel through combustion of tires in suspension in a slipstream of a high energy user. This invention allows an efficient use of the heating power of waste materials, preferably solids such as whole vehicle tires, and also other waste materials in bulk or crushed form to reduce fuel consumption expenses in large capacity boiler systems.
- Alternative waste derived fuels have been operably disposed within a pyrolysis chamber or a riser duct of a kiln. The use of such waste products is a function of the burning environment, for example, the amount of heat required and oxygen content within the chamber or kiln. Tires are currently being made use of alternative fuels to reduce usage of traditional fuels. Tires have been found to be highly suitable. In co-pending U.S. application Ser. No. 10/908,525, there is introduced a concept to inject tires into a column that was located next to a utility steam generator and combust them in a slipstream of gas drawn from the boiler. Tires, while being suspended in the gas stream by a number of forks that would methodically retract, would combust as they progress down the inside of the column, counter current to the gas stream. The heat generated by the tire combustion would then be recovered in the boiler and the steel and any ash would be removed at the bottom of the column for ultimate recycling or disposal.
- There remains a need to improve such technology to provide a highly efficient, easily operated, low cost, system for using such fuels.
- An object of the invention is to improve energy recovery in the combustion of waste fuel.
- Another object is to improve the method of recovery of energy in combustion of waste fuel in a column through gasification and a controlled movement of vaporized and residual byproducts into a combustion zone of a boiler so that the radiant energy of the waste fuel is recovered in the boiler, thereby eliminating ash in the column and providing a higher quality of steel produced.
- A further object is to provide a system and method for waste fuel fractionation.
- Yet another object of the invention is to improve boiler technology.
- Another object is to improve efficiency of boiler technology.
- Still another objective of this invention is to enhance the process in which waste material is burned within a suspension system.
- Accordingly, the invention is directed to an energy and steel recovery system. The system has a suspension column and a plurality of suspension burners operably disposed in the suspension column wherein the burners are spaced from one another along the length of the suspension column. The suspension column includes means for receiving the combustible material onto one of the burners and feeding, e.g., via gravity feeding, the combustible material to an adjacent downwardly disposed burner to further combust the combustible material. More specifically, the column is configured to provide for a number of zones including heating, drying, volatizing, combusting and ashing which are collectively referred to herein as a “fractionation process.” A first conduit includes a first end communicably connected to a heated air path of the suspension column and a second end communicably connected to an outflow air path of a boiler wherein air flow passes from the outflow air path of the boiler to heated air flow path of the suspension column. A second conduit includes a first end communicably connected to the heated air flow path of the suspension column and a second end communicably connected to a return air flow path of the boiler wherein air flow passes from the heated air flow path of the suspension column to the return air flow path of the boiler. In this regard, the boiler can include a combustion zone and an economizer with dual economizers feeding heat and oxygen to a lower end of the column. The system further includes means for removing residual combusted and noncombustible waste materials from the suspension column.
- Preferably, the suspension column can be equipped with an outer air passage jacket surrounding an inner column wall to which the first and second conduits are communicably connected. In this way, air or other medium enters the jacket and passes through the jacket being heated from the outer surface of the inner wall without mixing with air from the combustion occurring within the inner wall. Each suspension burner includes a plurality of support fingers each having a waste derived fuel support surface which is removably disposed in the suspension column to provide for self cleaning of the support surface of the fingers upon removal from the suspension column. Preferably, the suspension burner includes means for automatically retracting the fingers from the column. Further, means for automatically feeding the waste material on to the fingers of the suspension burner are provided.
- A
conduit 83 can be connected to the upper portion of the column to remove hot organic vapor and fixed carbon particulate to a cyclone which passes gas and fixed carbon particulate to the combustion zone of the boiler. A CO2 removal apparatus can be operably connected to the cyclone to remove CO2 from the gas reflux to the column further reducing the emissions of the process. - The present invention is particularly useful in providing additional heating energy to high energy user systems, such as boilers and using a novel a structure and method and provides an automated feed of waste materials, preferably tires, into a suspension column. Upon burning tires, residual metals from within the tires pass by virtue of their weight and gravity to the residual waste removal means where the metals, i.e., steel wires from tires can be removed. With the use of the invention, it is contemplated that the alternative waste energy including at least partially combustible organic-containing waste can provide a substantial amount of the heat required for heating high energy user systems, such as a boiler. Novelty of the invention will be apparent hereinafter as discussed more fully below and other objectives and advantages of this invention will be apparent from reading the drawings and description hereinafter.
