WO2009066251A1

WO2009066251A1 - Method and apparatus for treating waste materials

Info

Publication number: WO2009066251A1
Application number: PCT/IB2008/054859
Authority: WO
Inventors: Fulvio Molinari; Sergio Mottana; Giuseppe Zanoni
Original assignee: Vuzeta Brevetti S.R.L.
Priority date: 2007-11-22
Filing date: 2008-11-19
Publication date: 2009-05-28
Also published as: ITBO20070770A1

Abstract

The method for treating waste materials provides for initially introducing in a loading system a measured amount of operating fluid and subsequently introducing in said measured amount of operating fluid the waste materials to be treated in inert atmosphere, at least one additive catalyzing substance and at least one additive neutralizing substance. The mixture of said operating fluid, waste materials and additive substances is heated through kinetic energy conversion into thermal energy, triggering catalytic molecular restructuring reactions of the waste materials. The operating fluid transported by the water vapour is separated from the water which is in the solid waste and from that produced in the reaction, and re-circulated. The mixture deriving from the catalytic molecular restructuring reaction, which is separated from the operating fluid, is treated to obtain synthetic fuels from it.

Description

Description METHOD AND APPARATUS FOR TREATING WASTE

MATERIALS

Technical Field

[1] The present invention relates to a method and an apparatus for treating waste materials of various typologies, such as solid urban waste, exhausted oils, crude oil, refinery scraps, plastic materials and similar, purification sludge, animal dejections, digested and biological masses, through catalytic restructuring of the molecules of the above-mentioned materials in a liquid synthetic fuel. Background Art

[2] It is known that the disposal of waste and above-mentioned materials is a serious issue for contemporary society. In order to face, even partly, this problem, various processes have been proposed suitable to operate the waste materials treatment such as municipal solid waste, exhausted oils, crude oil, refinery waste, plastic materials, purification sludge, animal dejections, digested and biological masses. In particular, at present, some processes are known, which allow to synthesize, starting from these waste materials, fuel products of the type for instance of diesel oil or petrol. These processes provide for feeding the waste to a treatment plant, in which they are adequately treated to obtain the separation of the desired fuel from the residual substances.

[3] For instance, patent US 5,849,964 describes a process for treating plastic waste materials, to obtain chemical substances and fuel compounds in liquid state. The process provides that the entering plastic materials are subjected to an initial treatment of depolymerization, in order to obtain a liquid phase and a volatile phase to be treated separately. The volatile phase is then separated into a liquid phase and a gaseous phase, singularly treated to obtain again respective liquid phases that, through hydrogenation, lead to the desired final substances.

[4] European patent EP 1 538 191 describes, in its turn, a process to obtain fuel oil, which provides for mixing waste materials to an additive oil, to put this mixture in a working cycle and to make the same material undergo a separation treatment through distillation by which to obtain the desired fuel and by which the waste residuals are separated. More precisely, the process provides that the molecular bonds of the entering hydrocarbons are broken by cracking reactions of thermal-catalytic type, obtaining a mixture of lighter substances which are separable by distillation, and that the thermal energy supply required by the cracking reactions mainly derives from the transformation of kinetic energy. The thermal energy needed is, in fact, transferred to the flow of the mixture of additive oil and waste through suitable agitator means operating in countercurrent to the pumping means of the same flow. This allows a higher thermal-kinetic efficiency, and therefore a higher economic profit, compared to the traditional heating methods of conduction through the walls of the container.

[5] The processes of known type previously described, and in particular the method described in European patent No EP 1 538 191, allow to usefully exploit waste containing hydrocarbons.

[6] The main problem found in the application of the waste treatment technologies that use a diathermal oil as operating fluid, among which patent EP 1 538 191, is the need for continually reinstating the additive oil. This is mainly due to presence of water that progressively removes mainly the additive fluid. In particular, the water is found inside the materials to be treated, the solid or liquid waste, but mainly it is formed through chemical reaction inside the reactor.

[7] At present, there is an attempt to decrease as much as possible at least the water content in the waste inserted into the feeding circuit, making the waste undergo in advance some drying cycles. But being this process very expensive, it is not advantageous to lower the water content beyond 10%.

