WO2019056138A1 - Réacteur fixe et ses éléments internes pour la production de combustible liquide à partir d'hydrocarbures résiduels et/ou de matière organique et/ou d'huiles contaminées, procédés thermiques, utilisations et systèmes de gestion s'y rapportant - Google Patents

Réacteur fixe et ses éléments internes pour la production de combustible liquide à partir d'hydrocarbures résiduels et/ou de matière organique et/ou d'huiles contaminées, procédés thermiques, utilisations et systèmes de gestion s'y rapportant Download PDF

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Publication number
WO2019056138A1
WO2019056138A1 PCT/CA2018/051234 CA2018051234W WO2019056138A1 WO 2019056138 A1 WO2019056138 A1 WO 2019056138A1 CA 2018051234 W CA2018051234 W CA 2018051234W WO 2019056138 A1 WO2019056138 A1 WO 2019056138A1
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WIPO (PCT)
Prior art keywords
reactor
plates
mixture
stationary
solid
Prior art date
Application number
PCT/CA2018/051234
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English (en)
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WO2019056138A8 (fr
Inventor
Lucie B. Wheeler
Louis Bertrand
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Envirollea Inc.
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Publication date
Priority claimed from CA2979651A external-priority patent/CA2979651A1/fr
Application filed by Envirollea Inc. filed Critical Envirollea Inc.
Publication of WO2019056138A1 publication Critical patent/WO2019056138A1/fr
Publication of WO2019056138A8 publication Critical patent/WO2019056138A8/fr

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B1/00—Retorts
    • C10B1/02—Stationary retorts
    • C10B1/04—Vertical retorts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0006—Controlling or regulating processes
    • B01J19/0013—Controlling the temperature of the process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0006—Controlling or regulating processes
    • B01J19/0033—Optimalisation processes, i.e. processes with adaptive control systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053—Details of the reactor
    • B01J19/006—Baffles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J19/087—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/18—Stationary reactors having moving elements inside
    • B01J19/22—Stationary reactors having moving elements inside in the form of endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/001—Feed or outlet devices as such, e.g. feeding tubes
    • B01J4/002—Nozzle-type elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J6/00—Heat treatments such as Calcining; Fusing ; Pyrolysis
    • B01J6/008—Pyrolysis reactions
    • C—CHEMISTRY; METALLURGY
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    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B47/00—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion
    • C10B47/18—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge
    • C10B47/26—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge with the aid of hot liquids, e.g. molten salts
    • C—CHEMISTRY; METALLURGY
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    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C—CHEMISTRY; METALLURGY
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    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B55/00—Coking mineral oils, bitumen, tar, and the like or mixtures thereof with solid carbonaceous material
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • C—CHEMISTRY; METALLURGY
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    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/40—Thermal non-catalytic treatment
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G33/00—Dewatering or demulsification of hydrocarbon oils
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G55/00—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process
    • C10G55/02—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only
    • C10G55/04—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only including at least one thermal cracking step
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G9/02—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils in retorts
    • C10G9/04—Retorts
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/02—Liquid carbonaceous fuels essentially based on components consisting of carbon, hydrogen, and oxygen only
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P30/00—Technologies relating to oil refining and petrochemical industry
    • Y02P30/20—Technologies relating to oil refining and petrochemical industry using bio-feedstock

Definitions

  • the invention relates to a stationary reactor for producing valuable liquid fuel from waste hydrocarbon and/or from organic material and/or from contaminated soils and/or from an oily feed material.
  • the invention also relates to pyrolysis systems incorporating a stationary reactor of the invention.
  • the invention also relates to manufacturing processes for building the stationary reactor or a pyrolysis system of the invention and to thermal processes involving the vertical reactor or the pyrolysis system of the invention in the thermal step.
  • the invention further concern the use of the stationary reactor or of the pyrolysis system for converting mixtures, essentially made of hydrocarbons, Municipal Waste and/or waste oil, into valuable products.
  • the invention relates to a thermal process for producing fuel from a variety of organic material, such as municipal solid waste and/or waste hydrocarbons or a mixture of the two treated simultaneously.
  • the invention also concerns corresponding managing systems allowing a continuous optimisation of the corresponding thermalURSing astaiery reactor or a pyrolysis system of the invention.
  • US2017095790 describes a rotating reactor and its internals used for the thermal processing of a liquid mixture.
  • the reactor comprises plates and at least part of the surface of said plates is used to perform the thermal processing.
  • the reactor and its internals are used for the thermal processing of various liquid mixtures containing organic compounds.
  • This patent document also describe processes, for thermal processing the mixture comprising organic compounds, comprising the steps of feeding the reactor and its internals and being useful for treating wastes oils and/or for destroying hazardous and/or toxic products; and/or for reusing waste products in an environmentally acceptable form and/or way, and/or for cleaning contaminated soils or beaches, and/or cleaning tar pits, and/or use in coal-oil co-processing, and/or recovering oil from oil spills, and/or PCB free transformed oils.
  • US 2009/0114567 describes a continuous process and apparatus for treating feedstocks containing carbonaceous materials involves heating bodies to heat the feedstock to vaporize and crack hydrocarbons and carbon formed on heating bodies is removed through direct contact to a flame heater. There was a need for a compact stationary reactor free of at least one o the drawbacks of the prior art reactor and processes.
