US20140259923A1 - Apparatus, system, and method for processing materials - Google Patents

Apparatus, system, and method for processing materials Download PDF

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Publication number
US20140259923A1
US20140259923A1 US14/196,067 US201414196067A US2014259923A1 US 20140259923 A1 US20140259923 A1 US 20140259923A1 US 201414196067 A US201414196067 A US 201414196067A US 2014259923 A1 US2014259923 A1 US 2014259923A1
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feedstock
chamber
endothermic
processing
endothermic chamber
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John E. Blair
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Clean Blue Technologies Inc
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Clean Blue Technologies Inc
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Assigned to Clean Blue Technologies, Inc. reassignment Clean Blue Technologies, Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BLAIR, JOHN E.
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/721—Multistage gasification, e.g. plural parallel or serial gasification stages
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
    • C10K3/02—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J7/00—Apparatus for generating gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B5/00—Operations not covered by a single other subclass or by a single other group in this subclass
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09C—RECLAMATION OF CONTAMINATED SOIL
    • B09C1/00—Reclamation of contaminated soil
    • B09C1/06—Reclamation of contaminated soil thermally
    • B09C1/065—Reclamation of contaminated soil thermally by pyrolysis
    • 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
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/08—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal with moving catalysts
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • 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
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or 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

Definitions

  • the present disclosure relates to an apparatus, system, and method for processing materials.
  • Disposal in a landfill creates a multiplicity of problems, such as, for example, selecting a site for disposal, transport of material to and from the site, potential pollutions problems in the nearby soil, groundwater, and air, and issues associated with the lack of recycling when materials are disposed of in a landfill.
  • Pyrolysis may be used to dispose of certain plastic wastes, however, conventional pyrolysis methods are not energy or cost efficient.
  • a refinery system includes a feedstock supply line, a first endothermic chamber that receives feedstock from the feedstock supply line and processes the feedstock under elevated heat during a first time period, a second endothermic chamber that receives feedstock from the feedstock supply line under elevated heat during a second time period, and a refining processor downstream and in communication with each of the first chamber and the second chamber.
  • the feedstock is one of mostly polymers, contaminated soil, and animal processing byproducts.
  • the system includes respective first and second catalyst chambers downstream from the first and second endothermic chambers but upstream from the refining processor.
  • a common line is downstream of the first and second endothermic chambers and in communication with the refining processor downstream.
  • syngas is formed in the respective first and second catalyst chambers, and further wherein, syngas formed in the first and second catalyst chambers is used to heat one of the first and second endothermic chambers.
  • the catalyst chambers include a catalyst selected from the group consisting of Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, ZnO, CaO, K2O, and combinations thereof.
  • a catalyst selected from the group consisting of Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, ZnO, CaO, K2O, and combinations thereof.
  • the first and second time periods do not substantially overlap.
  • the first time period is between about two hours and about fifteen hours.
  • the feedstock is processed until the oxygen level is below about 10%.
  • the feedstock is processed until the oxygen level is below about 5%.
  • the system includes a third endothermic chamber that receives feedstock from the feedstock supply under elevated during a third time period.
  • the first endothermic chamber and the second endothermic chamber are configured to supply a continuous amount of processed feedstock to the refining processor.
  • the refining processor includes a crude oil refining system that includes an oil and water separator and one or more condensers for separating syngas.
  • the refining processor includes a crude oil refining system that includes a catalyst chamber and a condenser for separating syngas and leaving a biodiesel source.
  • each of the first and second endothermic chambers are sealed after feedstock is provided therein.
  • one of the first endothermic chamber and the second endothermic chamber is at a preferred operating temperature (POT) at all times during processing.
  • POT preferred operating temperature
  • the feedstock is algae.
  • the feedstock includes a polymer
  • the feedstock includes animal byproducts.
  • the refining processor processes syncrude and syngas.
  • processed feedstock is removed from the first endothermic chamber while feedstock is loaded into the second endothermic chamber.