[8] On the other hand, it is not possible, at present, to intervene on the amount of water produced through chemical reaction. For this reason, the fluidifying substances tend to be removed by the water vapour current after few operating cycles. It is therefore necessary to constantly monitor the amounts of fluidizers that are in the feeding flow and to intervene to top up the same amounts. The consumption of fluidifying substances and the employment of labour required for controlling the feeding flow have a remarkable effect upon the production costs.

[9] Therefore, the known methods for the waste materials treatment only partially solve the problem of waste disposal and do not allow to constantly and effectively control the quality and the features of the final products. Disclosure of Invention Disclosure

[10] The aim of the present invention is to overcome the cited drawbacks by devising a method that allows to optimally operate the treatment of waste materials such as municipal solid waste, exhausted oils, crude oil, refinery waste, plastic materials, purification sludge, animal dejections, digested and biological masses through catalytic molecular restructuring.

[11] Within this scope it is a further aim of the claimed invention to obtain from the waste materials mentioned above a synthetic liquid fuel conformed to the required specifications. [12] A further aim of the present invention is to provide a method and an apparatus for the treatment through catalytic molecular restructuring of the above-mentioned waste materials by which the water contained in the waste and/or produced in the reaction is separated, treating it, in order to make its composition satisfy the law requirements.

[13] Another aim of the present invention is to provide a method that allows to obtain, according to the nature of the waste materials to be treated, a liquid fuel, which is optimal both from the qualitative and the quantitative point of view.

[14] Yet another aim of the invention is to provide an apparatus for treating waste materials through catalytic molecular restructuring of simple conception, versatile use and certainly reliable functioning, and also to automatically manage the controls and detections using electronic means, which can also be remote controlled.

[15] The cited aims are reached, according to the claimed invention, by the method for treating waste materials through catalytic molecular restructuring according to claim 1. Description of Drawings

[16] Description details of the invention will be further evident in the illustrations of preferred embodiments of the apparatus that realises the method for treating waste materials through catalytic molecular restructuring according to the invention, illustrated in the guidelines drawings attached, wherein:

[17] Fig. 1 illustrates a schematic representation of the feeding devices suitable to be employed in the claimed apparatus for waste materials treatment;

[18] Fig. 2 illustrates a schematic view of the treatment devices suitable to be employed in the claimed apparatus. Best Mode

[19] With reference to such figures, the numeral 100 refers to the apparatus for treating through catalytic molecular restructuring waste materials for producing synthetic fuel.

[20] The apparatus 100 comprises a fixed structure, not Illustrated, developed preferably on different levels, equipped with a loading system 10 suitable to allow the loading of waste materials and of the other substances involved in a reactor unit 20 (fig. 1).

[21] The loading system 10, which is preferably positioned on transferable platforms, comprises a first tank 1 for the containment of a catalyzing substance, a third tank 3 for the containment of a neutralizing substance and a fourth tank 4 for the containment of waste oil to be treated. The tanks 1, 2, 3, 4 are connected through suitable pipes to a reaction tank 5, which is part of the reactor unit 20. The reaction tank 5 is further connected to an insertion unit 6 of the solid materials to be treated. Furthermore, it is possible to provide for a connection of the reaction tank 5 to a further feeding tank of suitable chemical reagents, of the type for instance of hydrogen donors such as tetraline and similar, to increase the features of the fuel liquid obtained. [22] The first tank 1, preferably made of steel, is equipped with level and capacity sensors, and also with safety means of known type. The first tank 1 is connected to the reaction tank 5 through a first connection tank 7 on which a first pumping member 8 is arranged.

[23] The operating fluid suitable to be contained into and fed by the first tank 1 preferably consists of a diathermal oil resistant to high temperatures. Nevertheless, it is possible to provide for using different fluid means, such as for instance purified waxes and similar. The operating fluid has the function of diluting and fluidizing the current of material both liquid and solid circulating inside the reactor unit 20 in order to realize the catalytic molecular restructuring.