  • a stationary reactor and its internals for thermal processing of a mixture comprising plates and at least one plate(s) supporting and/or guiding mean(s) configured to allow sliding of a plate on the upper surface of plate(s) supporting and/or guiding means, a plate sliding from an upper position of the reactor to a lower position of the reactor, said reactor being further characterized in that the at least one plate(s) supporting and/or guiding means is preferably inclined and in that at least part of the surface of said plates being used to performed said thermal processing of the mixture.
  • a pyrolysis system for thermal processing of a mixture comprising:
  • means such as spray nozzles, for directing or for contacting the mixture to be thermally processed to the surface of at least part of the plates; e. means for removing the fine solids from the reactor, preferably either through entrainment with the exiting vapours, or through a separate solids exit, or both;
  • a process for thermally processing a mixture comprising organic compounds which process comprises the steps of:
  • a process for producing liquid fuels from starting material that is organic material, in a form of agglomerates, said starting material, preferably with a reduced content in water, metal, glass and/or rocks, being thermally liquefied and further dewatered; the thereby obtained liquid fraction being thereafter submitted to a pyrolysis treatment, performed in a vertical stationary reactor, preferably of the type described in the present invention, and resulting in a solid gas fraction exiting the reactor, said solid-gas fraction allowing the recovery of a liquid fuel after a controlled gas-solid separation treatment.
  • a process for producing liquid fuels from starting material that are waste hydrocarbons and/or organic materials or a mixture of the two, such as municipal waste material, said process includes:
  • a pressure that is preferably ranging from 0,05 to 1 atmosphere and, more preferably, this pressure is about absolute, and preferably is about 0,5 atmosphere, and
  • step b) recovering of the liquid fraction resulting from step b), said liquid fraction can contain solid matters in suspension;
  • - liquid fraction obtained in step b) or c) is treated in a stationary reactor, preferably of the type described in the present invention and preferably under positive pressure and/or preferably in the presence of a sweep gas, that is preferably an inert gas,
  • part of the heavy bio-oil and/or heavy hydrocarbon fraction recovered from pyrolysis step may be incorporated in the liquid fraction resulting from step c), preferably in order to adjust solid liquid ratio in the liquid feed stream entering the reactor.
  • a process for producing liquid fuels from starting material that are waste hydrocarbons and/or organics material or a mixture of the two, such as municipal waste material, said process includes:
  • an absolute pressure that is preferably ranging from 0,05 to 1 atmosphere and more preferably this pressure is ranging from about 0,5 to 1,5 atmospheres, and
  • step e) mixing the fluid fraction obtained in step b) and the solid fraction resulting from grinding in a proportion that does not substantially affect the
  • thermodynamic properties of the liquid fraction the mixing results in a liquid containing solids in suspension
  • step c) or e) is treated in a stationary reactor, preferably of the type described in the present invention, advantageously under positive pressure and/or preferably in the presence of a sweep gas, that is preferably an inert gas, and
  • step c) wherein, in the case wherein liquefaction in step c) is incomplete, the remaining unliquified solid fraction is incorporated in the liquid obtained in step c) preferably before entering the pyrolysis stationary reactor and at concentration and/or particle size that does not affect significantly the physico-dynamic properties of the liquid entering the stationary reactor;
  • step c wherein heavy hydrocarbon and/or heavy bio-oil fraction recovered from pyrolysis step is incorporated in liquid fraction resulting from step c), preferably in order to adjust the solid-liquid ratio in the liquid feed stream entering the reactor.
  • a process for producing liquid fuels from starting material that are waste hydrocarbons and/or organics material or a mixture of the two, in a form of agglomerates, such as municipal waste material, said process includes:
  • a pre-treatment step wherein agglomerates, such as pellets and/or powder, are made from the starting material; an optional drying step, wherein agglomerates obtained in the pre-treatment step is(are) or coming from the market and/or waste collection are dried to a water content lower than 55% weight percent;
  • o liquid obtained in step c) is treated in a stationary kiln, preferably of the type described in the present invention and preferably under positive pressure and/or preferably in the presence of a sweep gas, that is preferably an inert gas, and
  • a condensation and/or fractionation step to obtain liquid fuel and gas, and wherein, in the case wherein liquefaction in step c) is incomplete, the remaining unliquified solid fraction is incorporated in the liquid obtained in step c), preferably before entering the stationary reactor and at concentration and/or particle size that does not affect significantly the physico-dynamic properties of the liquid entering the stationary reactor.
  • a managing system allowing continuous optimisation of a process as defined in any one of the preceeding process-claims for producing fuel from waste hydrocarbon and/or organic material, said system comprising at least one captor for measuring at least one of the following parameters
  • - calculation unit configured to adjust solid content present in the feed stream to the vessel, and/or to adjust solid content in the feed stream to the vertical stationary reactor.
  • Figure 1 is a simplified flow diagram illustrating an embodiment of the process according to the present invention.
