WO2010150272A1

WO2010150272A1 - System and method for material recycling and resource recovery

Info

Publication number: WO2010150272A1
Application number: PCT/IN2010/000156
Authority: WO
Inventors: Adishesh Bharthur Sreenivasa Iyengar
Original assignee: Adishesh Bharthur Sreenivasa Iyengar
Priority date: 2009-06-25
Filing date: 2010-03-17
Publication date: 2010-12-29
Also published as: ZA201200177B

Abstract

A system and method for material recycling and resource recovery by converting carbonaceous feedstocks into usable products such as biochar, gaseous and liquid products are disclosed. Said method involves the following steps: heating the feedstocks in reaction section in vacuum to generate volatiles or uncondensed gases and biochar; conveying said volatiles or uncondensed gases via negative pressure to distillery section; condensing said gases to generate non-condensable gas and heavy oil; removing particles and VOC's from non-condensable gas to produce clean gas; routing the clean gas for heating the reaction section and/or any other benefit utilization including gas turbines or IC engines.

Description

SYSTEM AND METHOD FOR MATERIAL RECYCLING AND RESOURCE RECOVERY

FIELD OF INVENTION

The present invention relates to a system of processing carbonaceous containing feedstock materials and transforming these feed-stocks and materials (including bio-mass, plastics, sewage (bio-solids), municipal solid waste, tyres, coal, (Lignite, bituminous etc.) into usable products such as biochar, gaseous and liquid products.

BACKGROUND ART

There is a need for sustainable and carbon neutral technology source of energy and method to transform and depolymerize carbonaceous wastes into biochar and alternative fuels. This is driven by many concerns including environmental, health, safety issues, global warming and the inevitable future scarcity of petroleum-based fuel supplies. Utilizing carbonaceous feedstocks to produce biochar and synthetic fuels is an economically viable method since the input feed stock is already considered of little value, discarded as waste, and disposal is often polluting.

There are known methods and arrangements for material recycling of carbonaceous wastes into fuel by gasification at the requisite gasification temperature with a feedstock medium which requires thermal energy needed for transformation. This is obtained by depolymeriszing the feedstock with the gasification medium. However, it is well known in the art that the above- mentioned process has a drawback wherein the produced pyro-gas is entrained with tars and carbon particles. Also, the chars recovered are not sufficiently volatized to acceptable levels in order to have environmental and economic value.

The use, per se, of a pyrolysis process to convert and depolymerize organic carbonaceous material, is well known, and a wide variety of devices/ units have been designed to accomplish such a result. A primary disadvantage of such devices is that a typical by-product of the pyrolysis process is a large quantity of tars and asphaltines eventually clogging the end use apparatus of the gas, such as the gas condensing system, internal combustion engine or equipments capable of utilizing such gas to produce heat or electricity. Such units typically operate best at a steady state, rather than with a variable demand. Hence, for many applications conventional devices are economically impractical and therefore have rather low market significance in the present times.

WO2008075105 describes a system and method for recycling carbon-containing material, in particular tyres and plastics materials. The system includes an inclined heating arrangement for anerobically heating the pre-heated carbon containing material in near atmospheric pressure conditions to produce carbon-containing gases. A condensing arrangement is also used to condense a proportion of the carbon-containing gases to provide condensed gases and non- condensed gases. In addition, a recirculating arrangement is provided for recirculating the non- condensed gases into the heating arrangement.

US 5,129,995 describe a process and apparatus for the continuous pyrolitic decomposition of a feed material having an organic and an inorganic component and recovery of the inorganic component, carbon-free, for reuse in essentially the same material as from which it originally emanated inter alia. The assembly includes a reactor assembly for pyrolitically decomposing a feed material having organic and inorganic components into gaseous decomposition products of the organic component and a solid residue. The reactor assembly includes a screw-type conveyor assembly to allow gaseous decomposition products to pass there through to preclude pressurization of the housing by the decomposition products.

US 4,412,889 describe a pyrolysis reaction apparatus and methods in which carbonizable waste material is heated in a reaction chamber in the absence of oxygen to decompose the material by pyrolytic reaction and produce hydrocarbon gas, liquid and solid residue.

US 4,439,209 describes an apparatus for the continuous non-oxidative thermal decomposition of heat-dissociable organic matter to a solid carbon residue, particularly activated carbon, and a mixture of gaseous products, without substantial coking or tar formation.