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FIG. 1 is a side elevation diagrammatic view embodying the invention, especially the suspension column with suspension burners. -
FIG. 2A is a view illustrating a first mode of a burner of the instant invention. -
FIG. 2B is a view illustrating a second mode of the burner ofFIG. 2A . -
FIG. 3A is another view illustrating the second mode of the invention. -
FIG. 3B is a view illustrating a third mode of the burner of the instant invention wherein combusted material has moved to a lower burner. -
FIG. 3C is a view illustrating a fourth mode of the burner of the instant invention wherein combusted material has moved to a recovery conveyor. -
FIG. 4 is a perspective view of a burner of the instant invention. -
FIG. 5 is a side elevation diagrammatic view embodying the invention test unit. -
FIG. 6 is a side elevation diagrammatic view embodying another aspect of the invention. -
FIG. 7 is a side elevation diagrammatic view embodying still another aspect of the invention. - Referring now to the drawings, an energy and steel recovery system is generally referred to by the
numeral 10. The present invention provides an improved way to recover the energy in the waste fuel, such as a tire(s) 12, by gasifying the tire and moving both the tire's vaporized organics and fixed carbon into thecombustion zone 73 of aboiler 72. Radiant energy of the tire is recovered in theboiler 72 eliminating ash in acolumn 14 and a higher quality of steel is produced. Thecolumn 14 is configured to provide for a number ofzones Tires 12 can be fractionated under low oxygen, high velocity and high temperature, i.e., approximately 1,100° F. conditions, producing a gaseous and solid fuel for theboiler 72 while producing no negative effects to theboiler 72 and generating a high quality of residual recyclable steel from thetire 12. - A sample of ash produced by the process was collected and analyzed. It contained no detectable Mercury, 12,300 mg/Kg of Zinc and conformed to ERA standards for metals, VOC and SVOC TCLP testing. Because tires, with the provision of a higher BTU value and a higher Zinc content, compare favorable with coal, Tire Derived Fuel (TDF) can be utilized worldwide as a supplemental fuel in coal burning operations.
- The energy and steel recovery system is generally referred to by the numeral 10. The alternative fuel, which can preferably be
combustible waste tires 12, is fed to asuspension column 14 by feedingmeans 16. Thesuspension column 14 can preferably include and one or more, preferably a plurality ofsuspension burners suspension column 14 wherein thesuspension burners suspension column 14. The number ofsuspension burners suspension column 14 as well as the material to be combusted and to accomplish fractionation. For example, spacing can be to provide that thetires 12 be readily removable from an upwardlydisposed suspension burner 18A toburner 18B and so on. Each of thesuspension burners burner 18A is connected to additional components described hereinafter. - In this regard,
suspension burner 18A connects to housing 24 which includes anexterior gate 20 and an interior gate ordoor 22 which provide an airlock during injection oftire 12 into thesuspension column 14. Theexterior gate 20 is opened while theinterior gate 22 is closed to pass waste derived fuel material into aburner housing 24. Theexterior gate 20 is closed while theinterior gate 22 is opened to passtires 12 fromburner housing 24 into thesuspension column 14. This is illustrated inFIGS. 2A-4 . - The
suspension burner 18A includes a plurality ofsupport fingers 26A each having awaste support surface 28A which are removably disposed in thesuspension column 14 through slottedopen surface 32A to provide for self cleaning of thesupport surface 28A of thefingers 26A upon removal from thecolumn 14. In this regard, slottedsurfaces 32A can be formed in a face of thecolumn 14 through which thefingers 26A move back and forth to effect the removal of the residual waste 13. - Preferably, the