  • Figure 2 is an example of an outside front view, according to a plan symmetrical to the central symmetrical axis, of a reactor and its accompanying elevator system, in which the reactor feed stream is thermally processed on hot plates, wherein there is no downstream processing to remove solids from the vapours exiting said reactor.
  • Figure 3 is an example of an outside front view, according to a plan symmetrical to the central symmetrical axis, of a reactor and its accompanying elevator system, in which the reactor feed stream is thermally processed on hot plates, wherein downstream processing to remove solids from the vapours exiting said reactor exists.
  • Figure 4 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the first embodiment of the reactor and its charge of plates, and in which the reactor feed stream is thermally processed on hot plates which slide down a series of n trays due to gravitational forces, and in which plates do not flip in between trays.
  • Figure 5 represents a top view cross section of the reactor in between points A and A' on Figure 4, illustrating the movement of plates and examples of three configurations of guides on which plates slide.
  • Figure 6 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the top-most section of the first embodiment of the reactor, showing the first tray, in which the angle with respect to the horizontal axis of said first tray changes from the right-most end of a tray to the left-most end of a tray, and in which there is no vertical gap between the reactor entrance door and said first tray.
  • Figure 7 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the second embodiment of the reactor and its charge of plates, in which the reactor feed stream is thermally processed on hot plates which slide down a series of n trays due to gravitational forces, and in which plates flip as they transition between trays via the use of flippers located at the bottommost extremity of each tray, excluding the last tray.
  • Figure 8 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the third embodiment of the reactor and its charge of plates, in which the reactor feed stream is thermally processed on hot plates which slide down a series of n trays due to gravitational forces, and in which plates flip as they transition between trays via the use of flipping trays located directly above each tray, excluding the last tray.
  • Figure 9 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the first embodiment of the elevator system, in which plates are heated via the use of burners and conveyed upwards via the use of lifters and supports, and in which the outside front view of the accompanying reactor, according to the same plan, is shown.
  • Figure 10 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the second embodiment of the elevator system, in which plates are heated via the use of induction heating and conveyed upwards via the use of lifters and supports, and in which the outside front view of the accompanying reactor, according to the same plan, is shown.
  • Figure 11 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 4, illustrating the movement of plates entering the reactor and sliding on the first tray, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 12 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 7, illustrating the movement of plates entering the reactor, sliding on the first tray and being flipped via the use of a flipper while transitioning between trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 13 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 8, illustrating the movement of plates entering the reactor, sliding on the first tray and being flipped via the use of a flipping tray while transitioning between trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 14 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 4, illustrating the movement of plates entering the reactor and sliding on the first and second trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 15 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 7, illustrating the movement of plates entering the reactor, sliding on the first and second trays and being flipped via the use of flippers while transitioning between trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 16 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 8, illustrating the movement of plates entering the reactor, sliding on the first and second trays and being flipped via the use of flipping trays while transitioning between trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 17 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 4, illustrating the movement of plates entering the reactor and sliding on the first, second and third trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 18 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 7, illustrating the movement of plates entering the reactor, sliding on the first, second and third trays and being flipped via the use of flippers while transitioning between trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 19 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top-most section of the embodiment of the reactor shown in Figure 8, illustrating the movement of plates entering the reactor, sliding on the first, second and third trays and being flipped via the use of flipping trays while transitioning between trays, in which there is a vertical gap between the entrance of the reactor and said first tray.
  • Figure 20 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom-most section of the embodiment of the reactor shown in Figure 4, illustrating the movement of plates on the last tray.
  • Figure 21 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom-most section of the embodiment of the reactor shown in Figure 4, illustrating the movement of plates on the two last trays.
  • Figure 22 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom-most section of the embodiment of the reactor shown in Figure 7, illustrating the movement of plates on the two last trays and the plates being flipped via the use of a flipper.
  • Figure 23 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom-most section of the embodiment of the reactor shown in Figure 8, illustrating the movement of plates on the two last trays and the plates being flipped via the use of a flipping tray.
  • Figure 24 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 7, showing the first sequence in a series of five sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flippers located at the bottom-most extremity of said trays, wherein the flippers are starting to lift said plates off of the trays and the plates are resting on a flipper arm.
  • Figure 25 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 7, showing the second sequence in a series of five sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flippers located at the bottom-most extremity of said trays, wherein the flippers are continuing to lift said plates off of the trays and the plates are still resting a flipper arm but have increased momentum relative to the sequence prior.
  • Figure 26 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 7, showing the third sequence in a series of five sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flippers located at the bottom-most extremity of said trays, wherein the flippers have lifted said plates off of the trays, the plates only have part of their lower surface resting on a flipper arm and the plates are flipping due to the momentum gained by the rotational movement of the flipper on which they were resting.
  • Figure 27 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 7, showing the fourth sequence in a series of five sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flippers located at the bottom-most extremity of said trays, wherein the flippers have lifted said plates off of the trays, the plates are no longer in contact with the flipper on which they were resting and the plates have flipped and are falling onto the tray directly below.
  • Figure 28 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 7, showing the fifth sequence in a series of five sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flippers located at the bottom-most extremity of said trays, wherein the flippers have lifted said plates off of the trays, the plates are no longer in contact with the flipper on which they were resting, the plates have flipped and have fell onto the tray directly below and the plates are now sliding on said tray below due to gravitational forces.
