US20240027065A1 - Plastic-powered power generator - Google Patents
Plastic-powered power generator Download PDFInfo
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- US20240027065A1 US20240027065A1 US18/373,129 US202318373129A US2024027065A1 US 20240027065 A1 US20240027065 A1 US 20240027065A1 US 202318373129 A US202318373129 A US 202318373129A US 2024027065 A1 US2024027065 A1 US 2024027065A1
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- fluidized polymer
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Images
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
- F23G5/44—Details; Accessories
- F23G5/46—Recuperation of heat
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K11/00—Plants characterised by the engines being structurally combined with boilers or condensers
- F01K11/02—Plants characterised by the engines being structurally combined with boilers or condensers the engines being turbines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K21/00—Steam engine plants not otherwise provided for
-
- 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
-
- 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
- F23G5/30—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having a fluidised bed
-
- 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
-
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2201/00—Pretreatment
- F23G2201/30—Pyrolysing
- F23G2201/303—Burning pyrogases
-
- 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
- F23G2205/00—Waste feed arrangements
- F23G2205/20—Waste feed arrangements using airblast or pneumatic feeding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2206/00—Waste heat recuperation
- F23G2206/20—Waste heat recuperation using the heat in association with another installation
- F23G2206/203—Waste heat recuperation using the heat in association with another installation with a power/heat generating installation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2207/00—Control
- F23G2207/10—Arrangement of sensing devices
- F23G2207/101—Arrangement of sensing devices for temperature
-
- 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
Definitions
- the embodiments described herein are generally directed to waste disposal, and, more particularly, to a waste disposal process that converts plastic waste into electricity using an electrochemical, thermal, and/or mechanical reactor, referred to herein as a plastic-powered power generator (PPG).
- PPG plastic-powered power generator
- Plastics have excellent corrosion resistance, chemical resistance, durability, and the like. While this makes them very useful for parts and products, it also means that plastics do not easily decompose in their natural state. This has a devastating effect on the environment. For example, marine life has been adversely affected by plastic waste, and especially by the micro-plastics that are generated from larger plastics. For example, plastic waste has decreased the number of plankton. However, not only does plastic waste affect marine life, it also affects human and other animal life, since a large amount of food is sourced from the ocean.
- a plastic-powered power generator that utilizes plastic waste as fuel to generate power.
- the plastic-powered power generator may comprise an electrochemical, thermal, and/or mechanical system that conveys heat from processed plastic waste to an inline heat exchanger.
- the plastic power generator may utilize micro-pulverized plastic to create thermal energy, and extract that thermal energy to turn a steam turbine that produces electricity.
- a plastic-powered power generator comprises: a primary reactor comprising an air-fuel distribution assembly, an ignition system, and a primary reactor chamber, wherein the primary reactor chamber comprises a first opening on one end of the primary reactor chamber and a second opening on a second end of the primary reactor chamber, wherein the air-fuel distribution assembly is configured to supply fluidized polymer, air, and an oxidizing agent through the first opening in the primary reactor chamber, and wherein the ignition system is configured to ignite a mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber, wherein the primary reactor chamber comprises a plurality of flat sides; a secondary reactor comprising a secondary reactor body with a first opening on one end of the secondary reactor body, a second opening on a second end of the secondary reactor body, and a third opening on a side of the secondary reactor body, wherein the second end of the primary reactor chamber extends through the third opening in the side of the secondary reactor body, such that the second opening of the primary reactor chamber is within the secondary reactor body; a heat
- the secondary reactor body may be cuboid.
- the secondary reactor body may comprise a temperature-sensor port, configured to receive a temperature sensor.
- the plastic-powered power generator may further comprise the temperature sensor, seated within the temperature-sensor port, such that a sensing portion of the temperature sensor extends into an interior of the secondary reactor body.
- the secondary reactor may comprise a first set of mounting holes encircling the first opening, a second set of mounting holes encircling the second opening, and a third set of mounting holes encircling the third opening.
- the primary reactor chamber may comprise an octagonal body with eight flat sides.
- the air-fuel distribution assembly may comprise an air-fuel mixer, wherein the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connected to the internal chamber.
- the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connected to the internal chamber.
- the plastic-powered power generator may further comprise a fluidizer, wherein the fluidizer comprises: a body comprising an internal cavity configured to house micro-fine polymer between a first end and a second end of the body, and an opening at the first end of the body; a base that covers the opening at the first end of the body, wherein the base comprises an internal cavity, and an air inlet port configured to receive air; a porous membrane between the internal cavity of the base and the internal cavity of the body; and a pump that pumps fluidized polymer from the internal cavity of the body to the fluidized polymer inlet port of the air-fuel mixer.
- a fluidizer comprises: a body comprising an internal cavity configured to house micro-fine polymer between a first end and a second end of the body, and an opening at the first end of the body; a base that covers the opening at the first end of the body, wherein the base comprises an internal cavity, and an air inlet port configured to receive air; a porous membrane between the internal cavity of the base and the internal cavity of the body;
- the pump may comprise: an outlet that is connected to the fluidized polymer inlet port of the air-fuel mixer; a fuel pick-up tube that provides a pathway from the internal cavity of the body of the fluidizer to the outlet; and an inlet configured to supply air over an end of the fuel pick-up tube to create a vacuum of low pressure within the fuel pick-up tube.
- the fluidizer may further comprise a vent tube that provides a pathway from the internal cavity of the body of the fluidizer to an exterior of the fluidizer.
- the fluidizer may further comprise a fill tube that provides a pathway from an exterior of the fluidizer to the internal cavity of the body of the fluidizer.
- the air-fuel distribution assembly may comprise an air-oxidizer manifold, wherein the air-oxidizer manifold comprises: a first dispersal port comprising a channel from a rear surface of the air-oxidizer manifold to a front surface of the air-oxidizer manifold; at least one concentric channel, surrounding the dispersal port and recessed into the front surface of the air-oxidizer manifold; at least one inlet port through a side surface of the air-oxidizer manifold and connected to the at least one concentric channel; and a jet plate covering the front surface of the air-oxidizer manifold and facing the first opening in the primary reactor chamber, wherein the jet plate comprises a second dispersal port in fluid communication with the first dispersal port, and one or more jet holes in fluid communication with the at least one concentric channel.
- the at least one concentric channel may comprise two or more concentric channels, wherein the at least one inlet port comprises two or more inlet ports that are each connected to one of the two or more concentric channels.
- One of the two or more concentric channels may be recessed deeper into the front surface of the air-oxidizer manifold than a second one of the two or more concentric channels.
- the plastic-powered power generator may further comprise a pneumatic system that is configured to supply air through a first one of the two or more inlet ports, and supply an oxidizing agent through a second one of the two or more inlet ports.
- the pneumatic system may be further configured to supply the air through the second inlet port.
- the pneumatic system may be further configured to: monitor a temperature in the primary reactor chamber; while the temperature remains below a predetermined threshold, supply the air through the first inlet port, and supply the oxidizing agent through the second inlet port; and, when the temperature exceeds the predetermined threshold, supply the air through both the first inlet port and the second inlet port, and reduce or stop the supply of the oxidizing agent through the second inlet port.
- the air-fuel distribution assembly may further comprise an air-fuel mixer, wherein the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connecting the internal chamber to the first dispersal port in the air-oxidizer manifold.
- the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connecting the internal chamber to the first dispersal port in the air-oxidizer manifold.
- the plastic-powered power generator may further comprise a one-piece dispenser nozzle that connects to the first dispersal port through the second dispersal port.
- a method comprises: fluidizing sub-micron-scale polymer; and using the plastic-powered power generator, with any combination of the features described above and herein, by supplying the fluidized polymer, air, and an oxidizing agent to the primary reactor; igniting the mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber using the ignition system, and operating the blower to create air flow through the secondary reactor into the heat exchanger.
- FIGS. 1 A- 1 C illustrate various views of a plastic-powered generator, according to an embodiment
- FIGS. 2 A and 2 B illustrate various views of a blower, according to an embodiment
- FIGS. 3 A- 3 D illustrate various views and components of a reducer, according to an embodiment
- FIGS. 4 A- 4 E illustrate various views and components of a secondary reactor, according to an embodiment
- FIGS. 5 A- 5 F illustrate various views and components of a heat exchanger, according to an embodiment
- FIGS. 6 A- 6 E illustrate various views of an air-fuel mixer, according to an embodiment
- FIGS. 7 A- 7 G illustrate various views and components of an air-oxidizer manifold, according to an embodiment
- FIGS. 8 A- 8 G illustrate various views and components of an air-fuel distribution assembly, according to an embodiment
- FIGS. 9 A- 9 G illustrate various views of a primary reactor chamber, according to an embodiment
- FIGS. 10 A- 10 G illustrate various views and components of a distributor system, according to an embodiment
- FIGS. 11 A- 11 D illustrate various views of a fluidizer, according to an embodiment
- FIGS. 12 A and 12 B illustrate a pneumatic system, according to embodiments
- FIGS. 13 A- 13 C illustrate various views of a catalytic converter, according to an embodiment
- FIG. 14 illustrates a Rankine cycle, according to an embodiment
- FIG. 15 illustrates an electrical system, according to an embodiment
- FIG. 16 illustrates a process for converting plastic waste into electrical power using a plastic-powered power generator, according to an embodiment
- FIGS. 17 A and 17 B illustrate various views of a plastic-powered generator, according to an embodiment
- FIGS. 18 A and 18 B illustrate various views and components of a secondary reactor, according to an embodiment
- FIGS. 19 A- 19 D illustrate various views of an air-fuel mixer, according to an embodiment
- FIGS. 20 A- 20 D illustrate various views and components of an air-oxidizer manifold, according to an embodiment
- FIGS. 21 A and 21 B illustrate various views and components of an air-fuel distribution assembly, according to an embodiment
- FIGS. 22 A- 22 G illustrate various views of a primary reactor chamber, according to an embodiment
- FIGS. 23 A- 23 D illustrate various views of a fluidizer, according to an embodiment
- FIG. 24 illustrates a pneumatic system, according to an embodiment.
- Embodiments of a plastic-powered power generator are disclosed.
- the plastic-powered power generator uses plastic waste, which is a clean and energy-rich material derived from crude oils, as fuel.
- plastic waste is a clean and energy-rich material derived from crude oils, as fuel.
- this conversion of plastic waste to fuel not only provides power, but also reduces plastic waste.
- FIGS. 1 A and 1 B illustrate a plastic-powered power generator 100 in different perspective views
- FIG. 1 C illustrates plastic-powered power generator 100 in an exploded perspective view, according to a first embodiment
- plastic-powered power generator 100 comprises a blower 200 , which may utilize a motor to blow air into an adaptor or reducer 300 .
- Reducer 300 increases the velocity of the blown air as the air is fed into a secondary reactor 400 .
- Secondary reactor 400 heats the air and outputs the heated air into heat exchanger 500 , which may heat water to produce steam.
- a primary reactor 600 is connected to secondary reactor 400 at a perpendicular angle with respect to a longitudinal axis through secondary reactor 400 .
- Plastic-powered power generator 100 may be manufactured from one or more materials, including pure ceramic, ferrous, or non-ferrous metal that is ceramic-coated or anodized.
- Anodization is an electrolytic passivation process, used to increase the thickness of the natural oxide layer on the surface of non-ferrous metal parts.
- ceramic-coated or anodized ferrous metal creates a dielectric state to protect against the dangers of static electricity, including grounding.
- Plastic-powered power generator 100 may be manufactured to any scale.
- plastic-powered power generator 100 may be manufactured as a small-scale, portable generator.
- plastic-powered power generator 100 may be manufactured as a large-scale regional power plant.
- a system, comprising any quantity of plastic-powered power generators 100 may be constructed to provide any desired amount of electrical power.
- FIGS. 17 A and 17 B illustrate a plastic-powered power generator 100 in a perspective view and exploded perspective view, respectively, according to a second embodiment.
- This alternative embodiment may differ from the first embodiment, illustrated in FIGS. 1 A- 1 C , in terms of secondary reactor 400 and/or primary reactor 600 .
- All other components of the second embodiment, including blower 200 , reducer 300 , and heat exchanger 500 may be similar or identical to those described with respect to the first embodiment. Thus, any and all descriptions of those components herein apply equally to those components in the second embodiment.
- the second embodiment is illustrated with a different secondary reactor 400 and primary reactor 600 than the first embodiment, the second embodiment may be implemented with a different secondary reactor 400 , but the same primary reactor 600 , as the first embodiment, or a different primary reactor 600 , but the same secondary reactor 400 , as the first embodiment.
- FIGS. 2 A and 2 B illustrate blower 200 in perspective and side views, respectively, according to an embodiment.
- blower 200 comprises a main body 210 and a flange 220 .
- Main body 210 may house a blower motor that spins to generate air flow out of opening 215 in main body 210 .
- another motor or mechanism may be used to generate the air flow out of opening 215 .
- Flange 220 may comprise one or more, and preferably multiple (e.g., four or more), holes 225 . Each hole 225 may be configured to receive a bolt therethrough.
- FIGS. 3 A and 3 B illustrate reducer 300 in perspective and side views
- FIGS. 3 C and 3 D illustrate individual components of reducer 300 , according to an embodiment.
- reducer 300 comprises an adapter cone 310 that is open on both ends, with a flange 320 on the larger end (i.e., the end with the larger diameter) and a flange 330 on the smaller end (i.e., the end with the smaller diameter).
- Adapter cone 310 has a substantially conical shape, with openings on both ends. However, adapter cone 310 may have substantially cylindrical portions 312 and 314 on both ends. Flanges 320 and 330 may be seated on or integrated with these substantially cylindrical portions 312 and 314 , respectively.
- Flange 320 may comprise one or more, and preferably multiple (e.g., four or more), holes 325 . Each hole 325 may be configured to receive a bolt therethrough. Specifically, flange 320 may be adjoined to flange 220 of blower 200 , with each hole 325 aligned to a corresponding hole 225 . Flange 320 may then be fixed to flange 220 by inserting bolts through the aligned holes 225 / 325 , and threading and tightening the bolts through corresponding nuts, to thereby fix reducer 300 to blower 200 . Alternatively or additionally, other mechanisms may be used to fix flanges 320 and 220 to each other and/or to fix reducer 300 and blower 200 to each other.
- Flange 330 may be substantially similar to flange 320 , but with a smaller inner diameter than flange 320 , and optionally a smaller outer diameter as well. Similarly to flange 320 , flange 330 may comprise one or more, and preferably multiple (e.g., four or more), holes 335 configured to receive a bolt therethrough.
- reducer 300 increases the speed of the air flowing out of opening 215 of blower 200 and into the proximal end of secondary reactor 400 .
- FIG. 4 A illustrates secondary reactor 400 in a perspective view
- FIGS. 4 B and 4 C illustrate secondary reactor 400 in different side views, according to a first embodiment
- FIGS. 4 D and 4 E illustrate individual components of secondary reactor 400 , according to the first embodiment.
- secondary reactor 400 comprises a substantially cylindrical body 410 that is open on both ends, with a flange 420 A on one end, a flange 420 B on the other end, and a flange 430 around a substantially cylindrical lip 415 that intersects cylindrical body 410 at an orthogonal angle to thereby provide an open pathway into the interior of cylindrical body 410 through the side of cylindrical body 410 .
- Cylindrical body 410 is substantially cylindrical, with openings on both ends and a circular hole defined by a cylindrical lip 415 extending out from cylindrical body 410 , to provide a pathway through the side of cylindrical body 410 into the interior of cylindrical body 410 .
- Cylindrical body 410 is configured to allow air from blower 200 to flow from one end (e.g., the opening surrounded by flange 420 A) to the opposite end (e.g., the opening surrounded by flange 420 B).
- Flanges 420 A and 420 B may be, but are not necessarily, identical. Each flange 420 may comprise one or more, and preferably multiple (e.g., four or more), holes 425 . Each hole 425 may be configured to receive a bolt therethrough. Specifically, flange 420 A may be adjoined to flange 330 of reducer 300 , with each hole 425 aligned to a corresponding hole 335 in flange 330 . Flange 420 A may then be fixed to flange 330 by inserting bolts through all of the aligned holes 335 / 425 , and threading and tightening the bolts through corresponding nuts, to thereby fix secondary reactor 400 to reducer 300 . Alternatively or additionally, other mechanisms may be used to fix flanges 420 A and 330 to each other and/or to fix secondary reactor 400 and reducer 300 to each other.
- Flange 430 may be substantially similar to flanges 420 , but may have a different inner and/or outer diameter than flanges 420 . In the illustrated embodiment, flange 430 has a smaller inner and outer diameter than flanges 420 . However, in a different embodiment, flange 430 may have the same or different inner and/or outer diameters than flanges 420 . Similarly to flanges 420 , flange 430 may comprise one or more, and preferably multiple (e.g., four or more), holes 435 . Each hole 435 may be configured to receive a bolt therethrough.
- secondary reactor 400 As air flows through secondary reactor 400 , the air is heated by primary reactor 600 via a flame, produced by primary reactor 600 , through the hole defined by lip 415 . The heated air from secondary reactor 400 flows into heat exchanger 500 .
- FIGS. 18 A and 18 B illustrate different perspective views of secondary reactor 400 , according to a second embodiment.
- the second embodiment may differ from the first embodiment in terms of the shape of body 450 , the lack of flanges, and/or the addition of a port 458 for a temperature sensor. While the second embodiment of secondary reactor 400 is illustrated with all of these features, it should be understood that secondary reactor 400 could instead be implemented with any subset of these features, including only one or two of these features.
- cuboid body 450 may be substantially cuboid, formed with six flat rectangular sides.
- Cuboid body 450 may comprise a first opening 452 on a first end, and a second opening 454 on a second end that is opposite the first end.
- cuboid body may comprise a third opening 456 on a first side, and a temperature-sensor port 458 on a second side (e.g., opposite the first side).
- Both the first end and the second end of cuboid body 450 may comprise one or more, and preferably multiple (e.g., four or more) mounting holes 425 , arranged to encircle first opening 452 and second opening 454 .
- each hole 425 may be configured to receive a bolt therethrough.
- the first end of cuboid body 450 may be adjoined to flange 330 of reducer 300 , with each hole 425 aligned to a corresponding hole 335 in flange 330 .
- Cuboid body 450 may then be fixed to flange 330 by inserting bolts through all of the aligned holes 335 / 425 , and threading and tightening bolts through corresponding nuts, to thereby fix secondary reactor 400 to reducer 300 .
- other mechanisms may be used to fix secondary reactor 400 and reducer 300 to each other.
- the second end of cuboid body 450 may be adjoined to heat exchanger 500 in a similar or identical manner.
- Third opening 456 on the first side of cuboid body 450 may be similar to first opening 452 and/or second opening 454 , but may have a different diameter than first opening 452 and/or second opening 454 .
- third opening 456 has a smaller diameter than both first opening 452 and second opening 454 , which have the same diameter.
- third opening 456 may have the same or a greater diameter than first opening 452 and/or second opening 454 .
- third opening 456 may be encircled by one or more mounting holes 435 .
- Each hole 435 may be configured to receive a bolt therethrough, such that primary reactor 600 may be fixed to cuboid body 450 as discussed elsewhere herein, and in a similar or identical manner as reducer 300 and/or heat exchanger 500 are fixed to cuboid body 450 .
- Temperature-sensor port 458 may be positioned on a second side of cuboid body 450 that is opposite the first side to which primary reactor 600 is fixed. However, in an alternative embodiment, temperature-sensor port 458 may be positioned on a different side of cuboid body 450 . Temperature-sensor port 458 may comprise an opening that is configured to receive a temperature sensor therethrough. The temperature sensor may be positioned and affixed to cuboid body 450 (e.g., using mating threaded portions, bolt-and-nut configuration, etc.) with a sensing portion of the temperature sensor within cuboid body 450 . In an embodiment, temperature-sensor port 458 may be fitted with a support body that is configured to receive the temperature sensor.
- the temperature sensor may be seated within the support body in temperature-sensor port 458 , with the sensing portion extending into the interior of cuboid body 450 , and fixed to cuboid body 450 by a ferrule nut that it is threaded and tightened over the support body.