[24] The second tank 2 is suitable to receive the catalyzing substance from a downloading system 9, of the type commonly defined 'big bag', comprising a screw feeding member 11 and a dust filter. Also, the second tank 2 is preferably equipped with an agitator member 12 and is connected to the reaction tank 5 through a second feeding duct 13 on which a second pumping member 14 is arranged, for instance of the single-screw type. For the feeding of the catalyzing substance, safety and control means of known type are further provided.

[25] The third tank 3 is suitable to receive the neutralizing substance from a downloading unit 15, preferably of the type called manual or automatic sack-breaker equipped with a dust filter. The downloading unit 15 comprises a screw feeding member 16 for feeding the third tank 3, which is equipped with an agitator member 17 and is connected to the reaction tank 5 through a third feeding duct 18 on which a third pumping member 19 is installed, preferably of the single-screw type. Means of a known type are further provided for the control and safety of the feeding of the neutralizing substance to the reaction tank 5.

[26] The fourth tank 4 for the oil to be treated is connected to the reaction tank 5 through a fourth feeding duct 58 equipped with a respective fourth pumping member 21, as well as with safety and control means of a known type.

[27] The insertion unit 6 of the solid materials forms a mechanical unit suitably protected, served by a feeding member of a known type for the insertion of the solid waste in the reaction tank 5. The insertion unit 6 is suitable to insert the solid waste keeping the environment inert through controlled intake of nitrogen and realizing the loading of the solid materials by means of a system of one or more valves with alternate opening. The insertion unit 6 is suitable to be controlled in order to automatically operate from a remote site equipped with PLC, suitably arranged to control the apparatus, not ilόlustrated in the drawing for simplicity.

[28] The reaction tank 5 of the reaction unit 20 preferably consists of a single tank suitable to receive the materials coming from the tanks 1, 2, 3, 4, and from the insertion unit 6 of the solid materials. The reaction tank 5 is connected to the reactor unit 20 and it is equipped with suitable control and safety means, in particular to monitor the amount of oxygen and to perform the inertization through nitrogen. Furthermore, the reaction tank 5 is connected to a system for the recovery of the operating fluid and other reaction products, separating them from the water which originates through chemical reaction and through evaporation of the humidity contained in the solid waste, as better explained below. Furthermore, the reaction tank 5 is connected on the upper side, through a safety valve and a downloading duct 26, to a downloading tank 25 called 'blow-down', into which through a further downloading duct, the downloading gaseous substance is suitable to further flow coming from the safety valve of a vessel 31, as better explained below.

[29] The reactor unit 20 comprises one or more reactor members 22 of the centrifugal type, each equipped with its own mover 23, with a cooling system of the swivel support mechanical means, with suitable control means of temperature and pressure inside each reactor. In the case illustrated in fig. 1, the reactor unit 20 consists, not only of the reaction tank 5, but also of a first and a second centrifugal reactor 22 connected through respective ducts 24 to the lower part of the reaction tank 5 to receive the flow of substances coming from the tanks of the loading system 10. Preferably the centrifugal reactors 22 are controlled by inverter control devices.

[30] The centrifugal reactors 22 comprise also a mechanical agitator, operated in rotational motion by the mover 23, which generates a flow in counter-current with respect to the motion of the entering fluid. This causes the conversion of part of the kinetic energy of the feeding flow in thermal energy and, as consequence, a corresponding increase of the temperature of the fluid, which allows the catalytic molecular restructuring reactions to start.

[31] This result is obtained, in particular, in known way, through an asynchronous motor connected to the centrifugal reactor and controlled by an electronic converter that, through a complex vectorial algorithm, allows accelerations from zero to the maximum speed in less than 100 ms and decelerations in less then 80 ms.

[32] Downstream of the reactor unit 20 a treating system 30 is arranged, consisting of modules suitable to operate the separation of the final products from the reaction products (fig. 2). The treatment system 30 provides for a vessel 31 connected in input with the centrifugal reactors 22 through respective inlet ducts 32. The vessel 31 is connected in the lower part to a recuperator container 33 of the liquid substances and in the upper part to a distillation column 34. The recuperator container 33 is connected in output to the reaction tank 5 for the recirculation of the liquid substances and, among these, mainly to the diathermal oil.

[33] The treating system 30 further provides for a level-control tank 36 arranged parallel to the vessel 31 to control the level of the liquid substances in it. The tank 36 is suitable to receive the liquid substances in excess from the container 31, to convey them in output to the recuperator container 33.