  • Figure 29 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the first sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates are sliding downwards and have not yet reached the bottom-most edges of the trays on which they slide.
  • Figure 30 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the second sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates are sliding downwards and have begun to surpass the bottom-most edges of the surfaces of the trays on which they slide, but have not yet passed said edges enough to start falling downwards off said trays.
  • Figure 31 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the third sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates are sliding downwards and have continued to surpass the bottom-most edges of the surfaces of the trays on which they slide, have surpassed said edges enough to start falling downwards off said trays, and are starting to tip over off said trays.
  • Figure 32 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the fourth sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates have slid downwards and have sufficiently surpassed the bottom-most edges of the surfaces of the trays on which they slid to begin flipping, have continued to fall downwards off said trays, but their downwards movement is inhibited by the flipping trays directly above said trays and the plates have not yet made contact with the curved trays directly below. Due to this inhibition of movement caused by the flipping trays, the top-most part of said plates are beginning to slide on said flipping trays and said plates are rotating towards the center of the reactor during their descent, causing the plates to flip.
  • Figure 33 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the fifth sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates have slid downwards and have sufficiently surpassed the bottom-most edges of the surfaces of the trays on which they slid to begin flipping, have continued to fall downwards off said trays, but their downwards movement is inhibited by the flipping trays directly above said trays and the plates have made contact with the curved trays directly below, but are still in contact with the flipping trays and have not yet begun to slide on the curved trays. Due to this inhibition of movement caused by the flipping trays, the top-most part of said plates have continued to slide on said flipping trays and said plates are rotating towards the center of the reactor during their descent, causing the plates to
  • Figure 34 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the sixth sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates have slid downwards and have sufficiently surpassed the bottom-most edges of the surfaces of the trays on which they slid to begin flipping, have continued to fall downwards off said trays, their downwards movement is no longer inhibited by the flipping trays and are now in contact with the curved tray directly below as they continue to flip.
  • Figure 35 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an intermediate stage within the reactor according to the embodiment of the reactor shown in Figure 8, showing the seventh sequence in a series of seven sequences illustrating an example of the flipping motion plates undergo while transitioning between trays via the use of flipping trays located above the trays supporting said plates, wherein the plates have slid downwards and have sufficiently surpassed the bottom-most edges of the surfaces of the trays on which they slid to begin flipping, have continued to fall downwards off said trays, their downwards movement is no longer inhibited by the flipping trays and are now in contact with both the curved tray directly below and the tray attached to said curved tray as they have finished flipping and are now sliding downwards due to gravitational forces.
  • Figure 36 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom section of the elevator system according to the first embodiment of said elevator system, showing the first sequence in a series of four sequences illustrating an example of how a plate may fall onto the elevator system and be carried upwards, wherein said plate is sliding on the bottom pressurised chamber floor and making contact with the top surface of a support.
  • Figure 37 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom section of the elevator system according to the first embodiment of said elevator system, showing the second sequence in a series of four sequences illustrating an example of how a plate may fall onto the elevator system and be carried upwards, wherein said plate is lifted off the bottom pressurised chamber floor by the support in contact with said plate and is sliding downwards on the arm of said support, in the direction of the lifter directly below the bottom-most part of said plate.
  • Figure 38 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom section of the elevator system according to the first embodiment of said elevator system, showing the third sequence in a series of four sequences illustrating an example of how a plate may fall onto the elevator system and be carried upwards, wherein said plate has hit the back end of the lifter directly below the bottom-most part of said plate and landed on the bottom end of said lifter, while the top-most part of said plate is being supported by the arm of the support in contact with said plate.
  • Figure 39 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom section of the elevator system according to the first embodiment of said elevator system, showing the fourth sequence in a series of four sequences illustrating an example of how a plate may fall onto the elevator system and be carried upwards, wherein the plate is being lifted and, due to the greater speed of ascent of the lifters relative to the speed of ascent of the supports, has caused the angle of said plate, relative to the horizontal axis, to decrease during said plate's ascent.
  • Figure 40 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top section of the elevator system according to the first embodiment of said elevator system, showing the first sequence in a series of four sequences illustrating an example of how a plate may be carried upwards and directed onto the top pressurised chamber floor, wherein said plate is being carried upwards by the support and lifter in contact with said plate, and wherein said plate's movement is inhibited by the elevator left wall.
  • Figure 41 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top section of the elevator system according to the first embodiment of said elevator system, showing the second sequence in a series of four sequences illustrating an example of how a plate may be carried upwards and directed onto the top pressurised chamber floor, wherein said plate's left side has surpassed the edge of said floor and is beginning to slide on the surface of said floor, while still being in contact with the lifter and support directly below said plate.
  • Figure 42 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top section of the elevator system according to the first embodiment of said elevator system, showing the first sequence in a series of four sequences illustrating an example of how a plate may be carried upwards and directed onto the top pressurised chamber floor, wherein said plate's left side is sliding on the surface of said floor, while still being in contact with the support directly below said plate and no longer being in contact with any lifter.