- a ferrule nut that it is threaded and tightened over the support body.
- the placement of temperature-sensor port 458 through a flat side of cuboid body 450 enables more precise placement of the temperature sensor and a tighter seal between cuboid body 450 and the support body and/or temperature sensor.
- air output by blower 200 can flow from reducer 300 at the first end of cuboid body 450 , through first opening 452 into the interior of cuboid body 450 , and through cuboid body 450 .
- air flows through cuboid body 450 of secondary reactor 400 , the air is heated by primary reactor 600 via a flame, produced by primary reactor 600 , through third opening 456 .
- the heated air flows out of second opening 454 , at the second end of cuboid body 450 , into heat exchanger 500 .
- a temperature sensor may be fixed through temperature-sensor port 458 , and output the internal reaction temperature within cuboid body 450 .
- the second embodiment of secondary reactor 400 achieves the same benefits as the first embodiment, while eliminating several components, such as flanges 420 and lip 415 , which may potentially simplify the manufacturing process.
- the second embodiment of secondary reactor 400 provides a temperature-sensor port 458 , such that a temperature sensor can be positioned within secondary reactor 400 to measure the temperature at or near the point at which the flame front, from primary reactor 600 , enters secondary reactor 400 .
- the temperature sensor may be communicatively connected to a control system that may control plastic-powered power generator 100 , based at least in part on the output of the temperature sensor.
- Cuboid body 450 also provides a dense body that is capable of withstanding the high temperatures generated within secondary reactor 400 .
- FIGS. 5 A and 5 B illustrate heat exchanger 500 in orthogonal side views, according to an embodiment.
- FIG. 5 C illustrates heat exchanger 500 down its longitudinal axis, according to an embodiment.
- FIGS. 5 D- 5 F illustrate individual components of heat exchanger 500 , according to an embodiment.
- heat exchanger 500 comprises a substantially cylindrical body 510 that is open on both ends, with a flange 520 A on one end, a flange 520 B on the other end, and at least two connector fittings 530 on substantially opposite sides of cylindrical body 510 .
- Cylindrical body 510 is substantially cylindrical, with openings on both ends and fitting holes 515 (e.g., circular holes in the illustrated embodiment) cut into substantially opposite sides to receive connector fittings 530 .
- Cylindrical body 510 may house a coil through which fluid flows.
- the coil may be wound around an inner circumference of cylindrical body 510 , with an open pathway through the center of the coil (i.e., down the longitudinal axis of cylindrical body 510 ), such that exhaust from secondary reactor 400 can pass through cylindrical body 510 via the open pathway, while heating the coils.
- the fluid, flowing through the coil may comprise water.
- the fluid may be an aqueous solution containing ethylene glycol, which helps reduce corrosion and freezing within the coil.
- Flanges 520 A and 520 B may be, but are not necessarily, identical. Each flange 520 may comprise one or more, and preferably multiple (e.g., four or more), holes 525 . Each hole 525 may be configured to receive a bolt therethrough. Specifically, flange 520 A may be adjoined to flange 420 B of secondary reactor 400 , with each hole 525 aligned to a corresponding hole 425 in flange 420 B. Flange 520 A may then be fixed to flange 420 B by inserting bolts through all of the aligned holes 425 / 525 , and threading and tightening the bolts through corresponding nuts, to thereby fix heat exchanger 500 to secondary reactor 400 . Alternatively or additionally, other mechanisms may be used to fix flanges 520 A and 420 B to each other and/or to fix heat exchanger 500 and secondary reactor 400 to each other.
- Connector fittings 530 A and 530 B may be, but are not necessarily, identical. Each connector fitting 530 is configured to be seated within fitting holes 515 in opposing sides of cylindrical body 510 , and be releasably connected to an external line. Within cylindrical body 510 , connector fittings 520 A and 530 B are attached to opposite ends of the coil, such that fluid may flow, through connector fitting 530 A, from one end of the coil to the other end of the coil, and out connector fitting 530 B. Thus, one connection fitting 520 A may be used to input fluid into the coil within cylindrical body 510 , whereas the other connection fitting 520 B may be used to output steam from cylindrical body 510 .
- An input fluid line may feed the fluid into connection fitting 520 A and into the internal coil of cylindrical body 510 , where it is converted to steam, while an output line may allow the steam from the internal coil of cylindrical body 510 to flow out into an output steam line or other device or system.
- FIGS. 6 A- 9 F illustrate various isolated components of primary reactor 600 , according to an embodiment.
- FIGS. 6 A- 6 E illustrate various views of an air-fuel mixer 610 of primary reactor 600
- FIGS. 7 A- 7 G illustrate various views and components of an air-oxidizer manifold 620
- FIGS. 8 A- 8 G illustrate various views and components of an air-fuel distribution assembly comprising air-fuel mixer 610 and air-oxidizer manifold 620
- FIGS. 9 A- 9 G illustrate various views and components of primary reaction chamber 630 , according to embodiments.
- FIGS. 10 A- 10 G illustrate various views and components of an ignition system that may be utilized to ignite primary reactor 600 , according to an embodiment, FIGS.
- FIGS. 12 A and 12 B illustrate pneumatic systems 1200 that may be used with primary reactor 600 , according to embodiments. While primary reactor 600 may comprise or utilize all of the illustrated components, it is not necessary for all embodiments of primary reactor 600 to comprise all of the illustrated components in the illustrated configuration. Rather, embodiments of primary reactor 600 may comprise a combination of some of the illustrated embodiments of components with non-illustrated embodiments of the other components, and/or may omit some of the illustrated components.
- FIG. 6 A illustrates air-fuel mixer 610 in a perspective view
- FIGS. 6 B- 6 D illustrate air-fuel mixer 610 in a front view, rear view, and bottom view, respectively, according to a first embodiment
- FIG. 6 E illustrates air-fuel mixer 610 in a cross-sectional side view, according to the first embodiment.
- air-fuel mixer 610 comprises an air inlet port 612 , a fluidized polymer inlet port 614 , an internal chamber 616 , and a fluidized polymer outlet port 618 .
- Air inlet port 612 may comprise an opening in the rear of air-fuel mixer 610 that provides a first pathway (e.g., a straight and/or cylindrical flow path) into internal chamber 616 within the body of air-fuel mixer 610 .
- a regulated air source e.g., tank of compressed air
- Air inlet port 612 may be formed in any suitable manner, so that it may be connected to a regulated air source.
- fluidized polymer inlet port 614 may comprise an opening in the bottom-rear of air-fuel mixer 610 that provides a second pathway (e.g., a straight and/or cylindrical flow path) into internal chamber 616 within the body of air-fuel mixer 610 .
- a fluidizer e.g., fluidizer 1100
- Fluidized polymer inlet port 614 may be formed in any suitable manner, so that it may be connected to a fluidizer.
- Fluidized polymer outlet port 618 may comprise an opening in the front of air-fuel mixer 610 that provides a third pathway (e.g., a straight and/or cylindrical flow path) out of internal chamber 616 .
- a third pathway e.g., a straight and/or cylindrical flow path
- regulated air provided through air inlet port 612
- fluidized polymer provided through fluidized polymer inlet port 614
- This air-fuel mixture within internal chamber 616 flows out of fluidized polymer output port 618 .
- Fluidized polymer output port 618 may be formed in any suitable manner, so that it may be connected to air-oxidizer manifold 620 . As illustrated in particular in FIGS. 6 B and 6 E , the diameter of fluidized polymer output port 618 and/or internal chamber 616 may be larger than the diameter of air inlet port 612 and/or fluidized polymer inlet port 614 .
- air-fuel mixer 610 comprises a straight pathway through air inlet port 612 , internal chamber 616 , and fluidized polymer output port 618 (e.g., comprising the first and third pathways), and an angled pathway through fluidized polymer inlet port 614 into internal chamber 616 (e.g., comprising the second pathway).
- the angled pathway may be at any suitable angle with respect to the straight pathway (e.g., 30°-45°).
- first, second, and third pathways may be arranged in any suitable configuration with respect to each other, as long as the pathways result in the air, from air inlet port 612 , converging with the fluidized polymer, from fluidized polymer inlet port 614 , to create an air-fuel mixture that exits fluidized polymer outlet port 618 .
- FIG. 19 A illustrates air-fuel mixer 610 in a perspective view
- FIGS. 19 B and 19 C illustrate air-fuel mixer 610 in front and rear views, respectively
- FIG. 19 D illustrates air-fuel mixer 610 in a cross-sectional side view, according to a second embodiment.
- This second embodiment of air-fuel mixer 610 is more compact and less complex than the first embodiment of air-fuel mixer 610 .
- air-fuel mixer 610 may be formed by drilling ports into a solid block.
- air inlet port 612 converges to a narrow throat 613 prior to joining internal chamber 616 .
- the substantially reduced diameter of throat 613 increases the velocity of air through internal chamber 616 , relative to the first embodiment of air-fuel mixer 610 . In turn, this creates a stronger low-pressure area in fluidized polymer inlet port 614 .
- Fluidized polymer inlet port 614 and/or fluidized polymer outlet port 618 may also be reduced in diameter to increase the velocity of fluidized polymer into internal chamber 616 and/or to increase the velocity of the air-fuel mixture out of fluidized polymer output port 618 .
- FIG. 7 A illustrates air-oxidizer manifold 620 in perspective view
- FIG. 7 B illustrates air-oxidizer manifold 620 in a rear view, according to a first embodiment
- FIG. 7 C illustrates a close-up of a region, on the rear of air-oxidizer manifold 620 , defined by circle A in FIG. 7 B , according the first an embodiment.
- FIGS. 7 D and 7 E illustrate a cut-away of a rear portion of air-oxidizer manifold 620 in perspective and rear views, respectively, according to the first embodiment.
- FIGS. 7 F and 7 G illustrate a deeper cut-away of the rear portion of air-oxidizer manifold 620 , than in FIGS.
- the rear surface of air-oxidizer manifold 620 comprises a fluidized polymer dispersal port 710 , with concentric channels 720 and 730 around fluidized polymer dispersal port 710 . While dispersal port 710 and concentric channels 720 and 730 are illustrated as circular, it should be understood that other shapes could be used instead (e.g., square, triangular, etc.).
- Concentric channel 720 may be an oxidizer distribution channel formed as a circular recess in the rear surface of air-oxidizer manifold 620 .
- Concentric channel 720 comprises one or more, and preferably multiple (e.g., four or more), jet holes 722 .
- Jet holes 722 may be arranged equidistantly apart from each other within the recessed surface of concentric channel 720 .
- Each jet hole 722 provides a pathway for an oxidizing agent from concentric channel 720 in the rear surface of air-oxidizer manifold 620 , through the interior of air-oxidizer manifold 620 , out the front surface of air-oxidizer manifold 620 .
- Each jet hole 722 may be angled (e.g., 4°) with respect to a longitudinal axis X passing through the center of fluidized dispersal port 710 . This angling of jet hole(s) 722 facilitates the creation of a vortex as the oxidizing agent exits the front surface of air-oxidizer manifold 620 .
- the diameter of each jet hole 722 may be approximately 0.01 to 0.1 inches, with all jet holes 722 having the same diameter as each other, or alternatively, two or more jet holes 722 having different diameters than each other.
- concentric channel 720 is connected to an oxidizer inlet port 724 .
- oxidizer inlet port 724 provides a pathway, along a lateral axis that is perpendicular to the longitudinal axis X, from a side surface of air-oxidizer manifold 620 , into concentric channel 720 .
- the oxidizing agent may flow through oxidizer inlet port 724 , into concentric channel 720 , where it is distributed through jet hole(s) 722 , and out of the front of air-oxidizer manifold 620 .
- Concentric channel 730 may be an air distribution channel formed as a circular recess in the rear surface of air-oxidizer manifold 620 .
- Concentric channel 730 comprises one or more, and preferably multiple (e.g., four or more), jet holes 732 .
- Jet holes 732 may be arranged equidistantly apart from each other within the recessed surface of concentric channel 730 .
- Each jet hole 732 provides a pathway for air from concentric channel 730 in the rear surface of air-oxidizer manifold 620 , through the interior of air-oxidizer manifold 620 , out the front surface of air-oxidizer manifold 620 .
- Each jet hole 732 may be angled (e.g., 4°) with respect to the longitudinal axis X passing through the center of fluidized dispersal port 710 .
- the angle may be the same or different than the angle of jet hole(s) 722 .
- This angling of jet hole(s) 732 facilitates the creation of a vortex as the air exits air-oxidizer manifold 620 .
- the diameter of each jet hole 732 may be approximately 0.01 to 0.1 inches, with all jet holes 732 having the same diameter as each other, or alternatively, two or more jet holes 732 having different diameters than each other.
- concentric channel 730 is connected to an air inlet port 734 .
- air inlet port 734 provides a pathway, along a lateral axis that is perpendicular to the longitudinal axis X, from a side surface of air-oxidizer manifold 620 , into concentric channel 730 .
- the air may flow through air inlet port 734 , into concentric channel 730 , where it is distributed through jet hole(s) 732 , and out of the front of air-oxidizer manifold 620 .
- jet hole(s) 722 and 732 may be offset from each other, such that no jet hole 722 is aligned with any jet hole 732 along a lateral axis passing through the center of fluidized dispersal port 710 .
- the pattern of jet holes 722 and the pattern of jet holes 732 may be such that the distances of jet holes 722 from jet holes 732 is maximized.
- the pattern of jet holes 722 is a square (e.g., a jet hole 722 positioned at each corner of a square), and the pattern of jet holes 732 is a square that is rotated 45° with respect to the square pattern of jet holes 722 .
- concentric channel 720 is deeper (i.e., recessed farther from the rear surface of air-oxidizer manifold 620 ) than concentric channel 730 . Consequently, as shown by FIGS. 7 D and 7 F , oxidizer inlet port 724 is also deeper (i.e., farther from the rear surface of air-oxidizer manifold 620 ) than air inlet port 734 .
- a first pathway is provided through air-oxidizer manifold 620 by the combination of oxidizer inlet port 724 , concentric channel 720 , and jet(s) 722
- a second pathway is provided through air-oxidizer manifold 620 by the combination of air inlet port 734 , concentric channel 730 , and jet(s) 732 .
- the first pathway will be described as providing a flow of oxidizing agent and the second pathway will be described as providing a flow of air, this configuration could be reversed, such that the first pathway provides the flow of air and the second pathway provides the flow of oxidizing agent.
- the different pathways may provide different fluids at different times.
- the first pathway may provide a flow of oxidizing agent during ignition, but be switched to provide a flow of air once a temperature in the primary reactor 600 exceeds a certain threshold temperature value (e.g., 600° C.).
- air-oxidizer manifold 620 could comprise additional pathways than those illustrated, including, for example, additional inlet ports, concentric channels, and/or jet holes.
- Air-oxidizer manifold 620 may also comprise one or more, and preferably multiple (e.g., four or more), holes 740 .
- Each hole 740 may pass through both the front and rear surfaces of air-oxidizer manifold, parallel to longitudinal axis X, and be configured to receive a bolt therethrough.
- FIG. 20 A illustrates air-oxidizer manifold 620 in perspective view
- FIG. 20 B illustrates a cut-away of a rear portion of air-oxidizer manifold 620 in perspective view
- FIG. 20 C illustrates a deeper cut-away of the rear portion of air-oxidizer manifold 620 than in FIG. 20 B
- FIG. 20 D illustrates a jet plate 2000 , according to a second embodiment.
- the second embodiment of air-oxidizer manifold 620 comprises a fluidized dispersal port 710 , encircled by concentric channel 720 , which is encircled by concentric channel 730 .
- Concentric channel 720 is connected to an oxidizer inlet port 724
- concentric channel 730 is connected to an air inlet port 734
- air-oxidizer manifold 620 comprises one or more, and preferably multiple (e.g., four or more), holes 740 , encircling fluidized dispersal port 710 , concentric channel 720 , and concentric channel 730 , and configured to receive a bolt therethrough. It should be understood that these components in the second embodiment of air-oxidizer manifold 620 perform the same functions as in the first embodiment of air-oxidizer manifold 620 in the same basic manner as in the first embodiment of air-oxidizer manifold 620 .
- concentric channel 720 and concentric channel 730 of the second embodiment of air-oxidizer manifold 620 do not comprise jet(s) 722 and jet(s) 732 , respectively.
- the second embodiment of air-oxidizer manifold 620 comprises a jet plate 2000 that is fitted to the front surface of air-oxidizer manifold 620 , to form the interface of air-oxidizer manifold 620 with primary reactor chamber 630 .
- Jet plate 2000 may be affixed to the main body of air-oxidizer manifold 620 by aligning holes 2040 with holes 740 , such that the same bolts (or other fastening mechanism) that fix air-oxidizer manifold 620 to other components, such as air-fuel mixer 610 and/or primary reactor chamber 630 , may fasten jet plate 2000 to the main body of air-oxidizer manifold 620 .
- concentric channel 720 and concentric channel 730 were recessed into the rear surface of air-oxidizer manifold 620
- concentric channel 720 and concentric channel 730 may be recessed into the front surface of air-oxidizer manifold 620 .
- Jet plate 2000 comprises holes therethrough that form jet(s) 722 and jet(s) 723 .
- jet(s) 722 are in fluid communication with concentric channel 720
- jet(s) 732 are in fluid communication with concentric channel 730 .
- oxidizing agent in concentric channel 720 may be ejected out of jet(s) 722
- air in concentric channel 730 may be ejected out of jet(s) 732 .
- Jet(s) 722 may be spaced equidistantly apart, encircling fluidized polymer dispersal port 2010
- jet(s) 732 may be spaced equidistantly apart, encircling fluidized polymer dispersal port 2010
- Each jet hole 722 and/or 732 may be angled (e.g., 4°) with respect to the longitudinal axis X passing through the center of fluidized dispersal port 710 . Jet hole(s) 722 may have the same angle or a different angle than jet hole(s) 732 .
- the angling of jet hole(s) 722 and/or 732 facilitates the creation of a vortex as the air exits air-oxidizer manifold 620 .
- Fluidized polymer dispersal port 2010 in jet plate 2000 aligns with and is in fluid communication with fluidized polymer dispersal port 710 through the main body of air-oxidizer manifold 620 .
- the air-fuel mixture output by fluidized polymer output port 618 in air-fuel mixer 610 , may flow through fluidized polymer dispersal port 710 in the main body of air-oxidizer manifold 620 and out fluidized polymer dispersal port 2010 in jet plate 2000 , into primary reactor chamber 630 .
- FIGS. 8 A and 8 B illustrate an air-fuel distribution assembly 800 in front and rear perspective views, respectively, and FIG. 8 C illustrates air-fuel distribution assembly 800 in a side view, according to a first embodiment.
- FIG. 8 D illustrates air-fuel distribution assembly 800 in a cross-sectional side view, according to the first embodiment, and FIGS. 8 E- 8 G illustrate various components of air-fuel distribution assembly 800 , according to the first embodiment.
- air-fuel distribution assembly 800 comprises a combination of air-fuel mixer 610 and air-oxidizer manifold 620 .
- a transfer tube 810 with a flange 820 may be used to join air-fuel mixer 610 with air-oxidizer manifold 620 .
- a hollow transfer tube 810 may be inserted into fluidized polymer outlet port 618 and/or otherwise attached and/or fixed to air-fuel mixer 610 , so as to maintain an open pathway out of fluidized polymer outlet port 618 .
- transfer tube 810 may be integral with air-fuel mixer 610 .
- a flange 820 may be mounted on or integral with transfer tube 810 .
- Flange 820 may comprise one or more, and preferably multiple (e.g., four or more), holes 825 .
- Each hole 825 may be configured to receive a bolt therethrough.
- Hole(s) 825 may correspond to and align with hole(s) 740 in air-oxidizer manifold 620 , such that a bolt can be inserted through each hole 825 into a corresponding hole 740 to adjoin flange 820 with the rear surface of air-oxidizer manifold 620 .