[34] At a basically central height of the distillation column 34 a lateral draining is provided, for the extraction of the fraction of the fluid that forms the desired fuel liquid and that crosses the same distillation column 34. The collected fluid is suitable to be cooled through an exchanger device 56, preferably functioning with water, before flowing out in a second vessel 39, preferably a vertical centrifuge, for the mechanical separation water-hydrocarbons. The water coming out from the second mechanical separator 39 flows towards a water collection tank 42, while the liquid fuel is suitable to flow out in intermediate stocking tanks 49 in which it is possible to operate the control and verification of the quality features.

[35] From the intermediate stocking tanks 49, which in the illustrated case are two, the liquid fuel is suitable to be conveyed to a central tank through suitable pumping means 53 to feed utilizer means, for instance for generating electric energy. In such case it is further possible to exploit the thermal energy of the waste gases produced by the utilizer means to dry the waste materials before effecting the described treatment or to generate a steam current suitable to preheat the various components of the plant.

[36] At the top of the distillation column 34 is instead provided for the collection of the distilled vapours, that is of the light fraction of the fluid that crosses the same distillation column 34. The distilled vapour are then suitable to be conveyed in a condenser device 37 preferably water cooled, where their condensation is operated. The liquid condensed in the condenser device 37 is collected in a decanter tank 57 where the static separation of the water from the light hydrocarbons contained in the liquid is operated. From the decanter tank 57 two separated currents of liquid flow out: one of water towards the water collection tank 42 and one of light hydrocarbons towards a collection tank 38. From the water collection tank 42 the water can be conveyed through suitable pumping means to depuration systems, for instance of the membrane type, for a further use. A liquid current is suitable to be further collected from the collection tank 38 of the light hydrocarbons as backflow at the head of the column 34.

[37] The gaseous substances which are not condensed by the cooling system of the condenser device 37, are conveyed to a second condenser device 40 for the condensation of the most volatile compounds.

[38] The second condenser device 40 is suitable to be fed in countercurrent with a cooling liquid coming from a cooling system 27. The substances condensed by the second condenser device 40 flow out through an outlet duct 41 in a draining tank 43 of the residual light liquids. The draining tank 43 can usefully be connected with the system for the treatment of the liquid waste, if existing, or with a central tank for the collection of the liquid waste, adequately protected and controlled.

[39] The treating system 30 further comprises a third condenser device 44 suitable to receive in input the light vapours coming out from the outlet valves placed at the top of the feeding tank 5 or of the blow-down tank 25. The condenser 44 preferably employs a flow of tower water in countercurrent to the discharge vapours to be condensed. The liquid substances that condense in the fourth condenser device 44 are suitable to be conveyed in a decanter container 45, to separate the water from the other organic liquids, typically hydrocarbons. Subsequently the water flows out in the cited draining tank 43, while the other liquids flow towards a tank 55 from which they are conveyed back to the feeding tank 5 through a suitable recirculation duct 50 and through the aid of pumping members 54.

[40] The draining tank 43, the collection tank 38 of the hydrocarbons, the water collection tank 42, the tank 55 of the organic liquid part and the decanter container 45 are suitable to be kept in pressure by adjusting valves suitably arranged and by the intake of nitrogen.

[41] Finally, the third condenser device 44 provides for an outlet, on the upper part, for the outflow of the non-condensed gases, whose treatment implies a fourth condenser device 46, which is preferably suitable to be fed in countercurrent to a cooling liquid coming from the cited cooling circuit 27. The liquid substances condensed by this last condenser 46 are suitable to flow out in the draining tank 43 through the discharge duct 51, while the incondensable gases in output are suitable to be discharged in atmosphere through a suitable outlet chimney and/or sent to a combustion system. In the case of discharge in atmosphere, the passage through a circuit equipped with suitable filters 47 is provided, preferably of the active carbons type, or other collection systems.

[42] Also the compounds extracted in gaseous state from the second separator device 40 through ventilators and/or vacuum pumps 48 installed in the outflow circuit 52 in output from the condenser device, are suitable to flow out through the filters 47.