  • a method of generating a resource includes receiving a feedstock in a first endothermic chamber, processing the feedstock in the first endothermic chamber during a first time period under heating, receiving a feedstock in a second endothermic chamber, processing the feedstock in the second endothermic chamber during a second time period under heating, and receiving, in a single downstream refining processor, the processed feedstock from each of the first endothermic chamber and the second endothermic chamber for further processing.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about two hours and about 15 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about four hours and about 13 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about six hours and about 11 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about eight hours and about 9 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock from ambient temperature to about 900 degrees C. during the first time period.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock from ambient to about 50 degrees C.
  • the method includes processing the feedstock in a respective first and second catalyst chamber downstream from each of the first and second endothermic chambers and upstream of the single downstream refining processor.
  • processing the feedstock in a respective first and second catalyst chamber includes introducing a catalyst consisting of Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, ZnO, CaO, K2O, and combinations thereof.
  • a catalyst consisting of Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, ZnO, CaO, K2O, and combinations thereof.
  • the first time period and the second time period do not substantially overlap.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber comprises heating the feedstock until the oxygen levels are below about 10%.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock until the oxygen levels are below about 5%.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock until the feedstock is reduced to primarily a light weight gas, a heavy weight gas, and carbon char.
  • the carbon char is removed from each of the first endothermic chamber and the second endothermic chamber.
  • the light weight gas is syngas
  • the method further comprising isolating the syngas and using the syngas to heat either of the first and second endothermic chambers during a subsequent processing step.
  • the processed feedstock from each of the first endothermic chamber and the second endothermic chamber for further processing includes receiving a continuous supply that is alternated from the first endothermic chamber and the second endothermic chamber.
  • one of the first endothermic chamber and the second endothermic chamber is maintained at a preferred operating temperature (“POT”) at all processing times.
  • POT preferred operating temperature
  • a method of generating a resource includes at a first time, receiving a feedstock in a first endothermic chamber, processing the feedstock in the first endothermic chamber under heating to an elevated processing temperature in which light weight heating gas is produced, and at a second time, receiving a feedstock in a second endothermic chamber, and processing the feedstock in the second endothermic chamber under heating to an elevated processing temperature in which light weight heating gas is produced.
  • One of the first and second endothermic chambers maintains the elevated processing temperature during a processing period of time, the processing period of time including at least one heating period for each of the first and second endothermic chambers.
  • a refinery system includes a feed stock supply line, a first endothermic chamber that receives feedstock from the feedstock supply and processes the feedstock under elevated heat during a first time period, a second endothermic chamber that receives feedstock from the feedstock supply under elevated heat during a second time period, a refining processor downstream and in communication with each of the first chamber and the second chamber, and a control module configured to direct a heating source to apply heat to the first endothermic chamber during the first time period, monitor the oxygen level in the first endothermic chamber to determine a desired oxygen level in the feedstock, upon determining a desired oxygen level in the feedstock of the first endothermic chamber, direct a heating source to apply heat to the second endothermic chambering during the second time period, monitor the oxygen level in the second endothermic chamber to determine a desired oxygen level in the feedstock, and upon determining a desired oxygen level in the feedstock of the second endothermic chamber, direct a heating source to apply heat to one of the first endothermic chamber
  • the first and second time periods are about the same.
  • a refinery system includes a feedstock supply line, a first endothermic chamber that receives feedstock from the feedstock supply and processes the feedstock under elevated heat during a first time period and a first catalyst chamber for interacting with syncrude from the first endothermic chamber, a second endothermic chamber that receives feedstock from the feedstock supply under elevated heat during a second time period and a second catalyst chamber for interacting with syncrude from the second endothermic chamber, and a refining processor downstream and in communication with each of the first chamber and the second chamber, the refining processor receiving a generally continuous supply of syncrude from one of the first catalyst chamber and the second catalyst chamber during a manufacturing process.
  • the refining processor processes syncrude and syngas.
  • a method of generating a resource includes at a first time, receiving a feedstock in a first endothermic chamber, processing the feedstock in the first endothermic chamber under heating to an elevated processing temperature to produce a product for downstream processing, at a second time, receiving a feedstock in a second endothermic chamber, processing the feedstock in the second endothermic chamber under heating to an elevated processing temperature to produce a product for downstream processing, and providing a product for downstream processing in a generally continuous manner from one of the first endothermic chamber and the second endothermic chamber.