- Air-fuel distribution assembly 800 may also comprise an air inlet fitting 830 , fluidized polymer inlet fitting 840 , an oxidizer fitting 850 , and/or an air fitting (not shown).
- Air inlet fitting 830 is installed in air inlet port 612 of air-fuel mixer 610
- fluidized polymer inlet fitting 840 is installed in fluidized polymer inlet port 614 of air-fuel mixer 610 .
- oxidizer fitting 850 is installed in oxidizer inlet port 724 in air-oxidizer manifold 620
- an air fitting may be installed in air inlet port 734 of air-oxidizer manifold 620 .
- Each fitting may be configured to be seated within its respective port and be releasably connected to an input line or other device.
- Each port permits its respective fluid (e.g., air, oxidizing agent, or fluidized polymer) to flow into air-fuel distribution assembly 800 .
- air inlet fitting 830 As regulated air flows through air inlet fitting 830 into air inlet port 612 and fluidized polymer flows through fluidized polymer inlet fitting 840 into fluidized polymer inlet port 614 , the regulated air and fluidized polymer mix in internal chamber 616 to form an air-fuel mixture.
- the air-fuel mixture flows out of output port 618 and through dispersal port 710 in air-oxidizer manifold 620 .
- air-fuel distribution assembly 800 comprises a dispenser nozzle 860 and/or a dispenser cone 870 .
- Dispenser cone 870 causes the air-fuel mixture, passing through dispenser nozzle 860 , to spray out of the front surface of air-fuel distribution assembly 800 in a substantially conical pattern.
- FIG. 8 E illustrates dispenser nozzle 860 in isolation
- FIG. 8 F illustrates dispenser cone 870 in isolation
- FIG. 8 G illustrates the combination of dispenser nozzle 860 and dispenser cone 870 .
- dispenser cone 870 comprises one or more, and preferably multiple (e.g., three), feet, that are configured to slide into corresponding slots 862 around an edge of an opening in dispenser nozzle 860 .
- the opposite end of dispenser nozzle 860 is configured to fit into dispersal port 710 through the front surface of air-oxidizer manifold 620 .
- oxidizing agent flows through oxidizer fitting 840 into oxidizer inlet port 724 , into channel 720 , through jet holes 722 , and out of the front surface of air-fuel distribution assembly 800 .
- air flows through the air fitting into air inlet port 734 , into channel 730 , through jet holes 732 , and out of the front surface of air-fuel distribution assembly 800 .
- jet holes 722 and 732 may be angled with respect to the longitudinal axis X, such that the oxidizing agent and air exit jet holes 722 and 732 , respectively, at an angle.
- FIG. 21 A illustrates an air-fuel distribution assembly 800 in a front perspective view
- FIG. 21 B illustrates an air-fuel distribution assembly 800 in a cross-sectional side view, according to a second embodiment.
- like-numbered components in the second embodiment of air-fuel distribution assembly 800 may perform the same functions as in the first embodiment of air-fuel distribution assembly 800 in the same basic manner as the first embodiment of air-fuel distribution assembly 800 , except for the specific differences described herein.
- transfer tube 810 in the second embodiment does not comprise a flange. Rather, one end of transfer tube 810 may be inserted into fluidized polymer dispersal port 710 of air-oxidizer manifold 620 , while the opposing end of transfer tube 810 is inserted into fluidized polymer output port 618 of air-fuel mixer 610 , to maintain an open pathway between fluidized polymer output port 618 and fluidized polymer dispersal port 710 . Alternatively, transfer tube 810 may be integral with air-fuel mixer 610 and/or air-oxidizer manifold 620 .
- the second embodiment of air-fuel distribution assembly 800 may comprise a one-piece dispenser nozzle 860 .
- dispenser cone 870 may be omitted or integrated into one-piece dispenser nozzle 860 .
- Dispenser nozzle 860 is configured to fit into fluidized polymer dispersal port 710 through fluidized polymer dispersal port 2010 of jet plate 2000 .
- FIG. 9 A illustrates primary reactor chamber 630 in a perspective view
- FIG. 9 B illustrated primary reactor chamber 630 in a top view
- FIGS. 9 C and 9 D illustrate primary reactor chamber 630 in opposing side views
- FIGS. 9 E and 9 F illustrate primary reactor chamber 630 in rear and front views, respectively
- FIG. 9 G illustrates primary reactor chamber 630 in a cross-sectional top or bottom view, according to a first embodiment.
- primary reactor chamber 630 comprises a substantially cylindrical body 910 that is open on both ends, with a flange 920 A on one end, and a flange 920 B on the other end.
- Cylindrical body 910 is substantially cylindrical, with openings on both ends.
- a portion 912 of cylindrical body 910 may extend beyond flange 920 B, and may be sized to fit into cylindrical lip 415 in cylindrical body 410 of secondary reactor 400 .
- portion 912 may comprise an angled opening and/or a lip 914 extending over the opening.
- the opening may be angled at an angle ⁇ (e.g., 45°) with respect to longitudinal axis X, as illustrated in FIG. 9 G .
- this angled opening in conjunction with lip 914 can stabilize the pressure between primary reactor 600 and secondary reactor 400 .
- Cylindrical body 910 may comprise a plurality of holes cut, perpendicular to the longitudinal axis X, through the sides of cylindrical body 910 .
- the plurality of holes may be cut as pairs of holes, which each hole in each pair aligned along a lateral axis extending, perpendicularly to the longitudinal axis, through opposite sides of cylindrical body 910 .
- Each hole is fitted with an electrode support body 950 that is configured to receive an electrode, and, for each pair of holes, one hole is configured to receive a positive electrode 930 (e.g., tungsten electrode) and the other hole is configured to receive a ground electrode 940 (e.g., tungsten electrode).
- Each electrode 930 and 940 may be seated within a respective electrode support body 950 in its respective hole and fixed to cylindrical body 910 by a ferrule nut 960 that is threaded and tightened over electrode support body 950 .
- Primary reactor chamber 630 may comprise a plurality of these electrode pairs.
- primary reactor chamber 630 comprises three electrode pairs oriented horizontally through primary reaction chamber 630 and two electrode pairs oriented vertically through primary reactor chamber 630 .
- one subset of electrode pairs is oriented in a plane that is orthogonal to a plane in which another subset of electrode pairs is oriented.
- each positive electrode 930 is adjacent to at least one ground electrode 940 .
- the lateral axes, on which each pair of electrodes is aligned are offset from each other so that they intersect the longitudinal axis X at different points, such that none of the electrode pairs intersect each other.
- Flanges 920 A and 920 B may be, but are not necessarily, identical.
- Each flange 920 may comprise one or more, and preferably multiple (e.g., four or more), holes 925 .
- Each hole 925 may be configured to receive a bolt therethrough.
- Flange 920 A may be adjoined to the front surface of air-oxidizer manifold 620 in air-fuel distribution assembly 800 , with each hole 925 aligned to a corresponding hole 740 in air-oxidizer manifold 620 and each hole 740 aligned to a corresponding hole 825 in flange 820 of air-fuel distribution assembly 800 .
- Flange 920 A may then be fixed to air-fuel distribution assembly 800 by inserting bolts through all of the aligned holes 925 , 740 , and 825 , and threading and tightening the bolts through corresponding nuts, to thereby fix primary reaction chamber 630 to air-fuel distribution assembly 800 .
- other mechanisms may be used to fix flanges 920 A and 820 to each other and/or to fix primary reaction chamber 630 and air-fuel distribution assembly 800 to each other.
- flange 920 B may be adjoined to flange 430 on secondary reactor 400 , with each hole 925 aligned to a corresponding hole 435 in flange 430 of secondary reactor 400 .
- Flange 920 B may then be fixed to flange 430 by inserting bolts through all of the aligned holes 925 and 435 , and threading and tightening the bolts through corresponding nuts, to thereby fix primary reactor 600 to secondary reactor 400 .
- other mechanisms may be used to fix flanges 920 B and 430 to each other and/or to fix primary reactor 600 and secondary reactor 400 to each other.
- an air-fuel mixture sprays, from dispersal port 710 of air-oxidizer manifold 620 in air-fuel distribution assembly 800 , into the opening at the end of cylindrical body 910 that is opposite portion 912 .
- an oxidizing agent and air may be jetted out of jet holes 722 and 732 , respectively, of air-oxidizer manifold 620 , into the same opening of cylindrical body 910 .
- jet holes 722 and 732 may facilitate the creation of a vortex within cylindrical body 910 , which saturates the air-fuel mixture with the oxidizing agent and air.
- This vortex of fuel within cylindrical body 910 is ignited by the electrode pairs formed by aligned positive electrodes 930 and ground electrodes 940 , as described elsewhere herein.
- the resulting flame through the opening in portion 912 heats the air flowing within secondary reactor 400 between blower 200 and heat exchanger 500 .
- FIG. 22 A illustrates primary reactor chamber 630 in a perspective view
- FIG. 22 B illustrated primary reactor chamber 630 in a top view
- FIGS. 22 C and 22 D illustrate primary reactor chamber 630 in opposing side views
- FIGS. 22 E and 22 F illustrate primary reactor chamber 630 in rear and front views, respectively
- FIG. 22 G illustrates primary reactor chamber 630 in a cross-sectional top or bottom view, according to a second embodiment.
- like-numbered components in the second embodiment of primary reactor chamber 630 may perform the same functions as in the first embodiment of primary reactor chamber 630 in the same basic manner as in the first embodiment, except for the specific differences described herein.
- body 910 of the second embodiment may be octagonal.
- body 910 may comprise flat sides. This enables more precise placement of positive electrodes 930 and ground electrodes 940 , as well as temperature sensor 955 .
- the flat sides also enable tighter seals to be achieved between body 910 and threaded support bodies 950 , which hold positive electrodes 930 , ground electrodes 940 , and/or temperature sensor 955 .
- body 910 may have a different shape with flat sides, such as triangular, rectangular, pentagonal, hexagonal, heptagonal, and the like.
- Portion 912 which fits into secondary reactor 400 , may remain substantially cylindrical with an angled opening.
- Temperature sensor 955 may be fitted and mated into a threaded support body 950 in a similar or identical manner as electrodes 930 and 940 . It should be understood that a threaded support body 950 and temperature sensor 955 may be similarly or identically affixed within temperature-sensor port 458 . Temperature sensor 955 can be positioned such that a sensing portion is within primary reactor chamber 630 to measure the temperature within primary reactor chamber 630 . Temperature sensor 955 may be communicatively connected to a control system that may control plastic-powered power generator 100 , based at least in part on the output of temperature sensor 955 .
- the ends of positive electrodes 930 and ground electrodes 940 may be shortened or retracted, relative to those shown in FIGS. 9 E and 9 F .
- this may reduce turbulence within primary reactor chamber 630 .
- the thickness of body 910 may be increased for thermal considerations.
- FIG. 10 A illustrates a distributor system 1000 in a perspective view
- FIGS. 10 B and 10 C illustrate distributor system 1000 in orthogonal side views
- FIGS. 10 D and 10 E illustrate distributor system 1000 in bottom and top views, respectively, according to an embodiment
- FIG. 10 E illustrates a distributor within distributor system 1000 in a cross-sectional side view
- FIG. 10 F illustrates the movement within a distributor within distributor system 1000 in a phantom view, according to an embodiment.
- distributor system 1000 comprises a high-energy spark generator 1010 and a ground distributor 1020 , joined by a timing belt 1030 that is rotated by a belt hub 1044 driven by a motor 1040 via a motor shaft 1042 .
- High-spark energy generator 1010 and ground distributor 1020 both comprise a distributor cap 1050 on top of a distributor body 1060 , and a pulley 1070 attached to a distributor shaft 1072 that spins with the pulley 1070 and extends into distributor body 1060 , where it is attached to a rotor 1074 .
- Each distributor cap 1050 comprises a central tower 1052 and a plurality of towers 1054 (e.g., five) encircling central tower 1052 and spaced equidistantly apart from each other.
- distributor rotor 1074 comprises a platform that is connected to central tower 1052 and is sized to pass under each tower 1054 .
- FIG. 10 G as distributor rotor 1074 rotates, it will repeatedly pass under each tower 1054 in a sequence of tower 1054 A, 1054 B, 1054 C, 1054 D, 1054 E, 1054 A, and so on and so forth.
- this rotation occurs simultaneously in both high-spark energy generator 1010 and ground distributor 1020 .
- the distributor rotor 1074 in high-spark energy generator 1010 is underneath tower 1054 A in high-spark energy generator 1010
- the distributor rotor 1074 in ground distributor 1020 is also underneath tower 1054 A
- the distributor rotor 1074 in high-spark energy generator 1010 is underneath tower 1054 B in high-spark energy generator 1010
- the distributor rotor 1074 in ground distributor 1020 is also underneath tower 1054 B, and so on and so forth.
- Each tower 1054 in high-spark energy generator 1010 may be electrically attached to a different one of the positive electrodes 930 in primary reactor chamber 630 .
- each tower 1054 in ground distributor 1020 may be electrically attached to a different one of the ground electrodes 940 in primary reactor chamber 630 .
- there is a one-to-one correspondence between positive electrodes 930 and towers 1054 on high-spark energy generator 1010 and a one-to-one correspondence between ground electrodes 940 and towers 1054 on ground distributor 1020 .
- FIG. 11 A illustrates a fluidizer 1100 in a perspective view
- FIG. 11 B illustrates fluidizer 1100 in a side view
- FIG. 11 C illustrates fluidizer 1100 in a front view down a longitudinal axis of fluidizer 1100 , according to a first embodiment
- FIG. 11 D illustrates fluidizer 1100 in an exploded perspective view, according to the first embodiment.
- fluidizer 1100 comprises a substantially cylindrical body 1110 , with a base 1120 on one end and a lid 1130 on the opposite end.
- lid 1130 may be attached to one end of cylindrical body 1110 , and the other end of cylindrical body 1110 may be seated (e.g., upright) on top of base 1120 .
- Base 1120 is substantially cylindrical, with a fitting hole 1122 (e.g., circular hole in the illustrated embodiment) cut into the side to receive air connection fitting 1124 .
- Air connection fitting 1124 is configured to be seated within fitting hole 1122 , and be releasably connected to a fluid line. Thus, an external fluid line may feed air, through air connection fitting 1124 , into an interior of base 1120 .
- Base 1120 may also comprise a porous separation membrane 1126 that is positioned between an air chamber in base 1120 and an internal cavity of cylindrical body 1110 .
- Cylindrical body 1110 may be substantially cylindrical, and may contain one or more layers of polymer, created by pulverizing plastic waste.
- processed micro-fine polymers may be placed inside the internal cavity of cylindrical body 1110 , partially filling the internal cavity. Air pressure inside base 1120 is forced through the pores of porous membrane 1126 , and bubbles through the micro-fine polymers inside cylindrical body 1110 . This bubbling action agitates the polymers inside cylindrical body 1110 , causing a static charge to build up in the polymers, which, in turn, causes the polymer particles to repel each other. This creates a statically charged cloud of fluidized polymer.
- Lid 1130 may comprise an exit fitting 1132 .
- exit fitting 1132 may be fitted onto the front, external surface of lid 1130 , to provide a pathway from the internal cavity of cylindrical body 1110 to an exterior of fluidizer 1100 .
- the cloud of fluidized polymer in cylindrical body 1110 is forced out of exit fitting 1132 by the positive air pressure created inside cylindrical body 1110 by the air flow from base 1120 through porous membrane 1126 .
- fluidizer 1100 is connected to fluidized polymer inlet port 614 of air-fuel mixer 610 .
- exit fitting 1132 may be connected directly to fluidized polymer inlet fitting 840 of air-fuel distribution assembly 800 , or may be indirectly connected to fluidized polymer inlet fitting 840 via a line.
- exit fitting 1132 may be connected directly to or integrated with fluidized polymer inlet port 614 , such that no fluidized polymer inlet fitting 840 is required.
- fluidizer 1100 operates in a similar manner as a powder-coating gun, and may even comprise a powder-coating gun.
- Powder-coating guns are used to apply micro-fine polymer to surfaces to, for example, protect the surfaces from environmental elements.
- a powder-coating gun may be used to apply fine polymer powder to a surface, which is then heated by thermal energy to set the powder as a protective coating.
- FIG. 23 A illustrates fluidizer 1100 in a perspective view
- FIG. 23 B illustrates fluidizer 1100 in a front view down a longitudinal axis of fluidizer 1100
- FIG. 23 C illustrates a pump 1140 of a fluidizer 1100 in a cross-sectional side view
- FIG. 23 D illustrates fluidizer 1100 in an exploded perspective view, according to a second embodiment. It should be understood that like-numbered components in the second embodiment of fluidizer 1100 may perform the same functions as in the first embodiment of fluidizer 1100 in the same basic manner as in the first embodiment, except for the specific differences described herein.
- the main difference in the second embodiment of fluidizer 1100 is the addition of pump 1140 , in place of exit fitting 1132 .
- Pump 1140 provides better control of the delivery of the cloud of fluidized polymer than exit fitting 1132 .
- it may be difficult to achieve control and consistency with exit fitting 1132 due to changing levels of the micro-fine polymers in cylindrical body 1110 , atmospheric conditions, the need for high pressure to push the cloud of fluidized polymer out of fluidizer 1100 , and the like.
- the air pressure in base 1120 may be vented through a vent tube 1136 , which is fitted through lid 1130 to provide a pathway from the internal cavity of cylindrical body 1110 to the exterior of fluidizer 1100 .
- pump 1140 may comprise an inlet 1142 , a fuel pick-up tube 1144 , and an outlet 1146 .
- Air may be supplied through inlet 1142 to create a vacuum of low pressure as it passes over the end of fuel pick-up tube 1144 . This pressurizes fuel pick-up tube 1144 .
- Outlet 1146 may be directly or indirectly connected to fluidized polymer inlet port 614 of air-fuel mixer 610 , for example, via inlet fitting 840 of air-fuel distribution assembly 800 .
- a fill tube 1134 may be provided through lid 1130 , to provide a pathway from the exterior of fluidizer 1100 into the internal cavity of cylindrical body 1110 .
- Fill tube 1134 may be used to supply the internal cavity of cylindrical body 1110 with the micro-fine polymers (i.e., pulverized plastic waste) that are fluidized into a cloud within cylindrical body 1110 .
- cylindrical body 1110 may be replenished with the micro-fine polymers without having to shut down plastic-powered power generator 100 , opening fluidizer 1100 , and replenishing the micro-fine polymers. Rather, micro-find polymers can be added to fluidizer 1100 , through fill tube 1134 , as needed (e.g., manually or automatically under the control of a control system), while plastic-powered generator 100 continues operating.
- FIGS. 12 A and 12 B illustrate a pneumatic system 1200 that may be used to supply fluid to various components of primary reactor 600 , according to an embodiment.
- pneumatic sources 1210 may be connected to the various inlet ports described herein with one or more valves 1220 and/or gauges 1230 along pathways 1240 .
- Each valve 1220 may comprise a manual or automatic valve that regulates pressure.
- the pneumatic pressure in each pathway 1240 is measured by a gauge 1230 .
- a first pneumatic source 1210 A is connected, via a first pathway 1240 A, to air inlet port 734 .
- the first pneumatic source 1210 A is connected, via a second pathway 1240 B, to oxidizer inlet port 724 .
- a second pneumatic source 1210 B is connected, via a third pathway 1240 C, to air inlet port 734 .
- the second pneumatic source 1210 B is connected, via a fourth pathway 1240 D, to oxidizer inlet port 724 .
- Each of the four pathways 1240 A- 1240 D comprises a respective valve 1220 A- 1220 D and a respective gauge 1230 A- 1230 D.
- First pneumatic source 1210 A may comprise a tank of oxidizing agent (e.g., gas), whereas second pneumatic source 1210 B may comprise a tank of air.
- a pneumatic source 1210 B is connected, via a fifth pathway 1240 E, to air inlet port 734 .
- the pneumatic source 1210 B is connected, via a sixth pathway 1240 F, to air connection fitting 1124 .
- Each of the two pathways 1240 E and 1240 F comprises a respective valve 1220 E and 1220 F and a respective gauge 1230 E and 1230 F.