US 4,647,443 describes a process recovering carbon black, oil and fuel gas from vehicle tires by heating the tires directly without direct physical intrusion into the process reactor. US 7,339,087 describes to a process for pyrolyzing a light feed in a furnace designed for pyrolyzing heavy feed.

US 4,324,640 describes a process for recovery of values contained by flash pyrolysis of solid carbonaceous material, wherein the solid carbonaceous material is comminuted and then treated at an elevated temperature in a pretreatment zone with a first capping agent which is at treating conditions either a liquid or a gas.

US 4,356,077 describes a process for producing light aromatics, intermediate coal liquids, tar acids, and heavy hydrocarbons by the pyrolysis of coal thereby preventing or minimizing the degree of polymerization normally incurred before the vapors can be condensed and separated into tar acids, light aromatics, intermediate coal liquids, and heavy hydrocarbons.

Thus it is apparent from the aforesaid that there exists a need of a sustainable efficient and economical process with regard to conversion of carbonaceous waste streams into usable biochar, gaseous, liquid products.

Various other features of the method and apparatus of the present invention will become obvious to those skilled in the art upon reading the disclosure set forth hereinafter.

OBJECTS OF THE INVENTION

Accordingly, it is thus the primary object of the invention to provide for a system for recycling carbon containing wastes/ materials (like bio-mass, plastics, sewage, municipal solid waste, tires etc.) and a method thereof for converting/ processing such carbonaceous wastes into useful biochar, liquid and gaseous products.

In a yet another preferred aspect of the invention there is provided a system wherein the feedstock/ input material is passed through a volume reduction apparatus in order to process and effectively and efficiently convert this material to value added products.

Preferably, a system is provided wherein the feedstock processing components are comprises of: a. In-feed hopper b. Transfer conveyors c. Airlocks, and d. Auger feed mechanism

More preferably, a system is provided wherein the feedstock is introduced into the reactor through an airlock system which is comprised of compartments through which the feedstock is metered in the absence of oxygen.

It is yet another object of the invention to provide for a system and method of material recycling for the said production of gaseous products and liquid products that can be used as renewable energy or fuel and carbon based solid products (biochar) that can be used in agriculture, as well as for fuel and air and water purification.

It is another object of the present invention to provide for a process of converting carbonaceous wastes wherein the said gaseous products consist of light gaseous hydrocarbons and the liquid products consist of heavier liquid hydrocarbons.

It is another object of the present invention to provide for a system and method for converting the said carbonaceous materials into the said useful products by an aerobically heating it in the absence of air/ oxygen or any other gaseous materials.

It is yet another object of the present invention to provide for an improved, simplified and inclined heating arrangement in the said system for heating the feedstocks of carbonaceous materials.

It is a further objective of the present invention to provide for an energy efficient system wherein the recirculation of the flue gas is used for the application of pre-combustion air. Another object of the invention is to provide for a more efficient process and method for the recycling of carbonaceous materials wherein the feed and discharge ends for conveying the feedstock can be reasonably modified and altered according to the customer's requirements all based on the elliptical design of the furnace box and reaction chamber.

Still another object of the present invention is to provide for a system and method for the recycling of carbonaceous materials wherein the feedstock volume would be more than 70% of the gas production chamber and wherein there would be no need of preheating the feed to make the system further energy efficient.

SUMMARY OF THE INVENTION

Thus according to the basic aspect of the invention there is provided a system for material recycling and resource recovery for converting carbonaceous materials into usable products such as gaseous products, liquid products and char products comprising: heated reactor section maintained in vacuum adapted to receive and transforming feedstock into volatiles or uncondensed gases and biochar; means to convey the said volatiles or uncondensed gases via negative pressure to a distillery section which is uniformly heated; said distillery section comprising a condensing section wherein the heavy oil particles in the gas are condensed and collected ; a scrubber means adapted to remove entrained and fluidized carbon particles and

VOCs in the process to generate clean gas; and means for routing the clean gas thus generated for heating the reaction section and/or storage for any other benefit utilization including in gas turbines or IC engines.

In another aspect of the invention there is provided a system comprising a geometrically elliptical or oval chamber which houses an auger drive with said vessel made of high temperature stainless alloy metallurgy including inconel. In another aspect of the invention there is provided a system comprising of a geometrically round or square furnace box (the square box may not give advantage of cyclonic flame) which encompasses the reaction chambers and gives the advantage of creating a cyclonic flame thereby resulting in high heat transfer efficiency wherein the design is adapted for flexibility to increase or decrease capacity of reaction chambers for establishing throughput rates of a given feedstock.