  • Figure 43 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top section of the elevator system according to the first embodiment of said elevator system, showing the first sequence in a series of four sequences illustrating an example of how a plate may be carried upwards and directed onto the top pressurised chamber floor, wherein most of said plate's bottom surface is sliding on the surface of said floor, while no longer being in contact with any support or lifter, and while pushing on the top pressurised chamber entrance door, thus causing said door to open.
  • Figure 44 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the top, middle and bottom sections of the elevator system according to the first embodiment of said elevator system, illustrating an example of the change in the plates' angle relative to the horizontal as they ascend the elevator system due to the lifters having a greater speed than the supports and illustrating the movement of plates entering the bottom pressurised chamber and exiting the top pressurised chamber, wherein the trays are not shown for simplicity.
  • Figure 45 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of an example of the pulley system according to the first and second embodiment of the elevator system, illustrating the counter-clockwise rotation of pulleys which drive the movement of the supports and lifters to allow said supports and lifters to move upwards on the left side of said pulley system and move downwards on the right side of said pulley system.
  • Figure 46A represents an example of the front view of the first embodiment of a flipper which has a bar at the tip of each of said flipper's arms and which said bar connects the left and right sides of the flipper's arm, and which said arms are oriented parallel to the vertical and horizontal axis.
  • Figure 46B represents a left side view of the flipper represented in Figure 46A.
  • Figure 46C represents an example of the front view of the flipper described in Figure 46A in which said the arms of said flipper are oriented at an angle of approximately 45° from the vertical or horizontal axis.
  • Figure 46D represents a left side view of the flipper represented in Figure 46C.
  • Figure 47 represents 3D view of an example of a flipper arm, according to the first embodiment of a flipper, which has a bar at its tip and which said bar connects the left and right sides of a flipper arm.
  • Figure 48A represents a front view of an example of a tray which is equipped with four scraper bars, wherein said scraper bars are spaced out in order to allow for the movement of the arms of the flippers attached to said tray and of the arms of the flippers attached to the tray directly above said tray.
  • Figure 48B represents a top view of the tray described in Figure 48A.
  • Figure 48C represents a right-side view of the tray described in Figure 48A, in which the scraper bars are thin.
  • Figure 48D represents a right-side view of the tray described in Figure 48A, in which the scraper bars are thick.
  • Figure 49A represents a front view of an example of a tray which is not equipped with any means of scraping the bottom surface of the plates sliding on said tray, other than scraping of the bottom surface of said plates which contact the guides of said tray.
  • Figure 49B represents a top view of the tray described in Figure 49A.
  • Figure 49C represents a right-side view of the tray described in Figure 49 A.
  • Figure 50A represents a front view of an example of a tray which is equipped with two scraper meshes, wherein said scraper meshes are spaced out in order to allow for the movement of the arms of the flippers attached to said tray and of the arms of the flippers attached to the tray directly above said tray.
  • Figure 50B represents a top view of the tray described in Figure 5 OA.
  • Figure 50C represents a right-side view of the tray described in Figure 50A.
  • Figure 51A represents a front view of an example of a tray which is equipped with two punctured scrapers, wherein said punctured scrapers are spaced out in order to allow for the movement of the arms of the flippers attached to said tray and of the arms of the flippers attached to the tray directly above said tray.
  • Figure 51B represents a top view of the tray described in Figure 51 A.
  • Figure 51C represents a right-side view of the tray described in Figure 51 A.
  • Figure 52A represents a front view of an example of a tray which is equipped with nine scraper bars, wherein said scraper bars are spaced out approximately evenly along the length of said tray.
  • Figure 52B represents a top view of the tray described in Figure 52A.
  • Figure 52C represents a right-side view of the tray described in Figure 52A.
  • Figure 53A represents a front view of an example of a tray which is equipped with a scraper mesh along the total length of said tray.
  • Figure 53B represents a top view of the tray described in Figure 53 A.
  • Figure 53C represents a right-side view of the tray described in Figure 53A.
  • Figure 54A represents a front view of an example of a tray which is equipped with a punctured scraper along the total length of said tray.
  • Figure 54B represents a top view of the tray described in Figure 54A.
  • Figure 54C represents a right-side view of the tray described in Figure 54A.
  • Figure 55A represents a front view of an example of a tray and curved tray which are equipped with a scraper mesh along the total length of said tray and curved tray.
  • Figure 55B represents a top view of the tray and curved tray described in Figure 55A.
  • Figure 55C represents a right-side view of the tray and curved tray described in Figure 55A.
  • Figure 56A represents a front view of an example of a tray and curved tray which are equipped with total of 17 scraper bars along the total length of said tray and curved tray.
  • Figure 56B represents a top view of the tray and curved tray described in Figure 56A.
  • Figure 56C represents a right-side view of the tray and curved tray described in Figure 56A.
  • Figure 57A represents a front view of an example of a tray and curved tray which are not equipped with any means of scraping the bottom surface of the plates sliding on said tray and curved tray, other than scraping of the bottom surface of said plates which contact the guides of said tray and curved tray.
  • Figure 57B represents a top view of the tray and curved tray described in Figure 57A.
  • Figure 57C represents a right-side view of the tray and curved tray described in Figure 57A.