- Pneumatic source 1210 B may comprise a tank of air, to thereby supply air to air inlet port 734 and air connection fitting 1124 , via pathways 1240 E and 1240 F, respectively.
- Pneumatic systems 1200 A and 1200 B may be combined, such that a tank 1210 A of oxidizing gas is connected to oxidizer inlet port 724 (e.g., pathway 1240 B), and a tank 1210 B of air is connected to air inlet port 734 via pathway 1240 C, oxidizer inlet port 724 via pathway 1240 D or 1240 E, and air connection fitting 1124 via pathway 1230 F.
- the air tank can supply air to oxidizer inlet port 724 , for example, when a temperature within primary reactor chamber 630 exceeds a predetermined value (e.g., 600° C.).
- FIG. 24 illustrates an alternative pneumatic system 1200 C that may be used in a plastic-powered power generator 100 that utilizes the second embodiment of fluidizer 1100 illustrated in FIGS. 23 A- 23 D .
- Pneumatic system 1200 C is identical to pneumatic system 1200 B, except that pneumatic source 1210 B is connected, via a seventh pathway 1240 G, to inlet 1142 of pump 1140 of fluidizer 1100 .
- Air is supplied from pneumatic source 1210 B to inlet 1142 of pump 1140 of fluidizer 1100 .
- Pathway 1240 G may comprise a valve 1220 G and gauge 1230 G.
- pneumatic system 1200 C may be combined with pneumatic system 1200 A.
- primary reactor 600 is connected perpendicularly to secondary reactor 400 .
- end portion 912 of primary reactor 600 is inserted into cylindrical lip 415 , and flange 920 B of primary reactor 600 is fixed (e.g., bolted) to flange 430 of secondary reactor 400 , to join primary reactor 600 to secondary reactor 400 .
- the diameter of secondary reactor 400 should be larger than the diameter of primary reactor 600 , so that end portion 912 of primary reactor 600 can be accommodated within secondary reactor 400 .
- plastic-powered power generator 100 may include a catalytic converter to reduce toxic gas and pollutants in the exhaust of plastic-powered power generator 100 .
- FIG. 13 A illustrates a catalytic converter 1300 in a perspective view
- FIG. 13 B illustrates catalytic converter 1300 in a side view
- FIG. 13 C illustrates catalytic converter 1300 in a front or rear view down the longitudinal axis of catalytic converter 1300 , according to an embodiment.
- catalytic converter 1300 comprises a substantially cylindrical body 1310 that is open on both ends, with a flange 1320 A on one end, and a flange 1320 B on the other end.
- Cylindrical body 410 is substantially cylindrical, with openings on both ends, to provide a pathway for emissions through catalytic converter 1300 .
- cylindrical body 410 may have slightly conical sections on either end, sandwiched between a cylindrical central section, and cylindrical end sections on which flanges 1320 are mounted or integral.
- Emissions enter catalytic converter 1300 , through an opening in one end of catalytic converter 1300 (e.g., the opening encircled by flange 1320 A), and are cleaned by catalyzing a redox reaction. This catalytic conversion can be performed in any known manner.
- catalytic converter 1300 is a multi-phasic catalytic converter.
- Flanges 1320 A and 1320 B may be, but are not necessarily, identical. Each flange 1320 may comprise one or more, and preferably multiple (e.g., four or more), holes 1325 . Each hole 1325 may be configured to receive a bolt therethrough. Specifically, flange 1320 A may be adjoined to flange 520 B of heat exchanger 500 , with each hole 1325 aligned to a corresponding hole 525 in flange 520 B. Flange 1320 A may then be fixed to flange 520 B by inserting bolts through all of the aligned holes 525 and 1325 , and threading and tightening the bolts through corresponding nuts, to thereby fix catalytic converter 1300 to heat exchanger 500 . Alternatively or additionally, other mechanisms may be used to fix flanges 1320 A and 520 B to each other and/or to fix catalytic converter 1300 and heat exchanger 500 to each other.
- FIG. 14 illustrates the Rankine cycle for power generation using plastic-powered power generator 100 , according to an embodiment.
- heat exchanger 500 uses heated air from secondary reactor 400 to convert water 1410 into steam 1420 .
- water may be pumped by pump 1405 into connector fitting 530 A.
- the water may flow through a coil, comprising a high-pressure water line, within heat exchanger 500 , and exit heat exchanger 500 as steam via a steam pressure line connected to connector fitting 530 B.
- Steam 1420 from the steam pressure line turns turbine 1430 , which spins electrical generator 1440 to produce Direct Current (DC) power.
- Left-over steam 1420 then exits the turbine through a steam pressure line, and enters a water-cooling heat exchanger 1450 , that cools steam 1420 back into water 1410 .
- Heat exchanger 1450 may utilize a flow of cool air to cool steam 1420 back into water 1410 .
- heat exchanger 1450 is the reverse of heat exchanger 500 , which uses hot air to convert water 1410 into steam 1420 .
- Water-cooling heat exchanger 1450 may be used as a source of clean heat, for example, to operate a heat pump.
- Water 1410 flows out of a water line attached to heat exchanger 1450 and is pumped by pump 1405 back into heat exchanger 500 . It should be understood that this cycle of converting water to steam and steam to water may be maintained continuously, in a closed-loop system, to rotate electrical generator 1440 for as long as plastic-powered power generator 100 is supplied with plastic waste.
- FIG. 15 illustrates an electrical system of plastic-powered power generator 100 .
- Electrical generator 1440 supplies DC power to an inverter 1510 , which converts the DC power to Alternating Current (AC) power before the power is supplied to the grid.
- Inverter 1510 may also convert AC power from the grid into DC power.
- DC power from electrical generator 1440 and/or from DC-to-AC inverter 1510 is supplied to various components of plastic-powered power generator 100 .
- the DC power may be supplied to blower 200 via an electrical path 1505 A, an ignition system 1520 via an electrical path 1505 B, and pump 1405 via an electrical path 1505 C.
- Ignition system 1520 may comprise distributor system 1000 , and the power may drive motor 1040 of distributor system 1000 .
- Electrical path 1505 A may comprise a switch 1530 A and potentiometer 1540 A.
- variable power can be supplied through potentiometer 1540 A to blower 200 (i.e., blower 200 is on to force air into secondary reactor 400 through reducer 300 ), and when switch 1530 A is open, no power is supplied to blower 200 (i.e., blower 200 is off).
- electrical path 1505 B may comprise a switch 1530 B and potentiometer 1540 B.
- switch 1530 B is closed, variable power can be supplied through potentiometer 1540 B to ignition system 1520 (i.e., ignition system 1520 is on to ignite primary reactor 600 ), and when switch 1530 B is open, no power is supplied to ignition system 1520 (i.e., ignition system 1520 is off).
- electrical path 1505 C may comprise a switch 1530 C.
- switch 1530 C When switch 1530 C is closed, power is supplied to pump 1405 (i.e., pump 1405 is on to pump water 1410 into heat exchanger 500 ), and when switch 1530 C is open, no power is supplied to pump 1405 (i.e., pump 1405 is off).
- Each switch 1530 may comprise a Single Pole Single Throw (SPST) switch.
- the DC power may be supplied to a battery 1550 via an electrical path 1505 D.
- Battery 1550 may comprise a multi-cell battery.
- Battery 1150 can be used to store electrical energy from electrical generator 1440 and/or the grid (e.g., via inverter 1510 ), and may power blower 200 , ignition system 1520 , and/or pump 1405 (e.g., when electrical generator 1440 is not generating power, or when electrical generator 1440 is not generating sufficient power to power the entire system).
- each of the components described or implied herein may be implemented in a variety of manners, including in a manner that is different than disclosed herein.
- any of the various flanges described herein may integral with a component (e.g., formed as one piece with the component), or manufactured separately and seated and fixed to a component (e.g., welded, adhered, threaded, etc.).
- the various bolt holes described herein may all be identical, or alternatively, a subset of the bolt holes may be different than another subset of the bolt holes. However, it would generally be more efficient for all of the bolt holes to be identical, since the same bolts could be used for every bolt hole.
- FIG. 16 illustrates the usage and operation of plastic-powered power generator 100 , according to an embodiment. While the process is illustrated with a certain arrangement and ordering of steps, the process may be implemented with fewer, more, or different steps, and a different arrangement and/or ordering of steps. In addition, it should be understood that any step, which does not depend on the completion of another step, may be executed before, after, or in parallel with that other independent step, even if the steps are described or illustrated in a particular order.
- step 1605 waste products, including plastic waste, are sorted and collected.
- step 1610 the sorted and collected plastic waste is pulverized.
- This pulverization may comprise a shredding step, followed by a pelletizing step.
- the plastic waste may firstly be passed through a shredding device that reduces the plastic waste to objects ranging in size from 2,000 to 3,000 microns.
- this shredded plastic waste may secondly be passed through a pulverizing device that further reduces the plastic waste to pellets ranging in size from 0.5 to 100 microns, i.e., micron or sub-micron size.
- the pulverized plastic waste pellets may be powder coated as a layer of polymer in a fluidizing bed, such as cylindrical body 1110 of fluidizer 1100 .
- air pressure supplied by air connection fitting 1124 into base 1120 , passes through porous separation membrane 1126 , and agitates the layer of polymer in cylindrical body 1110 , thereby inducing a positive static charge.
- the static charge facilitates the polymer molecules in repelling each other, forming a cloud of fluidized polymer molecules within cylindrical body 1110 .
- a line fitted to air inlet fitting 830 supplies regulated air, through air inlet port 612 , into internal chamber 616 .
- the air, input to air-fuel distribution assembly 800 may be pressurized to approximately 1 to 10 pound-force per square inch (psi).
- the pressure of the air flow through internal chamber 616 creates a vacuum of low pressure, which pressurizes fluidized polymer inlet port 614 .
- fluidized polymer molecules flow, through exit fitting 1132 in fluidizer 1100 , which is connected, directly or indirectly, to fluidized polymer inlet fitting 740 in air-fuel distribution assembly 800 , through fluidized polymer inlet port 614 , and into internal chamber 616 .
- step 1630 the pressurized fluidized polymer flows through internal chamber 616 , through output port 618 , through dispersal port 710 , and sprays out of dispenser nozzle 860 (e.g., spreading in a substantially conical spray pattern, caused by dispenser cone 870 ) at the center of air-oxidizer manifold 620 .
- dispenser nozzle 860 e.g., spreading in a substantially conical spray pattern, caused by dispenser cone 870
- the pressurized fluidized polymer sprays into primary reactor chamber 630 , simultaneously, oxidizing agent jets (e.g., at an angle) out of jet holes 722 , and air jets (e.g., at an angle) out of jet holes 732 , into primary reactor chamber 630 .
- jet holes 722 and 732 may be angled to facilitate the rotation of the fluids exiting from jet holes 722 and 732 .
- oxidizing agent and air flow into primary reactor chamber 630 from jet holes 722 and 732 , they create a vortex which saturates the pressurized fluidized polymer, spraying from dispenser nozzle 860 , with the oxidizing agent and air.
- the vortex enhances thermo-energy and reliability within primary reactor chamber 630 .
- the pressurized fluidized polymer, mixed with air and oxidizing agent can be referred to as “fuel.”
- the oxidizing agent is gaseous oxygen.
- other oxidizing agents may be used, including, a mixture of oxygen and some other gas, ozone, and the like.
- each positive electrode 930 is aligned with exactly one ground electrode 940 along a lateral axis of primary reactor chamber 630 , and these pairs of positive and ground electrodes 930 / 940 are aligned along different lateral axes from each other, along and around a longitudinal axis X of primary reactor chamber 630 .
- a plurality of electrode pairs may be aligned along lateral axes that are perpendicular to the lateral axes along which a different plurality of electrode pairs are aligned.
- the ground electrode 940 in each electrode pair acts as a grounding field that attracts the fuel entering primary reactor chamber 630 from air-fuel distribution assembly 800 .
- the fluidized polymer is statically charged.
- the particles of fluidized polymer seek a grounding point in order to discharge.
- primary reactor chamber 630 is dielectric (e.g., formed from or coated with ceramic materials), such that the interior walls of primary reactor chamber 630 do not attract the charged particles of fluidized polymer. Instead, the charged particles of fluidized polymer are attracted to the currently grounded ground electrode 940 (e.g., which are grounded in sequence as discussed elsewhere herein).
- each ground electrode 940 provides a dual purpose: (1) a ground for the spark from the corresponding positive electrode 930 , as generated by high-spark energy generator 1010 ; and (2) a ground for the statically charged particles of fluidized polymer.
- distributor system 1000 may rotate a distributor rotor 1074 in each of a pair of high-spark energy generator 1010 and ground distributor 1020 , to provide a spark through electrode pairs in sequence.
- each of the electrode pairs each comprising an aligned positive electrode 930 and ground electrode 940 , fire in sequence, as described elsewhere herein, to ignite the fuel in primary reactor chamber 630 .
- the oxidizing agent being jetted from jet holes 722 may be replaced with compressed air or a mixture of compressed air and oxidizing agent, via pneumatic system 1200 .
- the predetermined threshold value may be 600° Celsius. At this temperature, the reaction no longer requires the oxidizing agent, but continues to require air. It should be understood that, during the ignition in step 1635 , assuming that tank 1210 A holds the oxidizing agent (e.g., gas) and tank 1210 B holds compressed air, normally, valve 1220 A should be off, valve 1220 B should be on, valve 1220 C should be on, and valve 1220 D should be off. Referring to FIG.
- valve 1220 B may be shut off to prevent oxidizing agent from tank 1210 A from flowing to oxidizer inlet port 724 , and valve 1220 D may be turned on to allow compressed air from tank 1210 B to flow to oxidizer inlet port 724 .
- valve 1220 B may be turned down, and valve 1220 D may be turned up, to create a mixture of oxidizing agent and compressed air at oxidizer inlet port 724 .
- Primary reactor chamber may comprise a temperature sensor, and a control device that monitors the output of the temperature sensor (e.g., a value representing the temperature within primary reactor chamber 630 ), and, when the monitored temperature value exceeds the predetermined threshold value, automatically controls valves 1220 (e.g., as described above) to replace the flow of oxidizing agent with air or some mixture of oxidizing agent and air (or simply turn of the flow of oxidizing agent).
- a control device that monitors the output of the temperature sensor (e.g., a value representing the temperature within primary reactor chamber 630 ), and, when the monitored temperature value exceeds the predetermined threshold value, automatically controls valves 1220 (e.g., as described above) to replace the flow of oxidizing agent with air or some mixture of oxidizing agent and air (or simply turn of the flow of oxidizing agent).
- step 1640 the flame front, created by the ignited fuel in primary reactor chamber 630 , heats the air in secondary reactor 400 via the opening in end portion 912 , which intrudes perpendicularly into secondary reactor 400 .
- blower 200 pushes air through secondary reactor 400 along an axis that is orthogonal to the longitudinal axis X of primary reactor 600 .
- Heated air exits primary reactor chamber 630 , rotationally in a vortex, and creates a low-pressure area at the junction of secondary reactor 400 and primary reactor 600 . This low-pressure area draws the flame from primary reactor chamber 630 into the air flow passing through secondary reactor 400 from blower 200 .
- the air flow from blower 200 mixes with the flame from primary reactor chamber 630 , inside secondary reactor 400 , thereby increasing the temperature and speed of the flame.
- the air flow from blower 200 increases the thermal output of primary reactor 600 , thereby improving the overall efficiency of plastic-powered power generator 100 .
- step 1645 the heated air and/or flame front from secondary reactor 400 flows into heat exchanger 500 , where it heats water 1410 , in the fluid flowing within the coil in heat exchanger 500 , to create steam 1420 .
- aqueous fluid flowing into the coil through connector fitting 530 A is heated within the coil to create steam and increased pressure.
- the pressure pushes the steam out of connector fitting 530 B.
- the heated exhaust gas may flow from heat exchanger 500 into catalytic converter 1300 , which removes pollutants from the exhaust gas prior to emitting the exhaust gas from plastic-powered power generator 100 (e.g., into the environment, or to be used as heat for another device and/or process).
- step 1650 the steam output from connector fitting 530 B passes through a turbine 1430 , causing turbine 1430 to spin.
- the thermal energy from heat exchanger 500 is used to drive turbine 1430 .
- the spinning turbine 1430 rotates electrical generator 1440 to produce electrical power. It should be understood that steps 1615 - 1650 may operate continuously, for as long as plastic-powered power generator 100 is supplied with polymer, to produce a continuous supply of electrical power.
- Combinations, described herein, such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” include any combination of A, B, and/or C, and may include multiples of A, multiples of B, or multiples of C.
- combinations such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” may be A only, B only, C only, A and B, A and C, B and C, or A and B and C, and any such combination may contain one or more members of its constituents A, B, and/or C.
- a combination of A and B may comprise one A and multiple B's, multiple A's and one B, or multiple A's and multiple B's.
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Abstract
Plastic-powered power generator. In an embodiment, the plastic-powered power generator comprises a primary reactor with an air-fuel distribution assembly configured to supply fluidized polymer, air, and oxidizer to a primary reactor chamber, and an ignition system configured to ignite a mixture of the fluidized polymer, air, and oxidizer. The primary reactor chamber extends into a secondary reactor, to, when ignited, heat air flowing through the secondary reactor from a blower to a heat exchanger. The heated air flow may convert fluid, in a coil within the heat exchanger, into steam, which can drive a turbine to generate electrical power.
Description
- This application is a continuation of U.S. patent application Ser. No. 17/751,475, filed on May 23, 2022, which is continuation-in-part of U.S. patent application Ser. No. 17/702,197, filed on Mar. 23, 2022, which is a continuation of U.S. patent application Ser. No. 16/859,580, filed on Apr. 27, 2020, which claims priority to U.S. Provisional Patent App. No. 62/991,438, filed on Mar. 18, 2020, which are all hereby incorporated herein by reference in their entireties.
- The embodiments described herein are generally directed to waste disposal, and, more particularly, to a waste disposal process that converts plastic waste into electricity using an electrochemical, thermal, and/or mechanical reactor, referred to herein as a plastic-powered power generator (PPG).
- Plastics play an important role in modern industrial society. Plastics can be found in packaging materials, heat-insulating materials, components of electrical and electronic devices, automobile parts, automobile interiors, and the like. In 2015, a study by the National Geographic Society estimated that humans had produced 6.3 billion metric tons of plastic waste since the early 1950's. Only 9% of this plastic waste had been recycled. The amount of plastic waste production has only continued to increase, as the consumption of plastics continues to increase.
- Plastics have excellent corrosion resistance, chemical resistance, durability, and the like. While this makes them very useful for parts and products, it also means that plastics do not easily decompose in their natural state. This has a devastating effect on the environment. For example, marine life has been adversely affected by plastic waste, and especially by the micro-plastics that are generated from larger plastics. For example, plastic waste has decreased the number of plankton. However, not only does plastic waste affect marine life, it also affects human and other animal life, since a large amount of food is sourced from the ocean.
- Because of the toxic nature of plastic waste and polymers, much effort has been directed to the problem of recycling plastics and using recycled plastics. One method of disposing of plastic waste uses fuel, such as natural gas, to burn the plastic waste. However, this method produces excessive pollutants, is not cost-effective, and requires high temperatures in order to consume the plastic waste. Another method involves complicated and expensive chemical processes.
- Accordingly, a plastic-powered power generator is disclosed that utilizes plastic waste as fuel to generate power. The plastic-powered power generator may comprise an electrochemical, thermal, and/or mechanical system that conveys heat from processed plastic waste to an inline heat exchanger. The plastic power generator may utilize micro-pulverized plastic to create thermal energy, and extract that thermal energy to turn a steam turbine that produces electricity.