[43] The apparatus further comprises an auxiliary unit 60 for feeding substances in gaseous state, in particular nitrogen and compressed air, suitable to be employed in the claimed apparatus. The auxiliary unit 60 basically consists of a compressor member 61 suitable to be fed with a flow of ambient air and to convey the compressed air to a respective tank 63 downstream, and to a nitrogen production unit 64, which in its turn feeds a buffer tank 62. In particular, the air compressed by the compressor member 61 collected in the tank 63 is usefully treated with a dryer placed on the respective outlet duct before being sent to the utilizer members of the described apparatus. The auxiliary unit 60 is preferably arranged close to the apparatus, for instance fixed on mobile support for an easier and more flexible use. [44] The described apparatus can finally provide for a further treatment for the residuals collected from the delivery pipes 32 of the centrifugal reactors 22. These residuals are sent to a residual collection-tank 67 agitated, in which they are cooled with tower water circulating outside the same tank. From the residual collection-tank 67 through a pumping member 65, for instance of the single-screw type, the liquid and solid residuals are sent to a centrifugal extractor device 66 or 'decanter' suitable to separate the solid part from the liquid part. The solid part is suitable to be adequately stored in a suitable protected tank, not illustrated in the drawing, for the subsequent treatment or delivery in discharge according to the material used. The liquid part separated from the extractor device 66 is suitable to be conveyed to the decanter container 45 for the separation of the water, while the organic part is suitable to flow out in the tank 55 from which, as previously described, it can partly be recovered for the recirculation in the feeding tank 5.

[45] The described apparatus is preferably handled by an integrated system for controlling the process, to which the parameters of process, control and safety of the whole apparatus are addressed. To guarantee the total safety of the apparatus can be provided further sound and/or visual alarms suitable to be operated in case the controlled parameters are above the safety levels for the same apparatus and/or the operators.

[46] The functioning of the apparatus that realises the method for treating waste materials through catalytic molecular restructuring is the following.

[47] In a starting phase, the operating fluid, preferably diathermal oil, is inserted in the reaction tank 5 according to controlled doses and modes of inflow, for instance in an amount of about 1800 kg at ambient temperature. At the same time, the reactor unit 20 is operated, for instance bringing the centrifugal reactors 22 at an initial speed of 450 rpm, then accelerating them at 1000 rpm and eventually at 1400-1500 rpm. In consequence of the activation of the centrifugal reactors 22, the operating oil temperature is increased up to about 18O⁰C.

[48] At this point, waste mineral oil is inserted in the reaction tank 5, preferably chlorine- and diluents-free, together with the chosen catalyzing substance, according to a prearranged mixing percentage.

[49] In the meanwhile, the temperature of the mixture inside the centrifugal reactors keeps increasing up to the working temperature. Controlling the angular velocity of the shaft of the centrifugal reactors it is possible to maintain this temperature constant within a relatively small interval, for instance of 2⁰C.

[50] Once the working temperature is reached, the waste materials to be treated are inserted in the reaction tank 5, both at liquid and solid state, preferably in amounts such to guarantee the correct reaching of the conditions required for the reaction and production of liquid fuel, for instance 15-20 kg each minute, continuatively. [51] The solid materials are inserted upon elimination of metals, stones, sand, glass and grist with dimension smaller than 0-3 mm.

[52] It is important to consider that the materials to be treated have to be inserted in absence of air, making sure that the amount of oxygen in the reaction tank 5 does not exceed the safety limit threshold of 5%. With this aim the solid materials are introduced by the insertion unit 6 in absence of air thanks to the alternate-opening valves system and to the nitrogen controlled insertion. The value of oxygen percentage in the reaction tank 5 is preferably monitored through an electronic control system.

[53] The liquid wastes, on the other hand, are inserted into the tank with the aid of a pumping member operating under-head, protected and controlled by a suitable automatic adjustment system of the flow.

[54] Once the substances come out from the treatment group 30, they undergo automatic sample checks to detect the value of the pH. In practice, samples of the mixture are constantly collected to verify that in the initial phase of the process the pH does not approach the neutral values, in correspondence with which the activity of the catalyzing substance would decrease.