suspension burner 18A includes means 30A for automatically retracting thefingers 26A from thecolumn 14. The means 30A can include amotor 31A and alinear actuator 33A which is operably interconnected to themovable housing 52 andfingers 26A. The means 30A sit on aplatform 56. - As for the
feeding tires 12, means 16 are provided for automatically feeding thetires 12 to theburner 18A onto thefingers 26A of thesuspension burner 18A. Feeding means 16 can include aninclined elevator belt 34 wherein thetires 12 are placed and elevated thereby to thehousing 24 throughgate 20. Atruck ramp 36 is operably disposed adjacent atrailer tipper 38 for enabling dumpingtires 12 into ahopper 40. A rotatingdisk tire separator 42 is operably disposed to thehopper 40 and separatestires 12 into anaccumulator 44 for inspection. Unsuitable tires can rejected onto a reject conveyor belt (not shown), while acceptedtires 12 are fed onto theinclined conveyor belt 34. Such feed is controlled by means of acontroller 46 which is operably connected to asensor 48 located in thesuspension column 14 to sense when the conditions are suitable for combustion to take place for the next inline tire 12. - As seen in
FIGS. 2A and 2B , a linear actuatedram 50 is partially operably disposed inhousing 52 andcasing 54 connected to thehousing 24 and is controllably moved back and forth throughburner housing 24. Thecontroller 46 receives a signal to feed atire 12 and initiate theram 50 to push thetire 12 from theburner housing 24 into thesuspension column 14 and onto thesuspension fingers 26A. Thetire 12 is burned within thesuspension column 14.Tires 12 may also be introduced mechanically onto thesuspension burner 18A by other means such as a screw feed or other similar device (not shown). - In this regard, the
boiler 72 can includecombustion zone 73 and aneconomizer zone 75 with dual economizers feeding heat and oxygen to a lower end of thecolumn 14.Boiler 72 can be equipped with one or more slip streams of hot gases taken fromeconomizer zone 75 ofboiler 72 and introduced into a lower end of thecolumn 14 as seen inFIG. 7 . The tire(s) 12 is exposed to the hot gas stream until the rubber is gasified and subjected to the fractionation process. As seen inFIG. 6 andFIG. 7 , avent 82 from thecolumn 14 can be routed back to theboiler combustion zone 73 as a fuel supplement. This is accomplished by providingconduit 83 which can be connected to the upper portion of thecolumn 14 to remove hot organic vapor and fixed carbon particulate to acyclone 85 which passes gas and fixed carbon particulate to thecombustion zone 73 of theboiler 72. A CO2 removal apparatus 87 can be operably connected to thecyclone 85 to remove CO2 from the gas reflux 89 to thecolumn 14 further providing lower emissions for theboiler 72. The fuel stream from the gasification of thetire 12 was sampled and analyzed for flow rate (velocity), temperature, moisture, molecular weight, heat content, gas density, semi-volatile organics speciation, volatile organics speciation, hydrogen sulfide (H2S), carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOx), total organic carbon (TOC), oxygen (O2), and absolute pressure under varying scenarios. The inlet of the chamber was monitored for flow rate (velocity), temperature, and O2. -
FIGS. 3A-3C show several of the steps of wherein thetires 12 are burned and residual oftires 12 is further gravity fed, such as to alower burner 18B and ultimately dispensed onto a drop-outconveyor 58 which can be a chain drag out assembly operably disposed in avessel 59. Awater seal 61 can be provided by virtue ofinner column wall 80 ofcolumn 14 extending below water level. In this way, the introduction of tramp air is isolated from entering the combustion zone and thesystem 10 only introduces slip stream air fromboiler 72 as is apparent herein. A steel or metal roll-offcontainer 60 and residual ash roll-offcontainer 62 are provided wherein theconveyor 58 can be equipped to automatically separate the residual ash and metal, such as via incorporating a magnetic conveyor. - As generally conceived,