- In an embodiment, a plastic-powered power generator comprises: a primary reactor comprising an air-fuel distribution assembly, an ignition system, and a primary reactor chamber, wherein the primary reactor chamber comprises a first opening on one end of the primary reactor chamber and a second opening on a second end of the primary reactor chamber, wherein the air-fuel distribution assembly is configured to supply fluidized polymer, air, and an oxidizing agent through the first opening in the primary reactor chamber, and wherein the ignition system is configured to ignite a mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber, wherein the primary reactor chamber comprises a plurality of flat sides; a secondary reactor comprising a secondary reactor body with a first opening on one end of the secondary reactor body, a second opening on a second end of the secondary reactor body, and a third opening on a side of the secondary reactor body, wherein the second end of the primary reactor chamber extends through the third opening in the side of the secondary reactor body, such that the second opening of the primary reactor chamber is within the secondary reactor body; a heat exchanger comprising a first opening on one end of the heat exchanger, wherein the first opening of the heat exchanger is connected to the second opening of the secondary reactor; and a blower configured to create air flow through the secondary reactor into the heat exchanger, such that the air flow is heated in the secondary reactor through the second opening of the primary reactor, and the heated air flow from the secondary reactor flows into the heat exchanger.
- The secondary reactor body may be cuboid.
- The secondary reactor body may comprise a temperature-sensor port, configured to receive a temperature sensor. The plastic-powered power generator may further comprise the temperature sensor, seated within the temperature-sensor port, such that a sensing portion of the temperature sensor extends into an interior of the secondary reactor body.
- The secondary reactor may comprise a first set of mounting holes encircling the first opening, a second set of mounting holes encircling the second opening, and a third set of mounting holes encircling the third opening.
- The primary reactor chamber may comprise an octagonal body with eight flat sides.
- The air-fuel distribution assembly may comprise an air-fuel mixer, wherein the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connected to the internal chamber.
- The plastic-powered power generator may further comprise a fluidizer, wherein the fluidizer comprises: a body comprising an internal cavity configured to house micro-fine polymer between a first end and a second end of the body, and an opening at the first end of the body; a base that covers the opening at the first end of the body, wherein the base comprises an internal cavity, and an air inlet port configured to receive air; a porous membrane between the internal cavity of the base and the internal cavity of the body; and a pump that pumps fluidized polymer from the internal cavity of the body to the fluidized polymer inlet port of the air-fuel mixer. The pump may comprise: an outlet that is connected to the fluidized polymer inlet port of the air-fuel mixer; a fuel pick-up tube that provides a pathway from the internal cavity of the body of the fluidizer to the outlet; and an inlet configured to supply air over an end of the fuel pick-up tube to create a vacuum of low pressure within the fuel pick-up tube. The fluidizer may further comprise a vent tube that provides a pathway from the internal cavity of the body of the fluidizer to an exterior of the fluidizer. The fluidizer may further comprise a fill tube that provides a pathway from an exterior of the fluidizer to the internal cavity of the body of the fluidizer.
- The air-fuel distribution assembly may comprise an air-oxidizer manifold, wherein the air-oxidizer manifold comprises: a first dispersal port comprising a channel from a rear surface of the air-oxidizer manifold to a front surface of the air-oxidizer manifold; at least one concentric channel, surrounding the dispersal port and recessed into the front surface of the air-oxidizer manifold; at least one inlet port through a side surface of the air-oxidizer manifold and connected to the at least one concentric channel; and a jet plate covering the front surface of the air-oxidizer manifold and facing the first opening in the primary reactor chamber, wherein the jet plate comprises a second dispersal port in fluid communication with the first dispersal port, and one or more jet holes in fluid communication with the at least one concentric channel. The at least one concentric channel may comprise two or more concentric channels, wherein the at least one inlet port comprises two or more inlet ports that are each connected to one of the two or more concentric channels. One of the two or more concentric channels may be recessed deeper into the front surface of the air-oxidizer manifold than a second one of the two or more concentric channels.
- The plastic-powered power generator may further comprise a pneumatic system that is configured to supply air through a first one of the two or more inlet ports, and supply an oxidizing agent through a second one of the two or more inlet ports. The pneumatic system may be further configured to supply the air through the second inlet port. The pneumatic system may be further configured to: monitor a temperature in the primary reactor chamber; while the temperature remains below a predetermined threshold, supply the air through the first inlet port, and supply the oxidizing agent through the second inlet port; and, when the temperature exceeds the predetermined threshold, supply the air through both the first inlet port and the second inlet port, and reduce or stop the supply of the oxidizing agent through the second inlet port.
- The air-fuel distribution assembly may further comprise an air-fuel mixer, wherein the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connecting the internal chamber to the first dispersal port in the air-oxidizer manifold.
- The plastic-powered power generator may further comprise a one-piece dispenser nozzle that connects to the first dispersal port through the second dispersal port.
- In an embodiment, a method comprises: fluidizing sub-micron-scale polymer; and using the plastic-powered power generator, with any combination of the features described above and herein, by supplying the fluidized polymer, air, and an oxidizing agent to the primary reactor; igniting the mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber using the ignition system, and operating the blower to create air flow through the secondary reactor into the heat exchanger.
- The details of the present invention, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:
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FIGS. 1A-1C illustrate various views of a plastic-powered generator, according to an embodiment; -
FIGS. 2A and 2B illustrate various views of a blower, according to an embodiment; -
FIGS. 3A-3D illustrate various views and components of a reducer, according to an embodiment; -
FIGS. 4A-4E illustrate various views and components of a secondary reactor, according to an embodiment; -
FIGS. 5A-5F illustrate various views and components of a heat exchanger, according to an embodiment; -
FIGS. 6A-6E illustrate various views of an air-fuel mixer, according to an embodiment; -
FIGS. 7A-7G illustrate various views and components of an air-oxidizer manifold, according to an embodiment; -
FIGS. 8A-8G illustrate various views and components of an air-fuel distribution assembly, according to an embodiment; -
FIGS. 9A-9G illustrate various views of a primary reactor chamber, according to an embodiment; -
FIGS. 10A-10G illustrate various views and components of a distributor system, according to an embodiment; -
FIGS. 11A-11D illustrate various views of a fluidizer, according to an embodiment; -
FIGS. 12A and 12B illustrate a pneumatic system, according to embodiments; -
FIGS. 13A-13C illustrate various views of a catalytic converter, according to an embodiment; -
FIG. 14 illustrates a Rankine cycle, according to an embodiment; -
FIG. 15 illustrates an electrical system, according to an embodiment; -
FIG. 16 illustrates a process for converting plastic waste into electrical power using a plastic-powered power generator, according to an embodiment; -
FIGS. 17A and 17B illustrate various views of a plastic-powered generator, according to an embodiment; -
FIGS. 18A and 18B illustrate various views and components of a secondary reactor, according to an embodiment; -
FIGS. 19A-19D illustrate various views of an air-fuel mixer, according to an embodiment; -
FIGS. 20A-20D illustrate various views and components of an air-oxidizer manifold, according to an embodiment; -
FIGS. 21A and 21B illustrate various views and components of an air-fuel distribution assembly, according to an embodiment; -
FIGS. 22A-22G illustrate various views of a primary reactor chamber, according to an embodiment; -
FIGS. 23A-23D illustrate various views of a fluidizer, according to an embodiment; and -
FIG. 24 illustrates a pneumatic system, according to an embodiment. - Embodiments of a plastic-powered power generator are disclosed. The plastic-powered power generator uses plastic waste, which is a clean and energy-rich material derived from crude oils, as fuel. Advantageously, this conversion of plastic waste to fuel not only provides power, but also reduces plastic waste.
- After reading this description, it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example and illustration only, and not limitation. As such, this detailed description of various embodiments should not be construed to limit the scope or breadth of the present invention as set forth in the appended claims.
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FIGS. 1A and 1B illustrate a plastic-poweredpower generator 100 in different perspective views, andFIG. 1C illustrates plastic-poweredpower generator 100 in an exploded perspective view, according to a first embodiment. In the illustrated embodiment, plastic-poweredpower generator 100 comprises ablower 200, which may utilize a motor to blow air into an adaptor orreducer 300.Reducer 300 increases the velocity of the blown air as the air is fed into asecondary reactor 400.Secondary reactor 400 heats the air and outputs the heated air intoheat exchanger 500, which may heat water to produce steam. In addition, aprimary reactor 600 is connected tosecondary reactor 400 at a perpendicular angle with respect to a longitudinal axis throughsecondary reactor 400. - Plastic-powered
power generator 100 may be manufactured from one or more materials, including pure ceramic, ferrous, or non-ferrous metal that is ceramic-coated or anodized. Anodization is an electrolytic passivation process, used to increase the thickness of the natural oxide layer on the surface of non-ferrous metal parts. Advantageously, ceramic-coated or anodized ferrous metal creates a dielectric state to protect against the dangers of static electricity, including grounding. - Plastic-powered
power generator 100 may be manufactured to any scale. For example, plastic-poweredpower generator 100 may be manufactured as a small-scale, portable generator. Alternatively, plastic-poweredpower generator 100 may be manufactured as a large-scale regional power plant. As another alternative, a system, comprising any quantity of plastic-poweredpower generators 100, may be constructed to provide any desired amount of electrical power. -
FIGS. 17A and 17B illustrate a plastic-poweredpower generator 100 in a perspective view and exploded perspective view, respectively, according to a second embodiment. This alternative embodiment may differ from the first embodiment, illustrated inFIGS. 1A-1C , in terms ofsecondary reactor 400 and/orprimary reactor 600. All other components of the second embodiment, includingblower 200,reducer 300, andheat exchanger 500, may be similar or identical to those described with respect to the first embodiment. Thus, any and all descriptions of those components herein apply equally to those components in the second embodiment. In addition, while the second embodiment is illustrated with a differentsecondary reactor 400 andprimary reactor 600 than the first embodiment, the second embodiment may be implemented with a differentsecondary reactor 400, but the sameprimary reactor 600, as the first embodiment, or a differentprimary reactor 600, but the samesecondary reactor 400, as the first embodiment. -
FIGS. 2A and 2B illustrateblower 200 in perspective and side views, respectively, according to an embodiment. In the illustrated embodiment,blower 200 comprises amain body 210 and aflange 220. -
Main body 210 may house a blower motor that spins to generate air flow out of opening 215 inmain body 210. Alternatively, another motor or mechanism may be used to generate the air flow out ofopening 215. -
Flange 220 may comprise one or more, and preferably multiple (e.g., four or more), holes 225. Eachhole 225 may be configured to receive a bolt therethrough. -
FIGS. 3A and 3B illustratereducer 300 in perspective and side views, andFIGS. 3C and 3D illustrate individual components ofreducer 300, according to an embodiment. In the illustrated embodiment,reducer 300 comprises anadapter cone 310 that is open on both ends, with aflange 320 on the larger end (i.e., the end with the larger diameter) and aflange 330 on the smaller end (i.e., the end with the smaller diameter). -
Adapter cone 310 has a substantially conical shape, with openings on both ends. However,adapter cone 310 may have substantiallycylindrical portions Flanges cylindrical portions -
Flange 320 may comprise one or more, and preferably multiple (e.g., four or more), holes 325. Eachhole 325 may be configured to receive a bolt therethrough. Specifically,flange 320 may be adjoined toflange 220 ofblower 200, with eachhole 325 aligned to acorresponding hole 225.Flange 320 may then be fixed toflange 220 by inserting bolts through the alignedholes 225/325, and threading and tightening the bolts through corresponding nuts, to thereby fixreducer 300 toblower 200. Alternatively or additionally, other mechanisms may be used to fixflanges reducer 300 andblower 200 to each other. -
Flange 330 may be substantially similar toflange 320, but with a smaller inner diameter thanflange 320, and optionally a smaller outer diameter as well. Similarly to flange 320,flange 330 may comprise one or more, and preferably multiple (e.g., four or more), holes 335 configured to receive a bolt therethrough. - As air flows through the conical reducer, from the larger diameter end, defined by
end portion 312 andflange 320, to the smaller diameter end, defined byend portion 314 andflange 330, the speed of the air will increase. Thus,reducer 300 increases the speed of the air flowing out of opening 215 ofblower 200 and into the proximal end ofsecondary reactor 400. -
FIG. 4A illustratessecondary reactor 400 in a perspective view, andFIGS. 4B and 4C illustratesecondary reactor 400 in different side views, according to a first embodiment.FIGS. 4D and 4E illustrate individual components ofsecondary reactor 400, according to the first embodiment. In the illustrated embodiment,secondary reactor 400 comprises a substantiallycylindrical body 410 that is open on both ends, with aflange 420A on one end, aflange 420B on the other end, and aflange 430 around a substantiallycylindrical lip 415 that intersectscylindrical body 410 at an orthogonal angle to thereby provide an open pathway into the interior ofcylindrical body 410 through the side ofcylindrical body 410. -
Cylindrical body 410 is substantially cylindrical, with openings on both ends and a circular hole defined by acylindrical lip 415 extending out fromcylindrical body 410, to provide a pathway through the side ofcylindrical body 410 into the interior ofcylindrical body 410.Cylindrical body 410 is configured to allow air fromblower 200 to flow from one end (e.g., the opening surrounded byflange 420A) to the opposite end (e.g., the opening surrounded byflange 420B). -
Flanges flange 420 may comprise one or more, and preferably multiple (e.g., four or more), holes 425. Eachhole 425 may be configured to receive a bolt therethrough. Specifically,flange 420A may be adjoined toflange 330 ofreducer 300, with eachhole 425 aligned to acorresponding hole 335 inflange 330.Flange 420A may then be fixed toflange 330 by inserting bolts through all of the alignedholes 335/425, and threading and tightening the bolts through corresponding nuts, to thereby fixsecondary reactor 400 toreducer 300. Alternatively or additionally, other mechanisms may be used to fixflanges secondary reactor 400 andreducer 300 to each other. -
Flange 430 may be substantially similar toflanges 420, but may have a different inner and/or outer diameter thanflanges 420. In the illustrated embodiment,flange 430 has a smaller inner and outer diameter thanflanges 420. However, in a different embodiment,flange 430 may have the same or different inner and/or outer diameters thanflanges 420. Similarly toflanges 420,flange 430 may comprise one or more, and preferably multiple (e.g., four or more), holes 435. Eachhole 435 may be configured to receive a bolt therethrough. - As air flows through
secondary reactor 400, the air is heated byprimary reactor 600 via a flame, produced byprimary reactor 600, through the hole defined bylip 415. The heated air fromsecondary reactor 400 flows intoheat exchanger 500. -
FIGS. 18A and 18B illustrate different perspective views ofsecondary reactor 400, according to a second embodiment. The second embodiment may differ from the first embodiment in terms of the shape ofbody 450, the lack of flanges, and/or the addition of aport 458 for a temperature sensor. While the second embodiment ofsecondary reactor 400 is illustrated with all of these features, it should be understood thatsecondary reactor 400 could instead be implemented with any subset of these features, including only one or two of these features. - Instead of a cylindrical body,
cuboid body 450 may be substantially cuboid, formed with six flat rectangular sides.Cuboid body 450 may comprise afirst opening 452 on a first end, and asecond opening 454 on a second end that is opposite the first end. In addition, cuboid body may comprise athird opening 456 on a first side, and a temperature-sensor port 458 on a second side (e.g., opposite the first side). - Both the first end and the second end of
cuboid body 450 may comprise one or more, and preferably multiple (e.g., four or more) mountingholes 425, arranged to encirclefirst opening 452 andsecond opening 454. As in the first embodiment, eachhole 425 may be configured to receive a bolt therethrough. Thus, the first end ofcuboid body 450 may be adjoined toflange 330 ofreducer 300, with eachhole 425 aligned to acorresponding hole 335 inflange 330.Cuboid body 450 may then be fixed toflange 330 by inserting bolts through all of the alignedholes 335/425, and threading and tightening bolts through corresponding nuts, to thereby fixsecondary reactor 400 toreducer 300. Alternatively or additionally, other mechanisms may be used to fixsecondary reactor 400 andreducer 300 to each other. The second end ofcuboid body 450 may be adjoined toheat exchanger 500 in a similar or identical manner. -
Third opening 456 on the first side ofcuboid body 450 may be similar tofirst opening 452 and/orsecond opening 454, but may have a different diameter thanfirst opening 452 and/orsecond opening 454. In the illustrated embodiment,third opening 456 has a smaller diameter than bothfirst opening 452 andsecond opening 454, which have the same diameter. However, in a different embodiment,third opening 456 may have the same or a greater diameter thanfirst opening 452 and/orsecond opening 454. Similarly, tofirst opening 452 andsecond opening 454,third opening 456 may be encircled by one or more mounting holes 435. Eachhole 435 may be configured to receive a bolt therethrough, such thatprimary reactor 600 may be fixed tocuboid body 450 as discussed elsewhere herein, and in a similar or identical manner asreducer 300 and/orheat exchanger 500 are fixed tocuboid body 450. - Temperature-
sensor port 458 may be positioned on a second side ofcuboid body 450 that is opposite the first side to whichprimary reactor 600 is fixed. However, in an alternative embodiment, temperature-sensor port 458 may be positioned on a different side ofcuboid body 450. Temperature-sensor port 458 may comprise an opening that is configured to receive a temperature sensor therethrough. The temperature sensor may be positioned and affixed to cuboid body 450 (e.g., using mating threaded portions, bolt-and-nut configuration, etc.) with a sensing portion of the temperature sensor withincuboid body 450. In an embodiment, temperature-sensor port 458 may be fitted with a support body that is configured to receive the temperature sensor. The temperature sensor may be seated within the support body in temperature-sensor port 458, with the sensing portion extending into the interior ofcuboid body 450, and fixed tocuboid body 450 by a ferrule nut that it is threaded and tightened over the support body. Notably, the placement of temperature-sensor port 458 through a flat side ofcuboid body 450 enables more precise placement of the temperature sensor and a tighter seal betweencuboid body 450 and the support body and/or temperature sensor. - When
cuboid body 450 is fixed toreducer 300 andheat exchanger 500, air output byblower 200 can flow fromreducer 300 at the first end ofcuboid body 450, throughfirst opening 452 into the interior ofcuboid body 450, and throughcuboid body 450. As air flows throughcuboid body 450 ofsecondary reactor 400, the air is heated byprimary reactor 600 via a flame, produced byprimary reactor 600, throughthird opening 456. The heated air flows out ofsecond opening 454, at the second end ofcuboid body 450, intoheat exchanger 500. During operation, a temperature sensor may be fixed through temperature-sensor port 458, and output the internal reaction temperature withincuboid body 450. - Advantageously, the second embodiment of