  • the method includes processing the product for downstream processing in a catalyst chamber.
  • a method of generating an oil byproduct includes providing a feedstock into a first endothermic chamber in communication with a first catalytic chamber, applying heat to the first endothermic chamber in order to process the feedstock into a processed syncrude, transporting the processed syncrude from the first endothermic chamber into the downstream processor, providing feedstock into the second endothermic chamber in communication with a second catalytic chamber, wherein each of the first and second endothermic chambers are in communication with a single downstream processor that processes the oil byproduct, applying heat to the second endothermic chamber from the second endothermic chamber in order to process the feedstock into a processed syncrude, and transporting the processed syncrude into the downstream processor.
  • FIG. 1 illustrates a system diagram of a portion of a processing system according to one or more embodiments disclosed herein;
  • FIG. 2 illustrates a system diagram of a portion of a processing system according to one or more embodiments disclosed herein;
  • FIG. 3 illustrates a system diagram of a portion of a processing system according to one or more embodiments disclosed herein;
  • FIG. 4 illustrates one or more methods of processing waste materials according to one or more embodiments disclosed herein.
  • FIG. 5 illustrates temperature versus time charts of respective first and second endothermic chambers according to one or more experiments according to the one or more methods disclosed herein.
  • FIG. 1 illustrates a portion of a system, where the portion is generally designated 10 A.
  • Portion of system 10 A works in conjunction with portion of system 10 B illustrated in FIG. 2 and portion of system 10 C illustrated in FIG. 3 to form an entire system that processes materials, such as, for example, plastics and the like.
  • System 10 A includes feedstock supplies 11 A and 11 B. While illustrated in the system diagram as being separate feedstocks, the feedstock supply may be one in the same for supplying feedstock to endothermic chambers 12 A and 12 B.
  • the feedstock supplies 11 A and 11 B may include any waste material.
  • the waste material may include waste plastics and other polymers from postindustrial manufacturing, municipal waste collections, or any other source of waste plastics.
  • the waste plastics may include plastics 1 through 7 and 9 .
  • the plastics may be bailed, bundled, shredded, or otherwise processed or unprocessed.
  • the waste material is transferred from storage using any appropriate material handler, such as a tractor, to a staging or loading area.
  • the waste material is then loaded onto a conveyor loader, hydraulic loader, or carried by hand, or other appropriate manner, and is then supplied to the endothermic chambers 12 A and 12 B. This is preferably done during alternating time periods, though may be done at the same time.
  • the endothermic chambers 12 A and 12 B are loaded with the feedstock material. Downstream from the endothermic chambers 12 A and 12 B are respective catalytic chambers 14 A and 14 B. Catalytic chambers 14 A and 14 B each have a catalyst compound loaded therein.
  • the catalyst compound used herein may include, but is not limited to, Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, and combinations thereof.
  • the catalysts may also be alkaline catalysts such as ZnO, CaO, K2O, and combinations thereof.
  • the polymer feedstock may include, but is not limited to, #1 PET (Polyethylene terephthalate), #2 HDPE (High-density polyethylene); #3 PVC (Polyvinyl chloride); #4 LDPE (Low-density polyethylene); #5 PP (Polypropylene); #6 PS (Polystyrene); #7 Other; and #9 or ABS.
  • #1 PET Polyethylene terephthalate
  • #2 HDPE High-density polyethylene
  • #3 PVC Polyvinyl chloride
  • #4 LDPE Low-density polyethylene
  • #5 PP Polypropylene
  • #6 PS Polystyrene
  • #7 Other and #9 or ABS.
  • endothermic chamber 12 A is sealed after the feedstock is provided therein.
  • processing occurs of the feedstock in the endothermic chamber. This occurs by subjecting the feedstock to a heating process where the temperature of the feedstock is raised from ambient to about 50 degrees C. in a first heating step. The temperature of the feedstock is then raised from about 50 degrees C. to about 900 degrees C. over less than about a 12 hour period.
  • the elevated temperature may be higher or lower than about 900 degrees C.
  • the elevated final temperature may be between about 450 and 550 degrees C.
  • the oxygen level therein is reduced during the heating process until it is at a suitably low level.