In another aspect of the invention there is provided a system comprising expansion joints having connected with said reaction chambers, wherein the said reaction chamber comprises elliptical reactors such that top vessel and bottom vessel preferably with an internal diameter varying between 150mm and 1 meter parallel to one another, and with augurs adapted to aid the material to travel from one side to the other side inside the reactors the said top reactor being connected to the bottom reactor through the expansion joint whereby the material falls into the bottom reactor and the char exits the reactor through a series of vacuum valves. The operative connection between the two reactors comprising of an expansion joint that is perpendicular to both the retorts, said expansion joint adapted to allow for expansion and contraction due to temperature difference, the centers of the reactor being eccentric are adapted for smooth flow of gas from the retort into the gas processing section.

In another aspect of the invention there is provided a system comprising mechanical filter canister which is adapted for self cleaning and removing fluidized micron sized carbon particles and tars from the pyro gas in a temperature above 175C prior to entering the distillery section and after passing through the filters the pyro gas enters a phase changer section in a temperature range of 50 to 9OC to distill the heavy components of the Pyrogas which then drop out into a collection tank with the gases then passing through a regenerative blower adapted to maintain vacuum condition in the reaction chamber and the gas and oil processing section. The remaining gas is then passed to the temporary gas storage tank before it is used for the process.

In another preferred aspect of the invention there is provided a system comprising condensate filtration module adapted to remove carbon particles from the fuel condensate down to 10 micron size to which is attached a oil water separator system adapted to separate water from the condensate all of which results in a high grade fuel for various commercial applications. In another aspect of the invention there is provided a system comprising a fully automated Human Machine Interface (HMI) and having remote monitoring and accessing to determine any faults in the system and aid in regular maintenance and operations and which houses a microprocessor based PLC operating system designed to control all processes.

In another aspect of the invention there is provided a system comprising an automation control mechanism having variable frequency drivers (VFD 's) which are programmed to receive a signal from the microprocessor control system based on the field readings and analysis thereof.

In another aspect of the invention there is provided a system comprising an oxygen transmitter provided at the exit of the gas reaction chamber to monitor and evaluate if there is any ingress of air or oxygen into the reaction chamber and to determine by way of the Human Interface System if the system should go into shutdown mode should a potential problem exist.

In another preferred aspect of the invention there is provided a method for material recycling by converting carbonaceous wastes into usable products such as gaseous products, liquid products and solid products using the system comprising: heating the feedstock in the reaction section to generate volatiles or uncondensed gases; conveying the said volatiles or uncondensed gases via negative pressure to said distillery section; - condensing the said gases in the gas condensing section to condensate; and re-routing any residual clean non-condensable gas thus generated for heating the reaction section and/or any other benefit utilization including in gas turbines or IC engines.

In yet another aspect of the invention there is provided a method comprising conversion in the absence of air or oxygen or any other gaseous material under negative pressure conditions anyone or more of the following: converting carbonaceous wastes preferably selected from bio-mass, plastics, sewage, municipal solid waste, tires into usable products such as gaseous products and condensate products and solid products including char; - material recycling and resource recovery for producing as gaseous products and condensate products useful as renewable energy or fuel and carbon based solid products useful in agriculture, as well as for fuel and air and water purification; and Converting carbonaceous wastes wherein the said gaseous products comprised of commercial grade gas, condensates and biochar.

In yet another aspect of the invention there is provided a method wherein the said Negative pressure/ vacuum condition may vary between -0 mm H20 to -50 mm H20 which is maintained continuously by a positive displacement compressor or by a blower.

The manner, in which the features, advantages and objects of the invention will become apparent, may be understood in more detail, by the illustrations in the appended drawing, which forms a part of this specification. It is to be noted; however, that the drawing illustrate only a preferred embodiment of the invention and is therefore not to be considered to limit the scope of the invention as it may be applicable to other equally effective embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1. Illustrates a system for recycling carbonaceous materials and providing for recovery of commercial grade condensates, gases and biochar products with oil purification system.

Figure 2. Illustrates a system for recycling carbonaceous materials and providing for recovery of commercial grade condensates, gases and biochar products with mechanical filter.

DETAILED DESCRIPTION FO THE INVENTION

Thus as discussed hereinbefore the present invention is directed to a system of recycling carbon containing materials and resource recovery and more specifically relates to the method of converting/ processing carbonaceous wastes (like bio-mass, plastics, sewage, municipal solid waste, tyres etc.) into usable such as fuel condensates and biochar products.