  • Figure 58A represents a front view of an example of a tray and curved tray which are equipped with a punctured scraper along the total length of said tray and curved tray.
  • Figure 58B represents a top view of the tray and curved tray described in Figure 58A.
  • Figure 58C represents a right-side view of the tray and curved tray described in Figure 58A.
  • Figure 59 represents a 3D view of an example of a lifter which has a back end and a bottom end and can be used alongside supports within the elevator system to carry plates from the bottom pressurised chamber floor to the top pressurised chamber floor, in which the lifter is represented as white instead of black to more effectively show its different parts.
  • Figure 60 represents a front view of the lifter described in Figure 59.
  • Figure 61 represents a 3D view of an example of a rectangular support which is equipped with an arm and can be used alongside lifters within the elevator system to carry plates from the bottom pressurised chamber floor to the top pressurised chamber floor.
  • Figure 62 represents a 3D view of an example of a cylindrical support which is equipped with an arm and can be used alongside lifters within the elevator system to carry plates from the bottom pressurised chamber floor to the top pressurised chamber floor.
  • Figure 63A represents a simplified representation of the left side view of an example of a pair of pulleys equipped with pins which could be used to pull on the chains on which the lifters are attached, thus allowing said lifters to move up and down in the elevator and carry plates from the bottom pressurised chamber floor to the top pressurised chamber floor.
  • Figure 63B represents a front view of the left-most pulley described in Figure 63A.
  • Figure 63C represents a 3D view of the pulley described in Figure 63B.
  • Figure 63D represents a 3D view of the pair of pulleys described in Figure 63 A.
  • Figure 64A represents a simplified representation of the left side view of an example of a pair the pulleys described in Figure 63A, in which a lifter, the lifter inner chain and the lifter outer chains attached to said lifter are being pulled by said pulleys, and in which the lifter, its inner chain and its outer chain are represented in white to illustrate its positioning.
  • Figure 64B represents a front view of the left-most pulley described in Figure 64A, in which the lifter's position along the inner and outer rings of said pulley is visible and in which said lifter, said inner chain and said outer chain are represented in white to illustrate its positioning.
  • Figure 64C represents a 3D view of the pair of pulleys, the lifter and the chains attached to said lifter described in Figure 64A, in which said lifter is represented in white and said inner chains and said outer chains are represented in black for simplicity.
  • Figure 65 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of a fourth embodiment of the reactor and its charge of plates which is used to describe an example illustrating the functionality of the reactor, in which liquid material is thermally processed by being sprayed, via the use of nozzles attached to the left side of said reactor, onto the hot plates moving downwards within said reactor on a series of four trays, in which the plates sliding down the trays do not flip in between trays, and in which solid material is shown to be falling downwards and being removed from the reactor through the solid exit tube after being removed from the bottom surfaces of the plates via the use of scraper bars (not shown) attached to the trays.
  • Figure 66 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of a fifth embodiment of the reactor and its charge of plates, in which liquid material is thermally processed by being sprayed, via the use of nozzles attached to the left side of said reactor, onto the hot plates moving within said reactor on a series of n trays, and in which the plates sliding down the trays flip in between trays via the use of flippers, according to their second embodiment shown in Figures 70 and 71, which allow liquid feed material to be sprayed onto plates located behind the flipper arms without having liquid feed material contact said flipper arms.
  • Figures 67A and 67B represent a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of a sixth embodiment of the reactor and its charge of plates, in which liquid material is thermally processed by being sprayed, via the use of nozzles attached to the back wall of said reactor and located below the trays, onto the bottom surfaces of the hot plates moving within said reactor on a series of n trays, in which the plates sliding down the trays flip in between trays via the use of flippers, according to their second embodiment shown in Figures 70 and 71, and in which only the first three spray nozzles are shown to spray liquid feed material for simplicity.
  • Figure 68 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of a seventh embodiment of the reactor and its charge of plates, in which liquid material is thermally processed by being sprayed, via the use of nozzles attached to the back wall of said reactor and located above the trays, onto the top surfaces of the hot plates moving within said reactor on a series of n trays, in which the plates sliding down the trays flip in between trays via the use of flippers, according to their second embodiment shown in Figures 70 and 71, and in which only the first spray nozzle is shown to spray liquid feed material for simplicity.
  • Figure 69 represents a left side view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the seventh embodiment of the reactor shown in Figure 68, in which the trays are not attached to the front and/or back reactor walls, wherein the scraper bars attached to the trays are shown, and wherein the charge of plates, the feed spray and the flippers are not shown for simplicity.
  • Figure 70A represents an example of the front view of a second embodiment of a flipper which has a no bar at the tip of each of said flipper's arms connecting each side of said arms, and thus said arms are in two separate pieces to allow for feed spray to pass through said arms without contacting said arms, and which said arms are oriented parallel to the vertical or horizontal axis.
  • Figure 70B represents a left side view of the flipper represented in Figure 70A.
  • Figure 70C represents an example of the front view of the flipper described in Figure 70A in which the arms of said flipper are oriented at an angle of approximately 45° from the vertical or horizontal axis.
  • Figure 70D represents a left side view of the flipper represented in Figure 70C.