first conduit 64 includes afirst end 66 which can be communicably connected to a heated air flow path defined by anannular jacket 68 of thesuspension column 14 and asecond end 70 communicably connected to an outflow air path of a high energy consumption device, such as aboiler 72, wherein air flow passes from theboiler 72 to thejacket 68. Asecond conduit 74 includes afirst end 76 communicably connected to the heated air flow path of thejacket 68 and asecond end 78 communicably connected to a return air flow path of theboiler 72 wherein air flow passes from thejacket 68 to theboiler 72. It is contemplated that thecolumn 14 andjacket 68 can be used for hot air, steam or hot oil to recover heat generated. - The embodiment shown in
FIG. 1 shows that thesuspension column 14 can be equipped with the outerair passage jacket 68 surrounding aninner column wall 80, although it is envisioned that other air channels can be configured. In this way, the air enters thejacket 68 and passes therethrough being heated from the outer surface of theinner wall 80 without mixing air from combustion occurring within theinner wall 80. Thesystem 10 includesair blowers 81 of the type known to circulate air through the described air flow path. Also, vent 82 is provided on thecolumn 14 andconduit 83 connects throughjacket 68 tocolumn 14. In this regard, a slip stream of theboiler 72 combustion gases can be fed throughconduit 83 and fed back to theboiler 72 as described. Thus, heat is recovered from thejacket 68 as well asboiler 72 through reintroduction of combustion gases and there provides a heat recovery boiler. - Samplings were performed under three different process conditions. The first condition consisted of the introduction of a quarter tire into the gasification unit under a high temperature, low oxygen and high velocity condition. The second condition consisted of the introduction of a whole tire into the tire gasification unit under the same high temperature, low oxygen and high velocity settings conducted during the first condition. The third test condition consisted of the introduction of one whole tire into the unit under high temperature, low oxygen and low airflow conditions. After the first tire was gasified, a second tire was immediately introduced into the unit.
- The tire gasification inlet stack was sampled for stack gas velocity, temperature, O2 and CO2 content. The tire gasification outlet stack was sampled for stack gas velocity, temperature, semi-volatile organic compounds, volatile organic compounds, hydrogen sulfide, fuel density, heat content, and gaseous pollutants (O2, CO2, NOx, CO, VOC). Results of the test are as follows.
- The invention thus provides for recovery the energy in the tire via gasification of the tire under low oxygen, high velocity and approximately 1,100° F. conditions. The
present system 10 can extract the slip stream gas from the boiler'seconomizers 75 at one or more points in order to be able to temper the inlet temperature and use the waste heat and low oxygen of the existing process to supply the operating conditions desired. An induced draft fan 77 can be installed where needed, e.g., on the exit side of the single tire column, to pull the hot gasses through the column and force the fuel gas and fixed carbon into thecombustion zone 73 of theboiler 72. - Several tests were performed. The first day of operation the unit was run in a high velocity mode. The second day, the velocity was reduced in order to collect data on how important the velocity was to the process.
- With a quarter tire weighing 3.6 pounds, under 4% oxygen and a gas stream of 1,149° F., the tire was reduced to 0.40 pounds of steel (88.88% reduction) in 10 minutes. All of the heat value of the tire was passed into the boiler's combustion zone including both the vapor and fixed carbon.
- A whole tire weighing 18.68 pounds was then introduced into the unit and under 4% oxygen and a gas stream of 1,168° F., it was reduced to 1.96 pounds of steel (92.40% reduction) in 9 minutes. The ashing of the rubber was stopped and 1.42 pounds of ash was collected and analyzed. The heat value of the ash was 4,867 BTU/pound.
- The next day two tires, totaling 37.48 pounds, were introduced 11 minutes apart into 4% oxygen and 1,181° F. conditions. The two tires were reduced to 3.72 pounds of steel (90.07% reduction) in 23 minutes.