secondary reactor 400 achieves the same benefits as the first embodiment, while eliminating several components, such asflanges 420 andlip 415, which may potentially simplify the manufacturing process. In addition, the second embodiment ofsecondary reactor 400 provides a temperature-sensor port 458, such that a temperature sensor can be positioned withinsecondary reactor 400 to measure the temperature at or near the point at which the flame front, fromprimary reactor 600, enterssecondary reactor 400. The temperature sensor may be communicatively connected to a control system that may control plastic-poweredpower generator 100, based at least in part on the output of the temperature sensor.Cuboid body 450 also provides a dense body that is capable of withstanding the high temperatures generated withinsecondary reactor 400. -
FIGS. 5A and 5B illustrateheat exchanger 500 in orthogonal side views, according to an embodiment.FIG. 5C illustratesheat exchanger 500 down its longitudinal axis, according to an embodiment.FIGS. 5D-5F illustrate individual components ofheat exchanger 500, according to an embodiment. In the illustrated embodiment,heat exchanger 500 comprises a substantiallycylindrical body 510 that is open on both ends, with aflange 520A on one end, aflange 520B on the other end, and at least twoconnector fittings 530 on substantially opposite sides ofcylindrical body 510. -
Cylindrical body 510 is substantially cylindrical, with openings on both ends and fitting holes 515 (e.g., circular holes in the illustrated embodiment) cut into substantially opposite sides to receiveconnector fittings 530.Cylindrical body 510 may house a coil through which fluid flows. For example, the coil may be wound around an inner circumference ofcylindrical body 510, with an open pathway through the center of the coil (i.e., down the longitudinal axis of cylindrical body 510), such that exhaust fromsecondary reactor 400 can pass throughcylindrical body 510 via the open pathway, while heating the coils. The fluid, flowing through the coil, may comprise water. In an embodiment, the fluid may be an aqueous solution containing ethylene glycol, which helps reduce corrosion and freezing within the coil. -
Flanges flange 520 may comprise one or more, and preferably multiple (e.g., four or more), holes 525. Eachhole 525 may be configured to receive a bolt therethrough. Specifically,flange 520A may be adjoined toflange 420B ofsecondary reactor 400, with eachhole 525 aligned to acorresponding hole 425 inflange 420B.Flange 520A may then be fixed toflange 420B by inserting bolts through all of the alignedholes 425/525, and threading and tightening the bolts through corresponding nuts, to thereby fixheat exchanger 500 tosecondary reactor 400. Alternatively or additionally, other mechanisms may be used to fixflanges heat exchanger 500 andsecondary reactor 400 to each other. -
Connector fittings fitting holes 515 in opposing sides ofcylindrical body 510, and be releasably connected to an external line. Withincylindrical body 510,connector fittings cylindrical body 510, whereas the other connection fitting 520B may be used to output steam fromcylindrical body 510. An input fluid line may feed the fluid into connection fitting 520A and into the internal coil ofcylindrical body 510, where it is converted to steam, while an output line may allow the steam from the internal coil ofcylindrical body 510 to flow out into an output steam line or other device or system. -
FIGS. 6A-9F illustrate various isolated components ofprimary reactor 600, according to an embodiment. Specifically,FIGS. 6A-6E illustrate various views of an air-fuel mixer 610 ofprimary reactor 600,FIGS. 7A-7G illustrate various views and components of an air-oxidizer manifold 620,FIGS. 8A-8G illustrate various views and components of an air-fuel distribution assembly comprising air-fuel mixer 610 and air-oxidizer manifold 620, andFIGS. 9A-9G illustrate various views and components ofprimary reaction chamber 630, according to embodiments. In addition,FIGS. 10A-10G illustrate various views and components of an ignition system that may be utilized to igniteprimary reactor 600, according to an embodiment,FIGS. 11A-11D illustrate afluidizer 1100 that may be used feed plastic waste as fuel to air-fuel mixer 610, according to an embodiment, andFIGS. 12A and 12B illustratepneumatic systems 1200 that may be used withprimary reactor 600, according to embodiments. Whileprimary reactor 600 may comprise or utilize all of the illustrated components, it is not necessary for all embodiments ofprimary reactor 600 to comprise all of the illustrated components in the illustrated configuration. Rather, embodiments ofprimary reactor 600 may comprise a combination of some of the illustrated embodiments of components with non-illustrated embodiments of the other components, and/or may omit some of the illustrated components. -
FIG. 6A illustrates air-fuel mixer 610 in a perspective view, andFIGS. 6B-6D illustrate air-fuel mixer 610 in a front view, rear view, and bottom view, respectively, according to a first embodiment.FIG. 6E illustrates air-fuel mixer 610 in a cross-sectional side view, according to the first embodiment. In the illustrated embodiments, air-fuel mixer 610 comprises anair inlet port 612, a fluidizedpolymer inlet port 614, aninternal chamber 616, and a fluidizedpolymer outlet port 618. -
Air inlet port 612 may comprise an opening in the rear of air-fuel mixer 610 that provides a first pathway (e.g., a straight and/or cylindrical flow path) intointernal chamber 616 within the body of air-fuel mixer 610. A regulated air source (e.g., tank of compressed air) may be connected toair inlet port 612 to provide regulated air throughair inlet port 612 intointernal chamber 616.Air inlet port 612 may be formed in any suitable manner, so that it may be connected to a regulated air source. - Similarly, fluidized
polymer inlet port 614 may comprise an opening in the bottom-rear of air-fuel mixer 610 that provides a second pathway (e.g., a straight and/or cylindrical flow path) intointernal chamber 616 within the body of air-fuel mixer 610. A fluidizer (e.g., fluidizer 1100) may be connected to fluidizedpolymer inlet port 614 to provide fluidized polymer through fluidizedpolymer inlet port 614 intointernal chamber 616. Fluidizedpolymer inlet port 614 may be formed in any suitable manner, so that it may be connected to a fluidizer. - Fluidized
polymer outlet port 618 may comprise an opening in the front of air-fuel mixer 610 that provides a third pathway (e.g., a straight and/or cylindrical flow path) out ofinternal chamber 616. Thus, regulated air, provided throughair inlet port 612, and fluidized polymer, provided through fluidizedpolymer inlet port 614, mix withininternal chamber 616. This air-fuel mixture withininternal chamber 616 flows out of fluidizedpolymer output port 618. Fluidizedpolymer output port 618 may be formed in any suitable manner, so that it may be connected to air-oxidizer manifold 620. As illustrated in particular inFIGS. 6B and 6E , the diameter of fluidizedpolymer output port 618 and/orinternal chamber 616 may be larger than the diameter ofair inlet port 612 and/or fluidizedpolymer inlet port 614. - In the illustrated embodiment, air-
fuel mixer 610 comprises a straight pathway throughair inlet port 612,internal chamber 616, and fluidized polymer output port 618 (e.g., comprising the first and third pathways), and an angled pathway through fluidizedpolymer inlet port 614 into internal chamber 616 (e.g., comprising the second pathway). The angled pathway may be at any suitable angle with respect to the straight pathway (e.g., 30°-45°). However, it should be understood that the first, second, and third pathways may be arranged in any suitable configuration with respect to each other, as long as the pathways result in the air, fromair inlet port 612, converging with the fluidized polymer, from fluidizedpolymer inlet port 614, to create an air-fuel mixture that exits fluidizedpolymer outlet port 618. -
FIG. 19A illustrates air-fuel mixer 610 in a perspective view,FIGS. 19B and 19C illustrate air-fuel mixer 610 in front and rear views, respectively, andFIG. 19D illustrates air-fuel mixer 610 in a cross-sectional side view, according to a second embodiment. This second embodiment of air-fuel mixer 610 is more compact and less complex than the first embodiment of air-fuel mixer 610. For example, instead of a body with protruding extensions, air-fuel mixer 610 may be formed by drilling ports into a solid block. - In addition, in the second embodiment,
air inlet port 612 converges to anarrow throat 613 prior to joininginternal chamber 616. The substantially reduced diameter ofthroat 613 increases the velocity of air throughinternal chamber 616, relative to the first embodiment of air-fuel mixer 610. In turn, this creates a stronger low-pressure area in fluidizedpolymer inlet port 614. Fluidizedpolymer inlet port 614 and/or fluidizedpolymer outlet port 618 may also be reduced in diameter to increase the velocity of fluidized polymer intointernal chamber 616 and/or to increase the velocity of the air-fuel mixture out of fluidizedpolymer output port 618. -
FIG. 7A illustrates air-oxidizer manifold 620 in perspective view, andFIG. 7B illustrates air-oxidizer manifold 620 in a rear view, according to a first embodiment.FIG. 7C illustrates a close-up of a region, on the rear of air-oxidizer manifold 620, defined by circle A inFIG. 7B , according the first an embodiment.FIGS. 7D and 7E illustrate a cut-away of a rear portion of air-oxidizer manifold 620 in perspective and rear views, respectively, according to the first embodiment.FIGS. 7F and 7G illustrate a deeper cut-away of the rear portion of air-oxidizer manifold 620, than inFIGS. 7D and 7E , in perspective and rear views, respectively, according to an embodiment. In the illustrated embodiments, the rear surface of air-oxidizer manifold 620 comprises a fluidizedpolymer dispersal port 710, withconcentric channels polymer dispersal port 710. Whiledispersal port 710 andconcentric channels -
Concentric channel 720 may be an oxidizer distribution channel formed as a circular recess in the rear surface of air-oxidizer manifold 620.Concentric channel 720 comprises one or more, and preferably multiple (e.g., four or more), jet holes 722. Jet holes 722 may be arranged equidistantly apart from each other within the recessed surface ofconcentric channel 720. Eachjet hole 722 provides a pathway for an oxidizing agent fromconcentric channel 720 in the rear surface of air-oxidizer manifold 620, through the interior of air-oxidizer manifold 620, out the front surface of air-oxidizer manifold 620. Eachjet hole 722 may be angled (e.g., 4°) with respect to a longitudinal axis X passing through the center offluidized dispersal port 710. This angling of jet hole(s) 722 facilitates the creation of a vortex as the oxidizing agent exits the front surface of air-oxidizer manifold 620. The diameter of eachjet hole 722 may be approximately 0.01 to 0.1 inches, with alljet holes 722 having the same diameter as each other, or alternatively, two or more jet holes 722 having different diameters than each other. - In addition,
concentric channel 720 is connected to anoxidizer inlet port 724. As illustrated,oxidizer inlet port 724 provides a pathway, along a lateral axis that is perpendicular to the longitudinal axis X, from a side surface of air-oxidizer manifold 620, intoconcentric channel 720. Thus, the oxidizing agent may flow throughoxidizer inlet port 724, intoconcentric channel 720, where it is distributed through jet hole(s) 722, and out of the front of air-oxidizer manifold 620. -
Concentric channel 730 may be an air distribution channel formed as a circular recess in the rear surface of air-oxidizer manifold 620.Concentric channel 730 comprises one or more, and preferably multiple (e.g., four or more), jet holes 732. Jet holes 732 may be arranged equidistantly apart from each other within the recessed surface ofconcentric channel 730. Eachjet hole 732 provides a pathway for air fromconcentric channel 730 in the rear surface of air-oxidizer manifold 620, through the interior of air-oxidizer manifold 620, out the front surface of air-oxidizer manifold 620. Eachjet hole 732 may be angled (e.g., 4°) with respect to the longitudinal axis X passing through the center offluidized dispersal port 710. The angle may be the same or different than the angle of jet hole(s) 722. This angling of jet hole(s) 732 facilitates the creation of a vortex as the air exits air-oxidizer manifold 620. The diameter of eachjet hole 732 may be approximately 0.01 to 0.1 inches, with alljet holes 732 having the same diameter as each other, or alternatively, two or more jet holes 732 having different diameters than each other. - In addition,
concentric channel 730 is connected to anair inlet port 734. As illustrated,air inlet port 734 provides a pathway, along a lateral axis that is perpendicular to the longitudinal axis X, from a side surface of air-oxidizer manifold 620, intoconcentric channel 730. Thus, the air may flow throughair inlet port 734, intoconcentric channel 730, where it is distributed through jet hole(s) 732, and out of the front of air-oxidizer manifold 620. As illustrated inFIG. 7C , jet hole(s) 722 and 732 may be offset from each other, such that nojet hole 722 is aligned with anyjet hole 732 along a lateral axis passing through the center offluidized dispersal port 710. For example, the pattern ofjet holes 722 and the pattern of jet holes 732 may be such that the distances ofjet holes 722 fromjet holes 732 is maximized. In the illustrated embodiment, the pattern of jet holes 722 is a square (e.g., ajet hole 722 positioned at each corner of a square), and the pattern of jet holes 732 is a square that is rotated 45° with respect to the square pattern of jet holes 722. - As illustrated by the cut-away views in
FIGS. 7D-7G ,concentric channel 720 is deeper (i.e., recessed farther from the rear surface of air-oxidizer manifold 620) thanconcentric channel 730. Consequently, as shown byFIGS. 7D and 7F ,oxidizer inlet port 724 is also deeper (i.e., farther from the rear surface of air-oxidizer manifold 620) thanair inlet port 734. Notably, a first pathway is provided through air-oxidizer manifold 620 by the combination ofoxidizer inlet port 724,concentric channel 720, and jet(s) 722, and a second pathway is provided through air-oxidizer manifold 620 by the combination ofair inlet port 734,concentric channel 730, and jet(s) 732. While the first pathway will be described as providing a flow of oxidizing agent and the second pathway will be described as providing a flow of air, this configuration could be reversed, such that the first pathway provides the flow of air and the second pathway provides the flow of oxidizing agent. Also, it should be understood that the different pathways may provide different fluids at different times. For example, the first pathway may provide a flow of oxidizing agent during ignition, but be switched to provide a flow of air once a temperature in theprimary reactor 600 exceeds a certain threshold temperature value (e.g., 600° C.). In addition, air-oxidizer manifold 620 could comprise additional pathways than those illustrated, including, for example, additional inlet ports, concentric channels, and/or jet holes. - Air-
oxidizer manifold 620 may also comprise one or more, and preferably multiple (e.g., four or more), holes 740. Eachhole 740 may pass through both the front and rear surfaces of air-oxidizer manifold, parallel to longitudinal axis X, and be configured to receive a bolt therethrough. -
FIG. 20A illustrates air-oxidizer manifold 620 in perspective view,FIG. 20B illustrates a cut-away of a rear portion of air-oxidizer manifold 620 in perspective view,FIG. 20C illustrates a deeper cut-away of the rear portion of air-oxidizer manifold 620 than inFIG. 20B , andFIG. 20D illustrates ajet plate 2000, according to a second embodiment. As in the first embodiment, the second embodiment of air-oxidizer manifold 620 comprises afluidized dispersal port 710, encircled byconcentric channel 720, which is encircled byconcentric channel 730.Concentric channel 720 is connected to anoxidizer inlet port 724, andconcentric channel 730 is connected to anair inlet port 734. In addition, air-oxidizer manifold 620 comprises one or more, and preferably multiple (e.g., four or more), holes 740, encirclingfluidized dispersal port 710,concentric channel 720, andconcentric channel 730, and configured to receive a bolt therethrough. It should be understood that these components in the second embodiment of air-oxidizer manifold 620 perform the same functions as in the first embodiment of air-oxidizer manifold 620 in the same basic manner as in the first embodiment of air-oxidizer manifold 620. - However, in contrast to the first embodiment of air-
oxidizer manifold 620,concentric channel 720 andconcentric channel 730 of the second embodiment of air-oxidizer manifold 620 do not comprise jet(s) 722 and jet(s) 732, respectively. Instead, the second embodiment of air-oxidizer manifold 620 comprises ajet plate 2000 that is fitted to the front surface of air-oxidizer manifold 620, to form the interface of air-oxidizer manifold 620 withprimary reactor chamber 630.Jet plate 2000 may be affixed to the main body of air-oxidizer manifold 620 by aligningholes 2040 withholes 740, such that the same bolts (or other fastening mechanism) that fix air-oxidizer manifold 620 to other components, such as air-fuel mixer 610 and/orprimary reactor chamber 630, may fastenjet plate 2000 to the main body of air-oxidizer manifold 620. Notably, whereas in the first embodiment,concentric channel 720 andconcentric channel 730 were recessed into the rear surface of air-oxidizer manifold 620, in the second embodiment,concentric channel 720 andconcentric channel 730 may be recessed into the front surface of air-oxidizer manifold 620. -
Jet plate 2000 comprises holes therethrough that form jet(s) 722 and jet(s) 723. In particular, whenjet plate 2000 is fixed to the main body of air-oxidizer manifold 620, jet(s) 722 are in fluid communication withconcentric channel 720, and jet(s) 732 are in fluid communication withconcentric channel 730. Thus, oxidizing agent inconcentric channel 720 may be ejected out of jet(s) 722, and air inconcentric channel 730 may be ejected out of jet(s) 732. Jet(s) 722 may be spaced equidistantly apart, encircling fluidizedpolymer dispersal port 2010, and jet(s) 732 may be spaced equidistantly apart, encircling fluidizedpolymer dispersal port 2010. Eachjet hole 722 and/or 732 may be angled (e.g., 4°) with respect to the longitudinal axis X passing through the center offluidized dispersal port 710. Jet hole(s) 722 may have the same angle or a different angle than jet hole(s) 732. The angling of jet hole(s) 722 and/or 732 facilitates the creation of a vortex as the air exits air-oxidizer manifold 620. - Fluidized
polymer dispersal port 2010 injet plate 2000 aligns with and is in fluid communication with fluidizedpolymer dispersal port 710 through the main body of air-oxidizer manifold 620. Thus, the air-fuel mixture, output by fluidizedpolymer output port 618 in air-fuel mixer 610, may flow through fluidizedpolymer dispersal port 710 in the main body of air-oxidizer manifold 620 and out fluidizedpolymer dispersal port 2010 injet plate 2000, intoprimary reactor chamber 630. -
FIGS. 8A and 8B illustrate an air-fuel distribution assembly 800 in front and rear perspective views, respectively, andFIG. 8C illustrates air-fuel distribution assembly 800 in a side view, according to a first embodiment.FIG. 8D illustrates air-fuel distribution assembly 800 in a cross-sectional side view, according to the first embodiment, andFIGS. 8E-8G illustrate various components of air-fuel distribution assembly 800, according to the first embodiment. In the illustrated embodiments, air-fuel distribution assembly 800 comprises a combination of air-fuel mixer 610 and air-oxidizer manifold 620. - A
transfer tube 810 with aflange 820 may be used to join air-fuel mixer 610 with air-oxidizer manifold 620. For example, ahollow transfer tube 810 may be inserted into fluidizedpolymer outlet port 618 and/or otherwise attached and/or fixed to air-fuel mixer 610, so as to maintain an open pathway out of fluidizedpolymer outlet port 618. Alternatively,transfer tube 810 may be integral with air-fuel mixer 610. - A
flange 820 may be mounted on or integral withtransfer tube 810.Flange 820 may comprise one or more, and preferably multiple (e.g., four or more), holes 825. Eachhole 825 may be configured to receive a bolt therethrough. Hole(s) 825 may correspond to and align with hole(s) 740 in air-oxidizer manifold 620, such that a bolt can be inserted through eachhole 825 into acorresponding hole 740 to adjoinflange 820 with the rear surface of air-oxidizer manifold 620. - Air-
fuel distribution assembly 800 may also comprise an air inlet fitting 830, fluidized polymer inlet fitting 840, anoxidizer fitting 850, and/or an air fitting (not shown). Air inlet fitting 830 is installed inair inlet port 612 of air-fuel mixer 610, and fluidized polymer inlet fitting 840 is installed in fluidizedpolymer inlet port 614 of air-fuel mixer 610. Similarly, oxidizer fitting 850 is installed inoxidizer inlet port 724 in air-oxidizer manifold 620, and an air fitting may be installed inair inlet port 734 of air-oxidizer manifold 620. Each fitting may be configured to be seated within its respective port and be releasably connected to an input line or other device. Each port permits its respective fluid (e.g., air, oxidizing agent, or fluidized polymer) to flow into air-fuel distribution assembly 800. - As regulated air flows through air inlet fitting 830 into
air inlet port 612 and fluidized polymer flows through fluidized polymer inlet fitting 840 into fluidizedpolymer inlet port 614, the regulated air and fluidized polymer mix ininternal chamber 616 to form an air-fuel mixture. The air-fuel mixture flows out ofoutput port 618 and throughdispersal port 710 in air-oxidizer manifold 620. - In an embodiment, air-