[55] Furthermore, the volume of each substance to be treated is kept under control, as well as the overall volume of the mixture inside the reaction tank 5, so that all these values are kept stables as much as possible. Control devices of the pressure inside the reaction tank 5 are also provided, which perform its monitoring and stabilization.

[56] After the insertion into the reactor unit 20, the temperature of the waste materials mixture, of the catalyzing substance and of the neutralizing substance stabilizes at around 35O⁰C with a pressure of about 1,05 bar. The catalyzing substance in particular triggers, inside the reactor unit, the chemical reactions that modify the molecules of the materials inserted. These reactions produce hydrocarbon gases and water vapour and can develop heat.

[57] From the reactor unit 20 the produced mixture of gases and liquids flows to the separator device 31, inside which, thanks also to the low pressure in there, an updraft originates towards the distillation column 34, where the distillation process takes place. In this phase of the process the volume and pressure of the mixture inside the vessel 31 are constantly controlled.

[58] In the distillation column 34 initially takes place the separation of the heavier fractions of the vapours, extracted in the central area of the column 34, while the lighter fractions flow out from the upper part of the column 34 and are inserted through a transport duct in the condenser 37, where the passage to the liquid state takes place. The incondensable gases are suctioned, through respective ducts, by the fans and/or vacuum pumps 48, which maintain the whole circuit in depression, and subsequently inserted in atmosphere upon passage through the filters 47, or treated and used with energetic purposes. The product in liquid phase is instead collected at the bottom of the condenser device 37 and discharged into the decanter tank 57, which generates two liquid currents, one of water that is sent towards the collection tank 42 and one of light products that are, in their place, reintroduced at the head of the column 34. From the lateral draining of the distillation column 34 the liquid fuel is extracted. Such fluid, after being cooled in the exchanged device 56, is then conveyed into the second vessel 39 for the separation of the oil from the water, to then be collected into the intermediate stocking tanks 49 where the quality controls and the collection take place, through the pumps 53, for the subsequent use.

[59] The devices to collect, control and recycle placed downstream of the distillation column 34 allow to obtain an adequate production of synthetic fuel and at the same time to separate the water therein. In particular, the majority of water is separated once it arises in the process while the remaining amount is separated at the end of the process, through the second vessel 39, and eliminated through the draining tank 43.

[60] The liquid effluents extracted at the bottom of the distillation column 34 are reinserted in the cycle upstream of the distillation column 34, in order to re-enter the circuit of the reaction unit 20 where they can still be transformed in useful product. The liquid effluents that flow out from the bottom of the distillation column 34, in fact, reach the recuperator container 33 and thus the reaction tank 5, which feeds the centrifugal reactors 22.

[61] Alternatively to the distillation in the column 34, as described above, it is possible to provide for using an apparatus of the known type as 'steam-drum', suitable to separate the diathermal oil intended to be recycled from water and liquid fuel.

[62] The method according to the invention reaches therefore the aim to optimally operate the treatment through catalytic molecular restructuring of the waste materials, such as in particular municipal solid waste, exhausted oils, plastic materials and similar, and also waste of the agricultural production and sludge obtained from the treatment of the waters of the cities. Furthermore, the method allows to obtain from such treatment a synthetic fuel conformed to the required specifications, without requiring the constant restoring of the fluidifying substances, in particular of the operating fluid used to fluidify the materials to be treated. This result is reached in particular through the controlled separation of the water in the process, both the part inserted together with the solid or liquid substances to be treated, and especially the part produced in the chemical reactions that take place inside the reactor unit 20.

[63] It has to be noted that the separation of the water is performed mainly in the process phases upstream of the distillation of the liquid fuel, in order to avoid that in this phase the presence of water vapour in the distillation column 34 causes the removal of the operating fluid. In fact, the presence of the water would lower the boiling temperature in the mixture oil/water below that of the water, separating from the head of the column also the operating oil, which has the important function to fluidify the mixture of materials to be treated.

[64] On the other hand, the proposed method allows to recycle in a basically complete way the operating fluid inserted during the starting phase, creating a recycle circuit of the operating fluid through the reaction tank 5, the centrifugal reactors 22, the vessel 31, the recuperator container 33, going back to the reaction tank 5 through the lateral duct 68.