  • the oxygen level may be about 10 percent. In one or more embodiments, the oxygen level may be about 5 percent. In one or more embodiments, the oxygen level is below about 5 percent after final processing within the endothermic chamber 12 A.
  • the endothermic chamber 12 A is in fluid communication with catalyst chamber 14 A.
  • the catalyst chamber 14 A includes a catalyst to aid in reacting with gases formed in the endothermic chamber 12 A.
  • the catalyst may include Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, and combinations thereof.
  • the catalysts may also be alkaline catalysts such as ZnO, CaO, K2O, and combinations thereof.
  • Gases are formed in endothermic chamber 12 A when a chemical reaction of the feedstock occurs. Specifically, the chemical reaction may be cracking where long chain molecules in the feedstock are broken down into shorter chain molecules that generally form into a light weight gas, which may be syngas, a heavy gas, which may be syncrude, and a carbon char.
  • the gases are formed and they flow out of the endothermic chamber 12 A into the catalyst chamber 14 A.
  • the gases collectively the syngas and syncrude, may further react with a catalyst.
  • feedstock 11 A is loaded into endothermic chamber 12 B in the same manner as it is loaded into endothermic chamber 12 A.
  • feedstock in endothermic chamber 12 B is also being processed in the same manner.
  • This has the advantage of maintaining a continuous supply of syngas, Syncrude, and carbon char from processed feedstock to be used for downstream processing. In this manner, inefficiencies associated with starting and stopping a pyrolysis system as new processed feedstock becomes available are eliminated.
  • Endothermic chamber 12 A may be loaded by about between 10 and 90 percent by volume with feedstock.
  • Feedstock is then processed in endothermic chamber 12 B according to the same manner as that which is processed in endothermic chamber 12 A while endothermic chamber 12 A cools. During this cooling period, char is removed from the endothermic chamber 12 A, as well as any other contaminants or materials such as metal. These materials may then be further processed or sold for industrial use.
  • syngas travels into a flue 16 .
  • the syngas may then further go through a filtering process to remove any dust or other contaminants in a filter 44 or 46 .
  • a compressor 20 may then compress the syngas before it is stored in a storage tank 22 where it is later used for providing heat treatment to each of the endothermic chambers 12 A and 12 B. In this manner, the majority of the energy used in the portion 10 A is from syngas made from recycled materials.
  • Char removed from either of endothermic chambers 12 A and 12 B may be subject to further processing FP, which may include any suitable processing for those materials.
  • Syncrude may be pumped or otherwise transferred into a portion 10 B of the system for further processing.
  • a separator 24 separates oil and water in the crude oil.
  • the crude oil then travels through one or more condensers 34 , 36 in order to cool the crude oil down to less than about 350 degrees C.
  • Syngas is separated from crude oil during this process, and may be stored in tank 22 for further use.
  • a transition tank 42 may contain the processed crude oil which will later be processed in a further processing step.
  • a backpressure module 40 may be provided in communication with condensers 34 , 36 in order to reduce any backpressures in the system.
  • a buffer tank 30 and pressure module 26 may be provided for storing processed materials during any of the processes.
  • Portion 10 C of the system may be further provided for additional processing.
  • an oil flow pump 44 may be provided for pumping the crude oil to a thermochemical distillation chamber 46 .
  • the crude oil is heated for further processing.
  • the oil is then transferred to a catalyst chamber 50 for additional processing.
  • a syngas filter 52 filters out any syngas, which is then filtered in filter 54 and filter 56 .
  • Steam from this portion of the refining process is processed through the dust filter 54 and then passed through the hydro filter module 56 , capturing the remaining steam and contaminants.
  • the collection of contaminants is then processed through the chamber 12 A or 12 B to convert from a liquid into a solid.
  • a back pressure module 70 may be in communication therewith, with buffer tank 72 and negative pressure module 74 .
  • Oil from the diesel collection tank 62 is transferred to a diesel measurement tank 76 that is in communication with a distillates measurement tank 80 .
  • An oil flow pump 82 provides pumping forces to pump oil to an acidic wash tank 84 .