  • Figure 71 represents 3D view of an example of a flipper arm, according to the second embodiment of a flipper, which has a no bar at the tip of each of said flipper's arms connecting each side of said arms, and thus said arms are in two separate pieces to allow for feed spray to pass through said arms without contacting said arms, and which said arms are oriented parallel to the vertical or horizontal axis.
  • Figure 72 represents a front view vertical cross section, according to a plan symmetrical to the central symmetrical axis, of the bottom section of the reactor according to its first embodiment, its charge of plates and the bottom section of the elevator according to its first embodiment used in the example illustrating the accumulation of plates on the bottom-most tray during start-up, in which said plates are immobile due to the placement of a support which blocks the movement of the bottom-most plate, which in turn blocks the movement of all subsequent plates, (highlighted in blue because I did not receive Figure 72 with all the other figures, but I remember what it looks like and will double check the correctness of this description on Tuesday September 4 th , 2018)
  • Figure 73 represents a 3D view of the front and top parts of a plate.
  • Figure 74 represents a 3D view of the front and bottom parts of a plate.
  • Figure 75 represents a 3D view of the back and top parts of a plate.
  • Figure 76 is an outside front view, according to a plan symmetrical to the vertical axis, of an example of the one piece reactor, in which the reactor liquid feed stream is thermally processed on hot plates by being sprayed onto said plates via the use of spray nozzles, and in which said plates are moved from the bottom-most tray to the top-most tray via the use of a conveyor system which is located in the same enclosement as the trays and feed spray, wherein there is no downstream processing to remove solids from the vapours exiting said reactor.
  • Figure 77 is an outside top view, according to a plan symmetrical to the horizontal axis, of the one piece reactor seen in Figure 76.
  • Figure 78 is an outside left view, according to a plan symmetrical to the vertical axis, of the one piece reactor seen in Figure 76.
  • Figure 79 represents a front view vertical cross section, according to a plan symmetrical to the vertical axis, of an example of the first embodiment of the one piece reactor and its charge of plates, in which liquid feed material is thermally processed on hot plates by being sprayed onto said plates, in which said plates slide down a series of n trays do not flip in between trays, in which said trays are equipped with scraping equipment (not shown) to remove solid material from the bottom surfaces of the plates, and in which the plates falling off the bottom-most tray land on a conveyor system which heats up the plates and carries them to the top-most tray, wherein the conveyor system is in the same enclosure as the trays and feed spray.
  • Figure 80 is an outside front view, according to a plan symmetrical to the vertical axis, of an example of the one piece reactor, in which the reactor liquid feed stream is thermally processed on hot plates by being sprayed onto said plates via the use of spray nozzles, and in which the plates are moved from the bottom-most tray to the top-most tray via the use of a conveyor system which is located in the same enclosement as the trays and feed spray, wherein there is downstream processing to remove solids from the vapours exiting said reactor.
  • Figure 81 represents a front view vertical cross section, according to a plan symmetrical to the vertical axis, of the embodiment of the one piece reactor seen in Figure 79, but wherein the reactor is equipped with equipment downstream from the reactor exit tube to remove entrained solid materials from the reactor vapor exit stream.
  • Figure 82A is the first sequence in a series of three sequences illustrating an example of how plates fall off the bottom-most tray, land on the conveyor belt and are heated as they are conveyed to the top-most tray, wherein the reactor walls, reactor ceiling, reactor floor, reactor solid exit tube, reactor sweep gas entrance tube and reactor screw conveyor are not shown for simplicity.
  • Figure 82B is the second sequence in a series of three sequences illustrating an example of how plates fall off the bottom-most tray, land on the conveyor belt and are heated as they are conveyed to the top-most tray, wherein the reactor walls, reactor ceiling, reactor floor, reactor solid exit tube, reactor sweep gas entrance tube and reactor screw conveyor are not shown for simplicity.
  • Figure 82C is the third sequence in a series of three sequences illustrating an example of how plates fall off the bottom-most tray, land on the conveyor belt and are heated as they are conveyed to the top-most tray, wherein the reactor walls, reactor ceiling, reactor floor, reactor solid exit tube, reactor sweep gas entrance tube and reactor screw conveyor are not shown for simplicity.
  • MSW Municipal solid waste
  • plastics commonly known as trash or garbage in the United States and as refuse or rubbish in Germany
  • Waste can be classified in several ways but the following list represents a typical classification:
  • biodegradable waste food and kitchen waste, green waste, paper (most can be recycled although some difficult to compost plant material may be excluded);
  • - recyclable materials paper, cardboard, glass, bottles, jars, tin cans, aluminum cans, aluminum foil, metals, certain plastics, fabrics, clothes, tires, batteries, etc.;
  • WEEE electrical and electronic waste
  • waste clothing Tetra Packs
  • waste plastics such as toys
  • hazardous waste including most paints, chemicals, tires, batteries, light bulbs, electrical appliances, fluorescent lamps, aerosol spray cans, and fertilizers
  • Organic material means organic matter, organic material, or natural organic matter (NOM) refers to the large pool of carbon-based compounds found within natural and engineered, terrestrial and aquatic environments, such as hydrocarbons. It is matter composed of organic compounds that has come from the remains of organisms such as plants and animals and their waste products in the environment. Organic molecules can also be made by chemical reactions that don't involve life. Basic structures are created from cellulose, tannin, cutin, and lignin, along with other various proteins, lipids, and carbohydrates. Organic matter is very important in the movement of nutrients in the environment and plays a role in water retention on the surface of the planet. Organic material may also include hydrocarbons and/or MSW or a mixture of the two. Contaminants: In MS W, the contaminants are non-combustible material and/or nonorganic material, for example metals, stones and glass.