[65] The water separated and collected in the tank of collection of the waters 42 can usefully be treated through known depuration means to be adequately re-used. Therefore, the method allows to dispose the waste with a very high yield, thanks to the result of obtaining, as secondary products, of both water and fuel liquid.

[66] A prerogative of the invention consists, in particular, in obtaining liquid fuel through lateral draining from the distillation column 34. The lateral draining of liquid fuel guarantees, within a restricted range, the high purity of the produced fuel independently from the nature of the waste materials to be treated.

[67] The invention represents a valid and strategic alternative to the waste treatment system through incineration, pyrolysis or standardization, allowing the recovery of fuel raw material with diversified and mobile use (electric energy and auto-traction), likewise contributing to the atmospheric pollution decrease both during the process, and through the production of fuel with low emission of particle material (PM 10) and the energy supplying from fossil fuel by turning to renewable energy sources.

[68] Materials adopted for the actual realisation of the invention, as well as their shapes and sizes, can be various, depending on the requirements.

[69] Where technical features mentioned in any claims are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the scope of each element identified by way of example by such reference signs.

Claims

[1] Method for treating waste materials through catalytic molecular restructuring, characterized in that it comprises the phases of: a. Initially introducing into a loading system (10) a measured amount of an operating fluid; b. Introducing in said measured amount of operating fluid the waste materials to be treated in inert atmosphere; c. Introducing in said amount of operating fluid at least one catalyzing additive substance, selected among possible catalyzing substances according to the nature of the material to be treated; d. Introducing in said amount of operating fluid at least one neutralizing additive substance; e. Heating the mixture of said operating fluid, waste materials to be treated and additive substances, obtaining at least partly said heating through conversion of kinetic energy in thermal energy and triggering reactions of molecular catalytic restructuring of said waste materials to be treated; f. Separating the water produced by said reactions of molecular catalytic restructuring; g. Separating said operating fluid from said heated mixture, in order to produce a recirculation of the same operating fluid to receive new waste materials to be treated and additive substances; h. Treating the steam mixture deriving from the separation of said operating fluid, to obtain from it synthetic fuel products. [2] Method according to claim 1, characterized in that said phase of h. treating said steam mixture provides for operating the distillation of the same steam mixture. [3] Method according to claim 1, characterized in that said phase of h. treating said steam mixture provides for operating the purification of the same steam mixture through apparatuses suitable to separate said operating fluid from water and fuel products, of the steam-drum type. [4] Method according to claim 2, characterized in that it provides for operating the distillation of said steam mixture in a distillation column (34). [5] Method according to claim 4, characterized in that it provides for extracting in a central area of said distillation column (34) the useful fraction of fluid, which runs through the same distillation column (34). [6] Method according to claim 5, characterized in that it provides for cooling said useful fraction extracted in said central area of the distillation column (34) for separating the water from a fuel liquid. [7] Method according to claim 4, characterized in that it provides for extracting at the upper end of said distillation column (34) the distilled steams forming the light fraction of the fluid which runs through the same distillation column (34).

[8] Method according to claim 7, characterized in that it provides for cooling said light fraction extracted at the upper end of the distillation column (34) for the separation of the water from a fuel liquid containing light hydrocarbons.

[9] Method according to claim 8, characterized in that it provides for collecting at least part of said fuel liquid containing light hydrocarbons to operate the reflux of it at the head of said distillation column (34).

[10] Method according to claim 1, characterized in that said phase of b. introducing in said measured amount of operating fluid the waste materials to be treated provides for maintaining in inert atmosphere the waste materials introduced in solid state through nitrogen controlled intake in an insertion unit (6) of the same waste materials.

[11] Method according to claim 1 characterized in that it provides for collecting at least part of said heated mixture, to separate a solid part containing said additive catalyzing substance together with said additive neutralizing substance, salts and impurities, and a liquid part containing principally said operating fluid.

[12] Method according to claim 11, characterized in that it provides for separating said catalyzing substance from said solid part, to operate the recirculation of it in said operating fluid.

[13] Method according to claim 11, characterized in that it provides for reintroducing said operating fluid into said loading system (10) to operate the recirculation of it.