  • An oil flow pump 86 further provides pumping forces to pump oil to an alkali wash tank 90 where sulfur is cleaned from the fuel, completing the refining process and resulting in transportation grade ultra-low biodiesel fuel D2.
  • the biodiesel fuel is then transferred to a transition tank 92 where further testing may be completed before transport to a transfer fuel trailer or other storage tank.
  • portions 10 A, 10 B, and 10 C form a system 10 that is capable of converting plastic waste into a highly efficient recycling process producing syngas for heating during the processing step, biodiesel for use as a fuel source, and char for further processing as desired.
  • a control module 94 may be in communication with one or more or all of the elements described herein for monitoring one or more aspects of the refining process.
  • the endothermic chambers 12 A and 12 B may have one or more sensors in communication therewith that monitor, for example, temperature, pressure, oxygen levels, and any other desired characteristic.
  • the control module 94 may then be configured to monitor the one or more characteristics, and direct additional elements to carry out one or more portions of the process disclosed herein.
  • control module 94 detects a release in negative pressure from system 10 A, particularly the refining of oil of the first feedstock from the endothermic chamber 12 A, the control module directs the oil pump 44 to pump oil from endothermic chamber 12 B to thereby cause a continuous flow of oil in the refining process.
  • system uptime is maximized and the system 10 is almost always running at operating temperatures and pressures, thereby increasing efficiency in the recycling process by eliminating the inefficiencies associated with startup when temperatures and pressures are not at operating ranges.
  • the control module 94 is configured to monitor a decrease in gas flow into the catalyst chamber 14 A in order to direct heating of endothermic chamber 12 B.
  • the system 10 utilized the processes disclosed herein to produce syngas, biodiesel, and char.
  • each of the first endothermic chamber 12 A and the second endothermic chamber 12 B had about the same amount of feedstock having about the same characteristics applied therein.
  • the first endothermic chamber 12 A was sealed and heat was applied according to the following schedule shown in TABLE I.
  • the second endothermic chamber 12 B was loaded with feedstock and the heating process began. In this manner, at about 7:00, the feedstock in the second endothermic chamber 12 B starts a gasification flow. At about 7:00, heat is no longer applied to endothermic chamber 12 A and ambient air is introduced to decrease pressure and increase the cooling rate. At about 8:30, the endothermic chamber 12 A is rotated to increase the cooling rate. At about 9:30, a chamber door is opened on the endothermic chamber 12 A, thereby allowing an increased cooling rate. The heating process for the second endothermic chamber 12 B was carried out to have consistent time measurements as the heating process for the first endothermic chamber 12 A. At about 10:30, the char is removed from the endothermic chamber 12 A. Feedstock may then be loaded into chamber 12 A for heating and processing at a later date. Maximum pressure was found to be about 500 pounds per square inch.
  • the syngas, crude oil, and char material are then processed according to the one or more processes disclosed herein.
  • FIG. 5 illustrates graphs plotting temperature of each endothermic chamber 12 A, 12 B relative to processing time.
  • POT preferred operating temperature
  • feedstocks 11 A and 11 B may be petroleum contaminated soils from, but not limited to, fuel spills, fuel tank leakage, petroleum beach wash, refining spills, fuel line spills, petroleum laden spills, and sands residue from separation washing.
  • the petroleum contaminated soils are transferred into the endothermic chambers 12 A and 12 B for processing. After the soil has been processed in the endothermic chambers 12 A and 12 B, the separated syngas and oil is sent for further processing as described herein with reference to other materials, and the soil and char is removed from the endothermic chambers 12 A and 12 B.
  • a vacuum or similar apparatus may be used to remove the soils.
  • feedstocks 11 A and 11 B may be poultry, swine, bovine, fish, or other animal processing byproducts.
  • the animal processing byproducts are transferred into the endothermic chambers 12 A and 12 B for processing.
  • the processing byproducts are preferably dewatered or dried to a moisture content of less than about 50%.
  • the separated syngas and oil is sent for further processing as described herein with reference to other materials, and the char is removed from the endothermic chambers 12 A and 12 B.
  • a vacuum or similar apparatus may be used to remove the char and other materials. These materials have particular applicability as a fertilizer grade material.
  • the one or more methods may include a method of generating a resource.