Thus by way of the system and method of the present invention a provision is made for material recycling and resource recovery for producing fuel condensates that may be used as renewable energy or fuel and biochar which may be used in agriculture, as well as for fuel and air and water purification. The said fuel condensate products consist of light gaseous hydrocarbons and the liquid products consist of heavy liquid hydrocarbons.

The said process of the present invention is operable in the absence of air/ oxygen or any other gaseous materials such as inert gases and therefore works under negative pressure conditions termed as vacuum wherein the said Negative pressure/ vacuum conditions may vary between -0 mm H20 to -50 mm H20 in the reaction chamber. This vacuum condition is maintained continuously by a regenerative blower. The vacuum condition inhibits the entry of air into the system and prevents the combustion of the feed stock. The said vacuum condition is attributed to a highly advanced high temperature carbon seals in the reaction chamber and high temperature vacuum valves.

The above said high temperature vacuum valves are high pressure valves that can vary in design such as: double flap valves, rotary air lock valves, knife gate valves etc. These valves help maintain the vacuum condition in the gasification chamber and also allow controlled flow of feed stock into the said reaction chamber.

Figure 2: illustrates a system wherein the material to be processed enters the reaction chamber through the valves (01) wherein the said material is heated indirectly by a gas fired burner (06). The feed material begins to disintegrate and vaporize into a gaseous product called Pyro-Gas. The gas at this stage is above 175 ⁰C of temperature. The gas travels through the reaction chamber which has an internal diameter varying between 150mm and one meter and which is made of high temperature stainless steel. Augurs aid the feedstock material to travel from one side to the other side inside the reaction chamber. At one end of the top retort, there is an opening that is connected to the bottom retort and feedstock material is conveyed to the bottom reaction chamber. The char exits (02) the chamber through a series of said vacuum valves (01). The connection between the two retorts consists of a circular pipe (05) that is perpendicular to both the retorts. This pipe has a special feature to allow for expansion and contraction due to temperature difference. By way of the system of the present invention the feedstock/ input material goes through a volume reduction process in order to effectively and efficiently convert this material to value added products.

Advantageously the system of the present invention is tailored for the specific feedstock. The feed system of the present invention is comprised of a series of material handling sections including

1. In-feed hopper

2. Transfer conveyors

3. Airlocks and 4. Auger feed mechanism

The said feedstock is introduced into the reaction chamber via airlock system consisting of multiplicity of compartments and reaction chambers through which the feedstock is metered in the absence of oxygen.

By way of the system geometry of the present invention there are provided two alternatives of heating the input material as discussed hereunder:

1. Induction: hi this process, the coils surrounding the retort use electricity to heat the feed inside the retort. The temperature can be maintained in the range of 1 deg C. The retorts have longer life and this type of heating eliminates the presence of a stack or burners.

2. Gas Fired: In this process, a part of the gas produced in the process is utilized to sustain the gasification process. There is no additional electricity that needs to be utilized to heat the feed inside the retort.

Further by way of the system of the invention, the input material in the retort is heated in the range of 450 to 800 °C. Since there is no air/ oxygen in the retorts, the feed does not undergo combustion. The volatile matter of the feed decomposes and is converted to gas called pyro-gas. The exclusion of air and the introduction of heat are used to breakdown long hydrocarbon chains by a process called cracking which results in gases being formed. The said gases are drawn off and cooled in stages; resulting in the distillation of heavy and light condensates and wax/ paraffin. In addition to this, a carbon is produced that occurs in the form of char if the feedstock is biomass, pre-graphitic carbon if the feedstock is certain post consumer plastics, carbon black if the feedstock is rubber compounds and activated carbon if the char is enhanced with steam in the process.

In accordance with the process of the present invention the said feedstock moves through the reactor and volatizes. The volatiles or uncondensed gases are conveyed via negative pressure to the distillery section of the system. The distillery or distillation section is uniformly heated to prevent the formation of tars and waxes. The heat is also controlled by the PLC operating system to a predetermined temperature using either pyro oil or gas is such a way that the conversion process is optimized. Prior to entering the distillation section, the pyro gases may travel through a catalytic filter (07) (depending on the chemistry of the feedstock) which minimizes the formation of tars and waxes. This filter is self cleaning and significantly reduces down time due to pressure build up related to fouling from these tars. The said filters are either ceramic or stainless steel mesh. From the filters, the gases travel to the condensing section (08) of the distillation section. Here, the gases pass through a shell and tube heat exchanger (14), where the cooling medium is water. Due to the controlled temperature drop, heavy oil particles in the gas are condensed and collected in the first collection tank (09) and then enters the oil processing section through oil process pump (10). The pyro gas then continues into a particle separator (PS) where the gas is further cleaned. The scrubbing liquid in the scrubber media tank (12) is condensed pyro-gas. This scrubbing method removes most of the heavy particles and VOC in the gas and allows clean gas to flow through the compressor (15).