[14] Method according to one of the claims above, characterized in that said operating fluid is a diathermal oil resisting high temperatures.

[15] Apparatus for the treatment through catalytic restructuring of waste materials characterized in that it comprises a loading system (10) for introducing a measured amount of an operating fluid, of waste materials to be treated in inert atmosphere, at least one catalyzing substance selected among possible catalyzing substances according to the nature of the materials to be treated, and at least one neutralizing substance; a reactor unit (20) to operate the heating and mixing of the mixture of said operating fluid, waste materials to be treated and additive substances, through the conversion at least partial of kinetic energy of said mixture into thermal energy, in order to trigger reactions of catalytic molecular restructuring of said waste materials to be treated; a treating system (30) comprising recuperators (33) of said operating fluid from said heated mixture to operate the recirculation of the said operating fluid into said loading system (10), and separating means (39, 45, 57) of the water produced by said molecular catalytic restructuring reactions; means (34) for treating the steam mixture deriving from the separation of said operating fluid, to obtain from it synthetic fuel products.

[16] Apparatus according to claim 15, characterized in that said reactor unit (20) comprises at least one reactor member of centrifugal type (22) suitable to be activated by a respective mover (23) and connected to a reaction tank (5) to receive the flow of said substances introduced by the said loading system (10).

[17] Apparatus according to claim 16, characterized in that said reaction tank (5) has an opening, with or without valve means, for the leakage of a mixture of vapour, operating fluid and hydrocarbons, suitable to undergo further treatments.

[18] Apparatus according to claim 15, characterized in that said loading system (10) comprises a first tank (1) for containing said operating fluid, a second tank (2) for containing said catalyzing substance, a third tank (3) for containing said neutralizing substance and a fourth tank (4) for containing waste liquid oil to be treated, an inlet unit (6) of the solid waste materials, being said tanks (1, 2, 3, 4) and said inlet unit (6) connected through suitable pipes to a reaction tank (5) of said reaction unit (20).

[19] Apparatus according to claim 18, characterized in that said inlet unit (6) comprises a mechanical unit served by a feeding member with one or more valves with alternate opening for introducing said waste materials in solid state into said reaction tank (5), and controlled nitrogen inlet means to maintain in inert atmosphere the waste materials introduced at solid state.

[20] Apparatus according to claim 16, characterized in that said centrifugal reactor

(22) comprises a mechanical agitator suitable to be activated by said mover (23), to generate a countercurrent flow with respect to the motion of said inlet flow.

[21] Apparatus according to claim 15, characterized in that said means (34) for treating the mixture of steams deriving from the separation of said operating fluid comprise at least one distillation column (34) connected at the upper end to a condenser device (37) to operate the condensation of distilled steams extracted at the same upper end of said distillation column (34), forming the light fraction of the fluid that runs through said distillation column (34).

[22] Apparatus according to claim 21, characterized in that said condenser device

(37) is suitable to allow the outflow of the condensed liquid in a decanter tank (57) for separating the water from a fuel liquid containing light hydrocarbons.

[23] Apparatus according to claim 21, characterized in that in a central area of said distillation column (34) collection means are provided, of the heavy fraction of the fluid that runs through the same distillation column (34). [24] Apparatus according to claim 23, characterized in that said heavy fraction extracted in said central area of the distillation column (34) is suitable to flow out in an exchanger device (56) to be cooled, before flowing out in a second separator vessel (39), for separating the water from a fuel liquid.

[25] Apparatus according to claims 16 and 21, characterized in that said treating system (30) provides for a further separator vessel (31) connected in input with said reactor unit (20) through respective inlet pipes (32), being said separator vessel (31) collected at the bottom to said recuperator means (33) and at the top to said distillation column (34).

[26] Apparatus according to one of the claim from 15 to 25, characterized in that it comprises an auxiliary unit (60) basically consisting of a compressor member (61) suitable to be fed with an ambient air flow and to convey the compressed air to a respective tank (63) downstream, and to a nitrogen production unit (64), which feeds a buffer tank (62), for feeding substances in gaseous state, in particular nitrogen and compressed air, suitable to be employed in said apparatus.