fuel distribution assembly 800 comprises adispenser nozzle 860 and/or adispenser cone 870.Dispenser cone 870 causes the air-fuel mixture, passing throughdispenser nozzle 860, to spray out of the front surface of air-fuel distribution assembly 800 in a substantially conical pattern.FIG. 8E illustratesdispenser nozzle 860 in isolation,FIG. 8F illustratesdispenser cone 870 in isolation, andFIG. 8G illustrates the combination ofdispenser nozzle 860 anddispenser cone 870. As illustrated,dispenser cone 870 comprises one or more, and preferably multiple (e.g., three), feet, that are configured to slide intocorresponding slots 862 around an edge of an opening indispenser nozzle 860. The opposite end ofdispenser nozzle 860 is configured to fit intodispersal port 710 through the front surface of air-oxidizer manifold 620. - As the air-fuel mixture sprays out of air-
fuel distribution assembly 800, oxidizing agent flows through oxidizer fitting 840 intooxidizer inlet port 724, intochannel 720, throughjet holes 722, and out of the front surface of air-fuel distribution assembly 800. Similarly, as the air-fuel mixture sprays out of air-fuel distribution assembly 800, air flows through the air fitting intoair inlet port 734, intochannel 730, throughjet holes 732, and out of the front surface of air-fuel distribution assembly 800. As discussed above, jet holes 722 and 732 may be angled with respect to the longitudinal axis X, such that the oxidizing agent and air exit jet holes 722 and 732, respectively, at an angle. -
FIG. 21A illustrates an air-fuel distribution assembly 800 in a front perspective view, andFIG. 21B illustrates an air-fuel distribution assembly 800 in a cross-sectional side view, according to a second embodiment. It should be understood that like-numbered components in the second embodiment of air-fuel distribution assembly 800 may perform the same functions as in the first embodiment of air-fuel distribution assembly 800 in the same basic manner as the first embodiment of air-fuel distribution assembly 800, except for the specific differences described herein. - Unlike
transfer tube 810 in the first embodiment,transfer tube 810 in the second embodiment does not comprise a flange. Rather, one end oftransfer tube 810 may be inserted into fluidizedpolymer dispersal port 710 of air-oxidizer manifold 620, while the opposing end oftransfer tube 810 is inserted into fluidizedpolymer output port 618 of air-fuel mixer 610, to maintain an open pathway between fluidizedpolymer output port 618 and fluidizedpolymer dispersal port 710. Alternatively,transfer tube 810 may be integral with air-fuel mixer 610 and/or air-oxidizer manifold 620. - The second embodiment of air-
fuel distribution assembly 800 may comprise a one-piece dispenser nozzle 860. In this embodiment,dispenser cone 870 may be omitted or integrated into one-piece dispenser nozzle 860.Dispenser nozzle 860 is configured to fit into fluidizedpolymer dispersal port 710 through fluidizedpolymer dispersal port 2010 ofjet plate 2000. -
FIG. 9A illustratesprimary reactor chamber 630 in a perspective view,FIG. 9B illustratedprimary reactor chamber 630 in a top view,FIGS. 9C and 9D illustrateprimary reactor chamber 630 in opposing side views,FIGS. 9E and 9F illustrateprimary reactor chamber 630 in rear and front views, respectively, andFIG. 9G illustratesprimary reactor chamber 630 in a cross-sectional top or bottom view, according to a first embodiment. In the illustrated embodiments,primary reactor chamber 630 comprises a substantiallycylindrical body 910 that is open on both ends, with aflange 920A on one end, and aflange 920B on the other end. -
Cylindrical body 910 is substantially cylindrical, with openings on both ends. Aportion 912 ofcylindrical body 910 may extend beyondflange 920B, and may be sized to fit intocylindrical lip 415 incylindrical body 410 ofsecondary reactor 400. Notablyportion 912 may comprise an angled opening and/or alip 914 extending over the opening. The opening may be angled at an angle θ (e.g., 45°) with respect to longitudinal axis X, as illustrated inFIG. 9G . Advantageously, this angled opening in conjunction withlip 914 can stabilize the pressure betweenprimary reactor 600 andsecondary reactor 400. -
Cylindrical body 910 may comprise a plurality of holes cut, perpendicular to the longitudinal axis X, through the sides ofcylindrical body 910. The plurality of holes may be cut as pairs of holes, which each hole in each pair aligned along a lateral axis extending, perpendicularly to the longitudinal axis, through opposite sides ofcylindrical body 910. Each hole is fitted with anelectrode support body 950 that is configured to receive an electrode, and, for each pair of holes, one hole is configured to receive a positive electrode 930 (e.g., tungsten electrode) and the other hole is configured to receive a ground electrode 940 (e.g., tungsten electrode). Each electrode 930 and 940 may be seated within a respectiveelectrode support body 950 in its respective hole and fixed tocylindrical body 910 by aferrule nut 960 that is threaded and tightened overelectrode support body 950. - When a positive electrode 930 and ground electrode 940 are fixed within a pair of holes, they are aligned with each other along a lateral axis extending through the sides of
cylindrical body 910 and intersecting longitudinal axis X at a right angle.Primary reactor chamber 630 may comprise a plurality of these electrode pairs. For example, in the illustrated embodiment,primary reactor chamber 630 comprises three electrode pairs oriented horizontally throughprimary reaction chamber 630 and two electrode pairs oriented vertically throughprimary reactor chamber 630. In other words, one subset of electrode pairs is oriented in a plane that is orthogonal to a plane in which another subset of electrode pairs is oriented. In addition, the orientation of the three horizontal electrode pairs and the two vertical electrode pairs alternate, such that no positive electrodes 930 are adjacent to each other on the same side ofcylindrical body 910 and no ground electrodes 940 are adjacent to each other on the same side ofcylindrical body 910. Conversely, each positive electrode 930 is adjacent to at least one ground electrode 940. Furthermore, the lateral axes, on which each pair of electrodes is aligned, are offset from each other so that they intersect the longitudinal axis X at different points, such that none of the electrode pairs intersect each other. -
Flanges hole 925 may be configured to receive a bolt therethrough. -
Flange 920A may be adjoined to the front surface of air-oxidizer manifold 620 in air-fuel distribution assembly 800, with eachhole 925 aligned to acorresponding hole 740 in air-oxidizer manifold 620 and eachhole 740 aligned to acorresponding hole 825 inflange 820 of air-fuel distribution assembly 800.Flange 920A may then be fixed to air-fuel distribution assembly 800 by inserting bolts through all of the alignedholes primary reaction chamber 630 to air-fuel distribution assembly 800. Alternatively or additionally, other mechanisms may be used to fixflanges primary reaction chamber 630 and air-fuel distribution assembly 800 to each other. - Similarly,
flange 920B may be adjoined toflange 430 onsecondary reactor 400, with eachhole 925 aligned to acorresponding hole 435 inflange 430 ofsecondary reactor 400.Flange 920B may then be fixed toflange 430 by inserting bolts through all of the alignedholes primary reactor 600 tosecondary reactor 400. Alternatively or additionally, other mechanisms may be used to fixflanges primary reactor 600 andsecondary reactor 400 to each other. - In operation, an air-fuel mixture sprays, from
dispersal port 710 of air-oxidizer manifold 620 in air-fuel distribution assembly 800, into the opening at the end ofcylindrical body 910 that isopposite portion 912. In addition, an oxidizing agent and air may be jetted out ofjet holes oxidizer manifold 620, into the same opening ofcylindrical body 910. - As discussed elsewhere herein, jet holes 722 and 732 may facilitate the creation of a vortex within
cylindrical body 910, which saturates the air-fuel mixture with the oxidizing agent and air. This vortex of fuel withincylindrical body 910 is ignited by the electrode pairs formed by aligned positive electrodes 930 and ground electrodes 940, as described elsewhere herein. The resulting flame through the opening inportion 912 heats the air flowing withinsecondary reactor 400 betweenblower 200 andheat exchanger 500. -
FIG. 22A illustratesprimary reactor chamber 630 in a perspective view,FIG. 22B illustratedprimary reactor chamber 630 in a top view,FIGS. 22C and 22D illustrateprimary reactor chamber 630 in opposing side views,FIGS. 22E and 22F illustrateprimary reactor chamber 630 in rear and front views, respectively, andFIG. 22G illustratesprimary reactor chamber 630 in a cross-sectional top or bottom view, according to a second embodiment. It should be understood that like-numbered components in the second embodiment ofprimary reactor chamber 630 may perform the same functions as in the first embodiment ofprimary reactor chamber 630 in the same basic manner as in the first embodiment, except for the specific differences described herein. - Unlike the cylindrical body of the first embodiment,
body 910 of the second embodiment may be octagonal. In particular,body 910 may comprise flat sides. This enables more precise placement of positive electrodes 930 and ground electrodes 940, as well astemperature sensor 955. The flat sides also enable tighter seals to be achieved betweenbody 910 and threadedsupport bodies 950, which hold positive electrodes 930, ground electrodes 940, and/ortemperature sensor 955. In an alternative embodiment,body 910 may have a different shape with flat sides, such as triangular, rectangular, pentagonal, hexagonal, heptagonal, and the like.Portion 912, which fits intosecondary reactor 400, may remain substantially cylindrical with an angled opening. -
Temperature sensor 955 may be fitted and mated into a threadedsupport body 950 in a similar or identical manner as electrodes 930 and 940. It should be understood that a threadedsupport body 950 andtemperature sensor 955 may be similarly or identically affixed within temperature-sensor port 458.Temperature sensor 955 can be positioned such that a sensing portion is withinprimary reactor chamber 630 to measure the temperature withinprimary reactor chamber 630.Temperature sensor 955 may be communicatively connected to a control system that may control plastic-poweredpower generator 100, based at least in part on the output oftemperature sensor 955. - As illustrated in
FIGS. 22E and 22F , the ends of positive electrodes 930 and ground electrodes 940, extending intoprimary reactor chamber 630, may be shortened or retracted, relative to those shown inFIGS. 9E and 9F . Advantageously, this may reduce turbulence withinprimary reactor chamber 630. In addition, the thickness ofbody 910 may be increased for thermal considerations. -
FIG. 10A illustrates adistributor system 1000 in a perspective view,FIGS. 10B and 10C illustratedistributor system 1000 in orthogonal side views, andFIGS. 10D and 10E illustratedistributor system 1000 in bottom and top views, respectively, according to an embodiment.FIG. 10E illustrates a distributor withindistributor system 1000 in a cross-sectional side view, andFIG. 10F illustrates the movement within a distributor withindistributor system 1000 in a phantom view, according to an embodiment. In the illustrated embodiments,distributor system 1000 comprises a high-energy spark generator 1010 and aground distributor 1020, joined by atiming belt 1030 that is rotated by abelt hub 1044 driven by amotor 1040 via amotor shaft 1042. - High-
spark energy generator 1010 andground distributor 1020 both comprise adistributor cap 1050 on top of adistributor body 1060, and apulley 1070 attached to adistributor shaft 1072 that spins with thepulley 1070 and extends intodistributor body 1060, where it is attached to arotor 1074. Eachdistributor cap 1050 comprises acentral tower 1052 and a plurality of towers 1054 (e.g., five) encirclingcentral tower 1052 and spaced equidistantly apart from each other. - As
motor 1040 rotatesmotor shaft 1042,motor shaft 1042 rotatesbelt hub 1044, which rotatestiming belt 1030. In turn,timing belt 1030 rotatespulleys 1070, which each rotates arespective distributor shaft 1072, which rotatesdistributor rotor 1074 attached to the other end ofdistributor shaft 1072. As illustrated inFIG. 10F ,distributor rotor 1074 comprises a platform that is connected tocentral tower 1052 and is sized to pass under eachtower 1054. Thus, as illustrated inFIG. 10G , asdistributor rotor 1074 rotates, it will repeatedly pass under eachtower 1054 in a sequence oftower - It should be understood that this rotation occurs simultaneously in both high-
spark energy generator 1010 andground distributor 1020. Thus, for example, as thedistributor rotor 1074 in high-spark energy generator 1010 is underneathtower 1054A in high-spark energy generator 1010, thedistributor rotor 1074 inground distributor 1020 is also underneathtower 1054A, as thedistributor rotor 1074 in high-spark energy generator 1010 is underneathtower 1054B in high-spark energy generator 1010, thedistributor rotor 1074 inground distributor 1020 is also underneathtower 1054B, and so on and so forth. - Each
tower 1054 in high-spark energy generator 1010 may be electrically attached to a different one of the positive electrodes 930 inprimary reactor chamber 630. Similarly, eachtower 1054 inground distributor 1020 may be electrically attached to a different one of the ground electrodes 940 inprimary reactor chamber 630. In other words, there is a one-to-one correspondence between positive electrodes 930 andtowers 1054 on high-spark energy generator 1010, and a one-to-one correspondence between ground electrodes 940 andtowers 1054 onground distributor 1020. - As the
distributor rotor 1074 in high-spark energy generator 1010 passes underneath thetower 1054A on high-spark energy generator 1010 and thedistributor rotor 1074 inground distributor 1020 passes underneath thetower 1054A onground distributor 1020, a spark is generated frompositive electrode 930A toground electrode 940A. This spark ignites the fuel mixture withinprimary reactor chamber 630. It should be understood that the same chain of events may occur for each of the correspondingtowers 1054 and their connected electrode pairs 930/940. -
FIG. 11A illustrates afluidizer 1100 in a perspective view,FIG. 11B illustratesfluidizer 1100 in a side view, andFIG. 11C illustratesfluidizer 1100 in a front view down a longitudinal axis offluidizer 1100, according to a first embodiment.FIG. 11D illustratesfluidizer 1100 in an exploded perspective view, according to the first embodiment. In the illustrated embodiment,fluidizer 1100 comprises a substantiallycylindrical body 1110, with abase 1120 on one end and alid 1130 on the opposite end. For example,lid 1130 may be attached to one end ofcylindrical body 1110, and the other end ofcylindrical body 1110 may be seated (e.g., upright) on top ofbase 1120. -
Base 1120 is substantially cylindrical, with a fitting hole 1122 (e.g., circular hole in the illustrated embodiment) cut into the side to receiveair connection fitting 1124. Air connection fitting 1124 is configured to be seated withinfitting hole 1122, and be releasably connected to a fluid line. Thus, an external fluid line may feed air, throughair connection fitting 1124, into an interior ofbase 1120.Base 1120 may also comprise aporous separation membrane 1126 that is positioned between an air chamber inbase 1120 and an internal cavity ofcylindrical body 1110. -
Cylindrical body 1110 may be substantially cylindrical, and may contain one or more layers of polymer, created by pulverizing plastic waste. For example, processed micro-fine polymers may be placed inside the internal cavity ofcylindrical body 1110, partially filling the internal cavity. Air pressure insidebase 1120 is forced through the pores ofporous membrane 1126, and bubbles through the micro-fine polymers insidecylindrical body 1110. This bubbling action agitates the polymers insidecylindrical body 1110, causing a static charge to build up in the polymers, which, in turn, causes the polymer particles to repel each other. This creates a statically charged cloud of fluidized polymer. -
Lid 1130 may comprise anexit fitting 1132. As illustrated, exit fitting 1132 may be fitted onto the front, external surface oflid 1130, to provide a pathway from the internal cavity ofcylindrical body 1110 to an exterior offluidizer 1100. In practice, the cloud of fluidized polymer incylindrical body 1110 is forced out of exit fitting 1132 by the positive air pressure created insidecylindrical body 1110 by the air flow from base 1120 throughporous membrane 1126. - In an embodiment,
fluidizer 1100 is connected to fluidizedpolymer inlet port 614 of air-fuel mixer 610. For example, exit fitting 1132 may be connected directly to fluidized polymer inlet fitting 840 of air-fuel distribution assembly 800, or may be indirectly connected to fluidized polymer inlet fitting 840 via a line. Alternatively, exit fitting 1132 may be connected directly to or integrated with fluidizedpolymer inlet port 614, such that no fluidized polymer inlet fitting 840 is required. - In practice,
fluidizer 1100 operates in a similar manner as a powder-coating gun, and may even comprise a powder-coating gun. Powder-coating guns are used to apply micro-fine polymer to surfaces to, for example, protect the surfaces from environmental elements. For instance, a powder-coating gun may be used to apply fine polymer powder to a surface, which is then heated by thermal energy to set the powder as a protective coating. -
FIG. 23A illustratesfluidizer 1100 in a perspective view,FIG. 23B illustratesfluidizer 1100 in a front view down a longitudinal axis offluidizer 1100,FIG. 23C illustrates apump 1140 of afluidizer 1100 in a cross-sectional side view, andFIG. 23D illustratesfluidizer 1100 in an exploded perspective view, according to a second embodiment. It should be understood that like-numbered components in the second embodiment offluidizer 1100 may perform the same functions as in the first embodiment offluidizer 1100 in the same basic manner as in the first embodiment, except for the specific differences described herein. - The main difference in the second embodiment of
fluidizer 1100 is the addition ofpump 1140, in place ofexit fitting 1132.Pump 1140 provides better control of the delivery of the cloud of fluidized polymer thanexit fitting 1132. In particular, it may be difficult to achieve control and consistency with exit fitting 1132, due to changing levels of the micro-fine polymers incylindrical body 1110, atmospheric conditions, the need for high pressure to push the cloud of fluidized polymer out offluidizer 1100, and the like. - With the addition of
pump 1140, less air pressure is needed insidebase 1120. In particular, the air pressure in base 1120 only needs to be sufficient to create the cloud of fluidized polymer. The air pressure in base 1120 no longer needs to be sufficient to push the cloud of fluidized polymer out offluidizer 1100. The air pressure, supplied to the internal cavity ofcylindrical body 1110 bybase 1120, may be vented through avent tube 1136, which is fitted throughlid 1130 to provide a pathway from the internal cavity ofcylindrical body 1110 to the exterior offluidizer 1100. - As illustrated in
FIG. 23C ,pump 1140 may comprise aninlet 1142, a fuel pick-uptube 1144, and anoutlet 1146. Air may be supplied throughinlet 1142 to create a vacuum of low pressure as it passes over the end of fuel pick-uptube 1144. This pressurizes fuel pick-uptube 1144. Thus, the cloud of fluidized polymer within the internal cavity ofcylindrical body 1110 is pulled up through fuel pick-uptube 1144, and pushed out ofoutlet 1146.Outlet 1146 may be directly or indirectly connected to fluidizedpolymer inlet port 614 of air-fuel mixer 610, for example, via inlet fitting 840 of air-fuel distribution assembly 800. - A
fill tube 1134 may be provided throughlid 1130, to provide a pathway from the exterior offluidizer 1100 into the internal cavity ofcylindrical body 1110.Fill tube 1134 may be used to supply the internal cavity ofcylindrical body 1110 with the micro-fine polymers (i.e., pulverized plastic waste) that are fluidized into a cloud withincylindrical body 1110. Thus,cylindrical body 1110 may be replenished with the micro-fine polymers without having to shut down plastic-poweredpower generator 100,opening fluidizer 1100, and replenishing the micro-fine polymers. Rather, micro-find polymers can be added tofluidizer 1100, throughfill tube 1134, as needed (e.g., manually or automatically under the control of a control system), while plastic-poweredgenerator 100 continues operating. -
FIGS. 12A and 12B illustrate apneumatic system 1200 that may be used to supply fluid to various components ofprimary reactor 600, according to an embodiment. Specifically, pneumatic sources 1210 may be connected to the various inlet ports described herein with one or more valves 1220 and/or gauges 1230 along pathways 1240. Although particular configurations are illustrated, it should be understood thatpneumatic system 1200 may be implemented in different configurations. Each valve 1220 may comprise a manual or automatic valve that regulates pressure. The pneumatic pressure in each pathway 1240 is measured by a gauge 1230. - In the embodiment of pneumatic system 1200A, illustrated in
FIG. 12A , a firstpneumatic source 1210A is connected, via afirst pathway 1240A, toair inlet port 734. In addition, the firstpneumatic source 1210A is connected, via asecond pathway 1240B, to oxidizerinlet port 724. A secondpneumatic source 1210B is connected, via athird pathway 1240C, toair inlet port 734. In addition, the secondpneumatic source 1210B is connected, via afourth pathway 1240D, to oxidizerinlet port 724. Each of the fourpathways 1240A-1240D comprises arespective valve 1220A-1220D and arespective gauge 1230A-1230D. Firstpneumatic source 1210A may comprise a tank of oxidizing agent (e.g., gas), whereas secondpneumatic source 1210B may comprise a tank of air. - In the embodiment of pneumatic system 1200B, illustrated in
FIG. 12B , apneumatic source 1210B is connected, via afifth pathway 1240E, toair inlet port 734. In addition, thepneumatic source 1210B is connected, via asixth pathway 1240F, toair connection fitting 1124. Each of the twopathways respective valve respective gauge Pneumatic source 1210B may comprise a tank of air, to thereby supply air toair inlet port 734 andair connection fitting 1124, viapathways - Pneumatic systems 1200A and 1200B may be combined, such that a