Typically, a regenerative blower is specified when conveying the pyro-gas. There are times when producing gases where the hydrogen percentage is higher; a lateral channel blower is advisable.

From the compressor (15), the gas enters a temporary gas storage tank (16) before entering either a burner, gas turbine or IC engine. Part of the gas that is directed to and is routed to burners connected to the chamber through a series of gas trains. This gas is utilized to sustain the process. The main advantage of this system lies in its automation and artificial intelligence that is enabled into the microprocessor based PLC. The PLC and automation control mechanism contains Variable Frequency Drives for all the motors on line. The VFDs receive signals from the microprocessor based control system based on the on field readings and calculations. The field termination points and analyzers analyze data such as temperature and pressure changes. Based on these changes, the microprocessor based control system changes the speed of the augers, the volume of coolant and other specific functions in the system.

Also, a fully automated Human Machine Interface (HMI) (17) is provided by the system of the present invention wherein the control system is user friendly and receives constant instantaneous feed back from the field. Based on these feed backs the control system adjusts the process continuously. The control can be remotely monitored and accessed to determine any faults in the system and aids regular maintenance.

It is yet another object of the present invention wherein the Pyro-Gas then passes through specially designed Carbon Filters (07) that aids in removing tar from the gas. After passing through the filters, the Pyro-Gas enters a heat exchanger (HE-I), where it is cooled to temperature in the range of 50 to 90 deg C. Here, the heavy components of the gas condense and collects in the first collection tank (09) and then enters the oil processing section through oil process pump (10). The lighter components, i.e. the Pyro-Gas continue on to a particle separator (PS). From the particle separator (PS), Pyro-Gas enters a second heat exchanger (HE -2) and then to the venturi scrubber (11). The venturi scrubber binds all the heavy particle in the gas, thus acting as the last stage of scrubbing and providing a clean gas. The heavy oils are collected in the scrubber media tank (12) after the two heat exchangers (HE-I and HE-2) and the venturi scrubber and then enter through quench oil pump (13) for processing. Some heavy oil fractions condense as soon as the temperature drops below their condensate temperature, which is around 175 ⁰C. The gases then pass through the compressor (15). The compressor maintains vacuum condition in the reaction chamber and the gas and oil processing section. The gas is then passed to the temporary gas storage tank (16) before it is used for the process. The said heavy oils are then circulated though the venturi scrubber to bind all the remaining heavy fractions in the gas. Additionally, the system of the present invention is provided with an oxygen transmitter that is situated at the exit of the gas from the reaction chamber for the purpose of monitoring. This enables the system operators to evaluate any ingress of air or oxygen into the reaction chamber and to help determine any leaks.

Thus it is possible by way of the present invention to provide for an improved and simplified system for decomposing carbon containing wastes/ materials (like bio-mass, plastics, sewage, municipal solid waste, tires etc.) and a method thereof for converting/ processing such carbonaceous wastes into useful solid, liquid and gaseous products to be utilized as fuel, for agricultural purposes, and for air and water purification purposes.

Claims

I CLAIM:

1. A system for material recycling and resource recovery for converting carbonaceous feedstocks into usable products such as gas and fuel grade condensates, water and biochar products comprising: a. heated reactor section maintained in vacuum adapted to receive and transforming feedstock into volatiles or uncondensed gases and biochar ; b. means to convey the said volatiles or uncondensed gases via negative pressure to a distillery section which is uniformly heated; c. said distillery section comprising a condensing section (08) wherein the heavy oil particles in the gas are condensed and collected ; d. a scrubber (11) means adapted to remove entrained and fluidized carbon particles and VOCs in the process to generate clean gas; and e. means for routing the clean gas thus generated for heating the reaction section and/or storage for any other benefit utilization including in gas turbines or IC engines.

2. The system as claimed in claim 1 comprising a geometrically elliptical or oval chamber which houses an auger drive (04) with said vessel made of high temperature stainless alloy metallurgy including inconel.