  • the method may include receiving a feedstock ⁇ in a first endothermic chamber 110 , processing the feedstock in a first endothermic chamber during a first time period under heating 112 , receiving a feedstock in a second endothermic chamber 114 , processing the feedstock in a second endothermic chamber during a second time period under heating 116 , and receiving, in a single downstream refining processor, the processed feedstock from each of the first endothermic chamber and the second endothermic chamber for further processing 120 .
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about two hours and about 15 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about four hours and about 13 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about six hours and about 11 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock for a period of between about eight hours and about 9 hours.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock from ambient temperature to about 900 degrees C. during the first time period.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock from ambient to about 50 degrees C. in a first portion of the heating process.
  • the method includes processing the feedstock in a respective first and second catalyst chamber downstream from each of the first and second endothermic chambers and upstream of the single downstream refining processor.
  • processing the feedstock in a respective first and second catalyst chamber comprises introducing a catalyst comprising one of Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, and combinations thereof.
  • the catalysts may also be alkaline catalysts such as ZnO, CaO, K2O, and combinations thereof.
  • the first time period and the second time period do not substantially overlap. In this manner, only a portion of the first and second time period overlaps, yet the endothermic chambers continually provide processed feedstock for further downstream processing.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber comprises heating the feedstock until the oxygen levels are below about 10%.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock until the oxygen levels are below about 5%.
  • processing the feedstock in either of the first endothermic chamber or the second endothermic chamber includes heating the feedstock until the feedstock is reduced to primarily a light weight gas, a heavy weight gas, and carbon char.
  • the carbon char is removed from each of the first endothermic chamber and the second endothermic chamber.
  • the light weight gas is syngas and the method further includes isolating the syngas and using the syngas to heat either of the first and second endothermic chambers during a subsequent processing step.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Soil Sciences (AREA)
  • Thermal Sciences (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Processing Of Solid Wastes (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Feeding, Discharge, Calcimining, Fusing, And Gas-Generation Devices (AREA)
  • Heat Treatments In General, Especially Conveying And Cooling (AREA)
  • Solid-Phase Diffusion Into Metallic Material Surfaces (AREA)
US14/196,067 2013-03-14 2014-03-04 Apparatus, system, and method for processing materials Abandoned US20140259923A1 (en)

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US11999920B2 (en) 2020-09-14 2024-06-04 Ecolab Usa Inc. Cold flow additives for plastic-derived synthetic feedstock
US12031097B2 (en) 2021-10-14 2024-07-09 Ecolab Usa Inc. Antifouling agents for plastic-derived synthetic feedstocks
US12054067B2 (en) 2019-09-09 2024-08-06 Lg Energy Solution, Ltd. Communication apparatus, communication method, and electric vehicle
US12304888B2 (en) 2021-03-10 2025-05-20 Ecolab Usa Inc. Stabilizer additives for plastic-derived synthetic feedstock

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CN113732036B (zh) * 2021-08-24 2023-10-20 中国环境科学研究院 一种促进重质石油污染土壤热处理修复的方法

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US12054067B2 (en) 2019-09-09 2024-08-06 Lg Energy Solution, Ltd. Communication apparatus, communication method, and electric vehicle
US11999920B2 (en) 2020-09-14 2024-06-04 Ecolab Usa Inc. Cold flow additives for plastic-derived synthetic feedstock
US12304888B2 (en) 2021-03-10 2025-05-20 Ecolab Usa Inc. Stabilizer additives for plastic-derived synthetic feedstock
US12031097B2 (en) 2021-10-14 2024-07-09 Ecolab Usa Inc. Antifouling agents for plastic-derived synthetic feedstocks

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WO2014158779A1 (en) 2014-10-02
KR20160008512A (ko) 2016-01-22
ZA201506992B (en) 2017-03-29
EP2969274A4 (en) 2016-12-21
JP2016516567A (ja) 2016-06-09
BR112015023296A2 (pt) 2017-07-18
CA2906354A1 (en) 2014-10-02
RU2015143290A (ru) 2017-04-18
EP2969274A1 (en) 2016-01-20
CN105163875A (zh) 2015-12-16
AU2014241900A1 (en) 2015-10-22

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