tank 1210A of oxidizing gas is connected to oxidizer inlet port 724 (e.g.,pathway 1240B), and atank 1210B of air is connected toair inlet port 734 viapathway 1240C,oxidizer inlet port 724 viapathway pathway 1230F. Thus, the air tank can supply air tooxidizer inlet port 724, for example, when a temperature withinprimary reactor chamber 630 exceeds a predetermined value (e.g., 600° C.). -
FIG. 24 illustrates an alternativepneumatic system 1200C that may be used in a plastic-poweredpower generator 100 that utilizes the second embodiment offluidizer 1100 illustrated inFIGS. 23A-23D .Pneumatic system 1200C is identical to pneumatic system 1200B, except thatpneumatic source 1210B is connected, via aseventh pathway 1240G, toinlet 1142 ofpump 1140 offluidizer 1100. Thus, air is supplied frompneumatic source 1210B toinlet 1142 ofpump 1140 offluidizer 1100.Pathway 1240G may comprise avalve 1220G and gauge 1230G. As with pneumatic system 1200B,pneumatic system 1200C may be combined with pneumatic system 1200A. - As illustrated in
FIG. 1A ,primary reactor 600 is connected perpendicularly tosecondary reactor 400. Specifically,end portion 912 ofprimary reactor 600 is inserted intocylindrical lip 415, andflange 920B ofprimary reactor 600 is fixed (e.g., bolted) toflange 430 ofsecondary reactor 400, to joinprimary reactor 600 tosecondary reactor 400. Thus, the diameter ofsecondary reactor 400 should be larger than the diameter ofprimary reactor 600, so thatend portion 912 ofprimary reactor 600 can be accommodated withinsecondary reactor 400. - In an embodiment, plastic-powered
power generator 100 may include a catalytic converter to reduce toxic gas and pollutants in the exhaust of plastic-poweredpower generator 100.FIG. 13A illustrates acatalytic converter 1300 in a perspective view,FIG. 13B illustratescatalytic converter 1300 in a side view, andFIG. 13C illustratescatalytic converter 1300 in a front or rear view down the longitudinal axis ofcatalytic converter 1300, according to an embodiment. In the illustrated embodiment,catalytic converter 1300 comprises a substantiallycylindrical body 1310 that is open on both ends, with aflange 1320A on one end, and aflange 1320B on the other end. -
Cylindrical body 410 is substantially cylindrical, with openings on both ends, to provide a pathway for emissions throughcatalytic converter 1300. As illustrated,cylindrical body 410 may have slightly conical sections on either end, sandwiched between a cylindrical central section, and cylindrical end sections on whichflanges 1320 are mounted or integral. Emissions entercatalytic converter 1300, through an opening in one end of catalytic converter 1300 (e.g., the opening encircled byflange 1320A), and are cleaned by catalyzing a redox reaction. This catalytic conversion can be performed in any known manner. In an embodiment,catalytic converter 1300 is a multi-phasic catalytic converter. -
Flanges flange 1320 may comprise one or more, and preferably multiple (e.g., four or more), holes 1325. Eachhole 1325 may be configured to receive a bolt therethrough. Specifically,flange 1320A may be adjoined toflange 520B ofheat exchanger 500, with eachhole 1325 aligned to acorresponding hole 525 inflange 520B.Flange 1320A may then be fixed toflange 520B by inserting bolts through all of the alignedholes catalytic converter 1300 toheat exchanger 500. Alternatively or additionally, other mechanisms may be used to fixflanges catalytic converter 1300 andheat exchanger 500 to each other. -
FIG. 14 illustrates the Rankine cycle for power generation using plastic-poweredpower generator 100, according to an embodiment. As illustrated,heat exchanger 500 uses heated air fromsecondary reactor 400 to convertwater 1410 intosteam 1420. For instance, water may be pumped bypump 1405 into connector fitting 530A. The water may flow through a coil, comprising a high-pressure water line, withinheat exchanger 500, and exitheat exchanger 500 as steam via a steam pressure line connected to connector fitting 530B. -
Steam 1420 from the steam pressure line turnsturbine 1430, which spinselectrical generator 1440 to produce Direct Current (DC) power. Left-oversteam 1420 then exits the turbine through a steam pressure line, and enters a water-cooling heat exchanger 1450, that coolssteam 1420 back intowater 1410.Heat exchanger 1450 may utilize a flow of cool air to coolsteam 1420 back intowater 1410. Essentially,heat exchanger 1450 is the reverse ofheat exchanger 500, which uses hot air to convertwater 1410 intosteam 1420. Water-coolingheat exchanger 1450 may be used as a source of clean heat, for example, to operate a heat pump. -
Water 1410 flows out of a water line attached toheat exchanger 1450 and is pumped bypump 1405 back intoheat exchanger 500. It should be understood that this cycle of converting water to steam and steam to water may be maintained continuously, in a closed-loop system, to rotateelectrical generator 1440 for as long as plastic-poweredpower generator 100 is supplied with plastic waste. -
FIG. 15 illustrates an electrical system of plastic-poweredpower generator 100.Electrical generator 1440 supplies DC power to aninverter 1510, which converts the DC power to Alternating Current (AC) power before the power is supplied to the grid.Inverter 1510 may also convert AC power from the grid into DC power. - DC power from
electrical generator 1440 and/or from DC-to-AC inverter 1510 is supplied to various components of plastic-poweredpower generator 100. For example, the DC power may be supplied toblower 200 via anelectrical path 1505A, anignition system 1520 via anelectrical path 1505B, and pump 1405 via anelectrical path 1505C.Ignition system 1520 may comprisedistributor system 1000, and the power may drivemotor 1040 ofdistributor system 1000.Electrical path 1505A may comprise aswitch 1530A andpotentiometer 1540A. Whenswitch 1530A is closed, variable power can be supplied throughpotentiometer 1540A to blower 200 (i.e.,blower 200 is on to force air intosecondary reactor 400 through reducer 300), and whenswitch 1530A is open, no power is supplied to blower 200 (i.e.,blower 200 is off). Similarly,electrical path 1505B may comprise aswitch 1530B andpotentiometer 1540B. Whenswitch 1530B is closed, variable power can be supplied throughpotentiometer 1540B to ignition system 1520 (i.e.,ignition system 1520 is on to ignite primary reactor 600), and whenswitch 1530B is open, no power is supplied to ignition system 1520 (i.e.,ignition system 1520 is off). In addition,electrical path 1505C may comprise aswitch 1530C. Whenswitch 1530C is closed, power is supplied to pump 1405 (i.e.,pump 1405 is on to pumpwater 1410 into heat exchanger 500), and whenswitch 1530C is open, no power is supplied to pump 1405 (i.e.,pump 1405 is off). Each switch 1530 may comprise a Single Pole Single Throw (SPST) switch. - In addition, the DC power may be supplied to a
battery 1550 via anelectrical path 1505D.Battery 1550 may comprise a multi-cell battery. Battery 1150 can be used to store electrical energy fromelectrical generator 1440 and/or the grid (e.g., via inverter 1510), and may powerblower 200,ignition system 1520, and/or pump 1405 (e.g., whenelectrical generator 1440 is not generating power, or whenelectrical generator 1440 is not generating sufficient power to power the entire system). - The embodiments described herein are merely given as examples. Thus, it should be understood that the described embodiments do not limit the invention. An embodiment does not have to contain all of the components described herein. Rather, a particular embodiment may comprise a subset of the components described herein.
- In addition, each of the components described or implied herein may be implemented in a variety of manners, including in a manner that is different than disclosed herein. For example, any of the various flanges described herein may integral with a component (e.g., formed as one piece with the component), or manufactured separately and seated and fixed to a component (e.g., welded, adhered, threaded, etc.). In addition, the various bolt holes described herein may all be identical, or alternatively, a subset of the bolt holes may be different than another subset of the bolt holes. However, it would generally be more efficient for all of the bolt holes to be identical, since the same bolts could be used for every bolt hole.
-
FIG. 16 illustrates the usage and operation of plastic-poweredpower generator 100, according to an embodiment. While the process is illustrated with a certain arrangement and ordering of steps, the process may be implemented with fewer, more, or different steps, and a different arrangement and/or ordering of steps. In addition, it should be understood that any step, which does not depend on the completion of another step, may be executed before, after, or in parallel with that other independent step, even if the steps are described or illustrated in a particular order. - Initially, in
step 1605, waste products, including plastic waste, are sorted and collected. Then, instep 1610, the sorted and collected plastic waste is pulverized. This pulverization may comprise a shredding step, followed by a pelletizing step. Specifically, the plastic waste may firstly be passed through a shredding device that reduces the plastic waste to objects ranging in size from 2,000 to 3,000 microns. Then, this shredded plastic waste may secondly be passed through a pulverizing device that further reduces the plastic waste to pellets ranging in size from 0.5 to 100 microns, i.e., micron or sub-micron size. - In
step 1615, the pulverized plastic waste pellets may be powder coated as a layer of polymer in a fluidizing bed, such ascylindrical body 1110 offluidizer 1100. Then, instep 1620, air pressure, supplied by air connection fitting 1124 intobase 1120, passes throughporous separation membrane 1126, and agitates the layer of polymer incylindrical body 1110, thereby inducing a positive static charge. The static charge facilitates the polymer molecules in repelling each other, forming a cloud of fluidized polymer molecules withincylindrical body 1110. - In
step 1625, a line fitted to air inlet fitting 830 supplies regulated air, throughair inlet port 612, intointernal chamber 616. The air, input to air-fuel distribution assembly 800, may be pressurized to approximately 1 to 10 pound-force per square inch (psi). The pressure of the air flow throughinternal chamber 616 creates a vacuum of low pressure, which pressurizes fluidizedpolymer inlet port 614. Simultaneously, fluidized polymer molecules flow, through exit fitting 1132 influidizer 1100, which is connected, directly or indirectly, to fluidized polymer inlet fitting 740 in air-fuel distribution assembly 800, through fluidizedpolymer inlet port 614, and intointernal chamber 616. - In
step 1630, the pressurized fluidized polymer flows throughinternal chamber 616, throughoutput port 618, throughdispersal port 710, and sprays out of dispenser nozzle 860 (e.g., spreading in a substantially conical spray pattern, caused by dispenser cone 870) at the center of air-oxidizer manifold 620. As the pressurized fluidized polymer sprays intoprimary reactor chamber 630, simultaneously, oxidizing agent jets (e.g., at an angle) out of jet holes 722, and air jets (e.g., at an angle) out of jet holes 732, intoprimary reactor chamber 630. As discussed elsewhere herein, jet holes 722 and 732 may be angled to facilitate the rotation of the fluids exiting fromjet holes primary reactor chamber 630 fromjet holes dispenser nozzle 860, with the oxidizing agent and air. The vortex enhances thermo-energy and reliability withinprimary reactor chamber 630. At this point, the pressurized fluidized polymer, mixed with air and oxidizing agent, can be referred to as “fuel.” In a preferred embodiment, the oxidizing agent is gaseous oxygen. However, other oxidizing agents may be used, including, a mixture of oxygen and some other gas, ozone, and the like. - In
step 1635, the fuel is ignited withinprimary reactor chamber 630. As described elsewhere herein, each positive electrode 930 is aligned with exactly one ground electrode 940 along a lateral axis ofprimary reactor chamber 630, and these pairs of positive and ground electrodes 930/940 are aligned along different lateral axes from each other, along and around a longitudinal axis X ofprimary reactor chamber 630. In an embodiment, a plurality of electrode pairs may be aligned along lateral axes that are perpendicular to the lateral axes along which a different plurality of electrode pairs are aligned. - The ground electrode 940 in each electrode pair acts as a grounding field that attracts the fuel entering
primary reactor chamber 630 from air-fuel distribution assembly 800. Specifically, as discussed elsewhere herein, the fluidized polymer is statically charged. Thus, the particles of fluidized polymer seek a grounding point in order to discharge. In an embodiment, to facilitate this attraction between the fuel and ground electrodes 940,primary reactor chamber 630 is dielectric (e.g., formed from or coated with ceramic materials), such that the interior walls ofprimary reactor chamber 630 do not attract the charged particles of fluidized polymer. Instead, the charged particles of fluidized polymer are attracted to the currently grounded ground electrode 940 (e.g., which are grounded in sequence as discussed elsewhere herein). Thus, the grounding of each ground electrode 940 provides a dual purpose: (1) a ground for the spark from the corresponding positive electrode 930, as generated by high-spark energy generator 1010; and (2) a ground for the statically charged particles of fluidized polymer. - As the fuel exits air-
fuel distribution assembly 800 and is propelled towards a ground electrode 940, the paired positive electrode 930 creates a spark towards the ground electrode 940, which ignites the fuel. For example, as described elsewhere herein,distributor system 1000 may rotate adistributor rotor 1074 in each of a pair of high-spark energy generator 1010 andground distributor 1020, to provide a spark through electrode pairs in sequence. Thus, each of the electrode pairs, each comprising an aligned positive electrode 930 and ground electrode 940, fire in sequence, as described elsewhere herein, to ignite the fuel inprimary reactor chamber 630. - In an embodiment, when the operating temperature within
primary reactor chamber 630 reaches a predetermined threshold value, the oxidizing agent being jetted fromjet holes 722 may be replaced with compressed air or a mixture of compressed air and oxidizing agent, viapneumatic system 1200. The predetermined threshold value may be 600° Celsius. At this temperature, the reaction no longer requires the oxidizing agent, but continues to require air. It should be understood that, during the ignition instep 1635, assuming thattank 1210A holds the oxidizing agent (e.g., gas) andtank 1210B holds compressed air, normally,valve 1220A should be off,valve 1220B should be on,valve 1220C should be on, andvalve 1220D should be off. Referring toFIG. 12A , to replace the oxidizing agent with compressed air,valve 1220B may be shut off to prevent oxidizing agent fromtank 1210A from flowing tooxidizer inlet port 724, andvalve 1220D may be turned on to allow compressed air fromtank 1210B to flow tooxidizer inlet port 724. To replace the oxidizing agent with a mixture of compressed air and oxidizing agent,valve 1220B may be turned down, andvalve 1220D may be turned up, to create a mixture of oxidizing agent and compressed air atoxidizer inlet port 724. Primary reactor chamber may comprise a temperature sensor, and a control device that monitors the output of the temperature sensor (e.g., a value representing the temperature within primary reactor chamber 630), and, when the monitored temperature value exceeds the predetermined threshold value, automatically controls valves 1220 (e.g., as described above) to replace the flow of oxidizing agent with air or some mixture of oxidizing agent and air (or simply turn of the flow of oxidizing agent). - In
step 1640, the flame front, created by the ignited fuel inprimary reactor chamber 630, heats the air insecondary reactor 400 via the opening inend portion 912, which intrudes perpendicularly intosecondary reactor 400. Specifically,blower 200 pushes air throughsecondary reactor 400 along an axis that is orthogonal to the longitudinal axis X ofprimary reactor 600. Heated air exitsprimary reactor chamber 630, rotationally in a vortex, and creates a low-pressure area at the junction ofsecondary reactor 400 andprimary reactor 600. This low-pressure area draws the flame fromprimary reactor chamber 630 into the air flow passing throughsecondary reactor 400 fromblower 200. In other words, the air flow fromblower 200 mixes with the flame fromprimary reactor chamber 630, insidesecondary reactor 400, thereby increasing the temperature and speed of the flame. In other words, the air flow fromblower 200 increases the thermal output ofprimary reactor 600, thereby improving the overall efficiency of plastic-poweredpower generator 100. - In
step 1645, the heated air and/or flame front fromsecondary reactor 400 flows intoheat exchanger 500, where it heatswater 1410, in the fluid flowing within the coil inheat exchanger 500, to createsteam 1420. Specifically, aqueous fluid flowing into the coil through connector fitting 530A is heated within the coil to create steam and increased pressure. The pressure pushes the steam out of connector fitting 530B. In addition, the heated exhaust gas may flow fromheat exchanger 500 intocatalytic converter 1300, which removes pollutants from the exhaust gas prior to emitting the exhaust gas from plastic-powered power generator 100 (e.g., into the environment, or to be used as heat for another device and/or process). - In
step 1650, the steam output from connector fitting 530B passes through aturbine 1430, causingturbine 1430 to spin. In other words, the thermal energy fromheat exchanger 500 is used to driveturbine 1430. The spinningturbine 1430 rotateselectrical generator 1440 to produce electrical power. It should be understood that steps 1615-1650 may operate continuously, for as long as plastic-poweredpower generator 100 is supplied with polymer, to produce a continuous supply of electrical power. - The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly not limited.
- Combinations, described herein, such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” include any combination of A, B, and/or C, and may include multiples of A, multiples of B, or multiples of C. Specifically, combinations such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” may be A only, B only, C only, A and B, A and C, B and C, or A and B and C, and any such combination may contain one or more members of its constituents A, B, and/or C. For example, a combination of A and B may comprise one A and multiple B's, multiple A's and one B, or multiple A's and multiple B's.
Claims (1)
1. A plastic-powered power generator comprising:
a primary reactor comprising an air-fuel distribution assembly, an ignition system, and a primary reactor chamber, wherein the primary reactor chamber comprises a first opening on one end of the primary reactor chamber and a second opening on a second end of the primary reactor chamber, wherein the air-fuel distribution assembly is configured to supply fluidized polymer, air, and an oxidizing agent through the first opening in the primary reactor chamber, and wherein the ignition system is configured to ignite a mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber, wherein the primary reactor chamber comprises a plurality of flat sides;
a secondary reactor comprising a secondary reactor body with a first opening on one end of the secondary reactor body, a second opening on a second end of the secondary reactor body, and a third opening on a side of the secondary reactor body, wherein the second end of the primary reactor chamber extends through the third opening in the side of the secondary reactor body, such that the second opening of the primary reactor chamber is within the secondary reactor body;
a heat exchanger comprising a first opening on one end of the heat exchanger, wherein the first opening of the heat exchanger is connected to the second opening of the secondary reactor; and
a blower configured to create air flow through the secondary reactor into the heat exchanger, such that the air flow is heated in the secondary reactor through the second opening of the primary reactor, and the heated air flow from the secondary reactor flows into the heat exchanger.
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US16/859,580 US11306916B2 (en) | 2020-03-18 | 2020-04-27 | Plastic-powered power generator |
US17/702,197 US11635205B2 (en) | 2020-03-18 | 2022-03-23 | Plastic-powered power generator |
US17/751,475 US11774094B2 (en) | 2020-03-18 | 2022-05-23 | Plastic-powered power generator |
US18/373,129 US20240027065A1 (en) | 2020-03-18 | 2023-09-26 | Plastic-powered power generator |
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FR2557280B1 (en) * | 1983-12-21 | 1986-03-28 | Commissariat Energie Atomique | SODIUM-WATER STEAM GENERATOR WITH STRAIGHT CONCENTRIC TUBES AND GAS CIRCULATION IN THE ANNULAR SPACE |
JP3653946B2 (en) | 1997-09-10 | 2005-06-02 | 株式会社日立製作所 | Waste plastic recycling system |
JP2003327978A (en) * | 2002-05-14 | 2003-11-19 | Ishikawajima Harima Heavy Ind Co Ltd | Method for treating waste plastic, apparatus therefor, power generation equipment and liquid fuel |
WO2006035441A2 (en) * | 2004-09-28 | 2006-04-06 | Amit Azulay | Method and system for processing waste materials |
US7768767B2 (en) * | 2006-05-05 | 2010-08-03 | Pratt & Whitney Canada Corp. | Triggered pulsed ignition system and method |
ITBS20070210A1 (en) * | 2007-12-21 | 2009-06-22 | Enzo Ranchetti | PROCESS AND PLANT FOR THE DISPOSAL OF WASTE CONTAINING METALS, INERT FRACTIONS AND ORGANIC FRACTIONS |
WO2009145884A1 (en) | 2008-05-30 | 2009-12-03 | Natural State Research, Inc. | Method for converting waste plastic to hydrocarbon fuel materials |
US8833276B2 (en) * | 2009-02-06 | 2014-09-16 | William Hunkyun Bang | Burner system for waste plastic fuel |
DE102011000037B4 (en) | 2011-01-05 | 2012-09-06 | Pyrum Innovations International S.A. | thermal reactor |
US9387640B1 (en) | 2011-08-01 | 2016-07-12 | David D. B. Rice | Recycling systems and methods for plastic waste |
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