- Observations
- It is found that the low oxygen conditions did not allow for the combustible products in the
tires 12 to burn. It is also found that the elevated temperatures were adequate to vaporize the organic volatile component in the rubber. Finally, it is found that high velocities were necessary in order to draw the fixed carbon component of thetires 12 off of the tire wire, out of the singletire test column 14 and into thecombustion zone 73 of the boiler. Thus the radiant energy of the tire was recovered in theboiler 72, no ash was left in thecolumn 14 and a higher quality of steel was produced. The invention thus provided a new process “tire fractionation.” It was also observed that the process proceeded in five individual steps: -
- 1) HEAT→2) DRY→3) VOLATILIZE→4) COMBUST→5) ASH
- It is determined that under the correct conditions the rate at which the
tires 12 fractionate are independent of their weights. (In other words, the quarter tire broke down in the same amount of time as the whole tire.) In general they follow the following timings:Heat 1 Minute Dry 1-2 Minutes Volatilize 2-3 Minutes Combust 4 Minutes Ash 1 Minute Start to Finish 9-11 Minutes -
- Also a sample of the ash produced by the process was collected and analyzed. It contained no detectable Mercury, 12,300 mg/Kg of Zinc, as expected, and conformed to EPA standards for metals, VOC and SVOC TCLP testing. No apparent reason exists that this ash added to the boiler's ash would be detrimental to the boilers operation such as a slagging factor.
- This test showed that
tires 12 can be fractionated under low oxygen and high temperature, approximately 1,100° F. conditions, producing a gaseous and solid fuel for the boiler while producing no negative effects to the boiler and generating a high quality of recyclable steel. - In one aspect of the invention, the gasses generated from the
tires 12 are concentrated by refluxing a portion of the overhead stream back into thevaporization zone 102 of thecolumn 14. Also, the fixed carbon fraction is separated from the overhead stream by aninline cyclone 85 and then reintroduced into the fuel feed duct 92 to theboiler 72. A delumper orgrinder 94 will be located at the bottom of thecyclone 85 in order to size the solids before they are sent to theboiler 72 for optimum combustion. - Because
tires 12, with the exception of a higher BTU value and a higher Zinc content, compare favorable with coal, Tire Derived Fuel (TDF) is being successfully utilized worldwide as a supplemental fuel in coal burning operations. - The above described embodiments are set forth by way of example and are not for the purpose of limiting the present invention. It will be readily apparent to those skilled in the art that obvious modifications, derivations and variations can be made to the embodiments without departing from the scope of the invention. Accordingly, the claims appended hereto should be read in their full scope including any such modifications, derivations and variations.
Claims (22)
Priority Applications (2)
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US11/850,148 US20070295248A1 (en) | 2005-05-16 | 2007-09-05 | Energy and steel recovery system |
US12/862,822 US8789480B2 (en) | 2005-05-16 | 2010-08-25 | Energy and steel recovery system |
Applications Claiming Priority (2)
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US10/908,525 US7647874B2 (en) | 2005-05-16 | 2005-05-16 | Energy and steel recovery system |
US11/850,148 US20070295248A1 (en) | 2005-05-16 | 2007-09-05 | Energy and steel recovery system |
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US10/908,525 Continuation-In-Part US7647874B2 (en) | 2005-05-16 | 2005-05-16 | Energy and steel recovery system |
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US10/908,525 Continuation-In-Part US7647874B2 (en) | 2005-05-16 | 2005-05-16 | Energy and steel recovery system |
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US20070295248A1 true US20070295248A1 (en) | 2007-12-27 |
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US11/850,148 Abandoned US20070295248A1 (en) | 2005-05-16 | 2007-09-05 | Energy and steel recovery system |
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WO2012027388A1 (en) * | 2010-08-25 | 2012-03-01 | Symbiotic Technology, Llc | Energy and steel recovery system |
CN103339444A (en) * | 2010-10-07 | 2013-10-02 | Afs技术有限责任公司 | Solid fuel skewer suspension burning system |
US9784502B2 (en) | 2012-03-05 | 2017-10-10 | Afs Technology, Llc | Solid fuel skewer suspension burning system |
US11085631B1 (en) * | 2015-12-08 | 2021-08-10 | Original Pellet Grill Company Llc | Wood pellet burner unit with sliding floor hopper |
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