3. The system as claimed in anyone of claims 1 or 2 comprising geometrically round or square furnace box which encompasses the reaction chambers and gives the advantage of creating a cyclonic flame thereby resulting in high heat transfer efficiency wherein the design is adapted for flexibility to increase or decrease capacity of reaction chambers for establishing throughput rates of a given feedstock.

4. The system as claimed in anyone of claims 1 to 3 comprising expansion joint (05) having connected with said reaction chambers, wherein the said reaction chamber comprises elliptical reactors such that top vessel and bottom vessel preferably with an internal diameter varying between 150mm and 1 meter parallel to one another, and with augurs adapted to aid the material to travel from one side to the other side inside the reactors the said top reactor being connected to the bottom reactor through the expansion joint whereby the material falls into the bottom reactor and the char exits (02) the reactor through a series of vacuum valves (01). The operative connection between the two reactors comprising of an expansion joint is perpendicular to both the retorts, said expansion joint adapted to allow for expansion and contraction due to temperature difference, the centers of the reactor being eccentric are adapted for smooth flow of gas from the retort into the gas processing section.

5. The system as claimed in anyone of claims 1 to 4 comprising mechanical filter canister (07) which is adapted for self cleaning and removing fluidized micron sized carbon particles and tars from the pyro gas in a temperature above 175C prior to entering the distillery section and after passing through the filters the pyro gas enters a phase changer section in a temperature range of 50 to 9OC to distill the heavy components of the Pyrogas which then drop out into a collection tank (09) with the gases then passing through a regenerative blower (15) adapted to maintain vacuum condition in the reaction chamber and the gas and oil processing section. The remaining gas is then passed to the temporary gas storage tank (16) before it is used for the process.

6. The system as claimed in anyone of claims 1 to 5 comprising condensate filtration module adapted to remove carbon particles from the fuel condensate down to 10 micron size to which is attached a oil water separator system adapted to separate water from the condensate all of which results in a high grade fuel for various commercial applications

7. The system as claimed in anyone of claims 1 to 6 comprising a fully automated Human Machine Interface (HMI) (17) and having remote monitoring and accessing to determine any faults in the system and aid in regular maintenance and operations and which houses a microprocessor based PLC operating system designed to control all processes.

8. The system as claimed in anyone of claims 1 to 7 comprising an automation control mechanism having variable frequency drivers (VFD 's) which are programmed to receive a signal from the microprocessor control system based on the field readings and analysis thereof.

9. The system as claimed in anyone of claims 1 to 8 comprising an oxygen transmitter provided at the exit of the gas reaction chamber to monitor and evaluate if there is any ingress of air or oxygen into the reaction chamber and to determine by way of the Human

Interface System if the system should go into shutdown mode should a potential problem exist.

10. The system as claimed in anyone of claims 1 to 9 wherein the feed systems comprise of: a. In-feed hopper b. Transfer conveyors c. Airlocks, and d. Auger feed mechanism

11. The system as claimed in anyone of claims 1 to 10 wherein the feedstock is introduced into the reactor through an airlock system which comprises of compartments through which the feedstock is metered in the absence of oxygen.

12. A method for material recycling by converting carbonaceous wastes into usable products such as gaseous products, liquid products and solid products using the system as claimed in anyone of claims 1 to 11 comprising: a. heating the feedstock in the reaction section to generate volatiles or uncondensed gases; b. conveying the said volatiles or uncondensed gases via negative pressure to said distillery section; c. condensing the said the heavy oil in the gas condensing section; and d. routing the clean non-condensable gas thus generated for heating the reaction section and/or any other benefit utilization including in gas turbines or IC engines.

13. The method as claimed in claim 12 comprising conversion in the absence of air or oxygen or any other gaseous material under negative pressure conditions anyone or more of the following: a. converting carbonaceous wastes preferably selected from bio-mass, plastics, sewage, municipal solid waste, tires into usable products such as gaseous products and liquid products and solid products including char; b. material recycling and resource recovery for producing as gaseous products and liquid products useful as renewable energy or fuel and carbon based solid products useful in agriculture, as well as for fuel and air and water purification; and c. converting carbonaceous wastes wherein the said gaseous products comprised of commercial grade gas, condensates and biochar.

14. The method as claimed in claim 13 wherein the said Negative pressure/ vacuum condition vary between -0 mm H20 to -50 mm H20 which is maintained continuously by a positive displacement compressor or by a blower.