  • Liquid fuel are combustible or energy-generating molecules that can be harnessed to create mechanical energy, usually producing kinetic energy; they also must take the shape of their container. It is the fumes of liquid fuels that are flammable instead of the fluid. Most liquid fuels in widespread use are derived from fossil fuels; however, there are several types, such as hydrogen fuel (for automotive uses), ethanol, and biodiesel, which are also categorized as a liquid fuel. Many liquid fuels play a primary role in transportation and the economy. Liquid fuels are contrasted with solid fuels and gaseous fuels.
  • Agglomerate are coarse accumulations of solid particles and/or blocks. In the meaning of the present invention they are accumulations of particles obtained from the solids present in MS W and that have been previously transformed into smaller particles, for example by mechanical means. Agglomerates are typically poorly sorted, may be monolithologic or heterolithic, and may contain some blocks of various rocks.
  • Flash cracking is a fast pryrolysis that preferably takes less than 2 seconds to be performed on a heated reaction's surface, such as a heated plate.
  • Guiding means are means that are in contact just a lateral side of a plate and that direct a plate during is sliding and force a plate within a specific path; for examples, guiding means have a section in form of L or of U, thus they can be to L shaped or U-shaped on the side of a plate.
  • Supporting means are means in contact with the lowest part of a plate there are fixed elements forcing the plate to slide rather that to fall, they are preferably inclined and planar.
  • Sliding means combination of a sliding means and of a supporting means.
  • Pellets means a small rounded compressed mass of substance, that may, for example, be in the general form of cylinders.
  • Used Lubricating Oil are oils or greases that were used as lubricants, usually in engines, and were discarded. Examples would include car engine oils, compressor oils, and diesel engine oils among others. Lubricating oils generally contain additives, which are carefully engineered molecules added to base oils to improve one or more characteristic of the lubricating oil for a particular use. Used lubricating oil is classified as a hazardous product in many jurisdictions because of its additives and contaminants.
  • Organic vapour is the vapour produced from the pyrolysis of the feed material entering the rotating kiln.
  • the components of the organic vapour may include hydrocarbons and may also comprise of only hydrocarbons.
  • Bio-oil is the product from the condensation of the organic vapour. Bio-oil also includes specific chemicals obtained from the condensed organic vapour, which may be separated individually from the other components of the condensed organic vapour.
  • Liquification means to increase the liquid fraction of a material which has at least a solid fraction.
  • the resulting material after liquification is then considered a liquid and may or may not have entrained solids and/or gasses.
  • Substantially non-reactive gas is a gas such as nitrogen, recycled reaction gas, carbon dioxide or water steam that does not affect or enter into the thermal processing or that does not substantially combine with either the feed or reaction products in the reactor operating range, for example in a temperature range ranging from 350 to 850 degrees Celsius, in a temperature range up to 700 degrees Celsius, preferably up to 525 degrees Celsius.
  • Waste oils are oils or greases that are discarded. They include used lubricating oils (ULO) as well as a wide range of other oils such as marpol, refinery tank bottoms, form oils, metal working oils, synthetic oils and PCB-free transmission oils, to name a few.
  • UEO used lubricating oils
  • other oils such as marpol, refinery tank bottoms, form oils, metal working oils, synthetic oils and PCB-free transmission oils, to name a few.
  • Consistent shapes means shapes so they can stay on the narrow shelves and/or each other, while protecting the reactor wall from direct contact with the relatively cold feed.
  • the expression consistent shapes also means:
  • Thermal processing/thermally treating is preferably any change in phase and/or composition, and/or reactions initiated or facilitated by the application, or withdrawal, of heat and/or temperature.
  • thermal processing include evaporating, cracking, condensing, solidifying, drying, pyrolyzing and thermocleaning.
  • the expressions Thermal processing/thermally treating preferably exclude combustion and more specifically apply in the context of indirectly fired rotating kiln.
  • Sweep gas is any non-reactive or substantially non-reactive gas. Preferably it is an inert gas such nitrogen, recycled reactor non-condensable gas or water steam.
  • the sweep gas is a gas stream that may additionally serve in various the following functions such as:
  • the sweep gas when injected into the reactor feed line, changes the density of the total feed stream; it changes the flow regimes within the feed line and/or nozzles, which results in lower incidence of fouling and plugging of the piping and spray nozzles, and in improved spray patterns; further, the sweep gas favours atomization of the organic liquid feed stream before the organic liquid reaches the reaction sites on the hot plates, and/or - if introduced into the liquid feed at temperatures above that of the organic liquid feed stream, it will increase the feed stream temperature and reduce the energy, or heat, provided by the kiln, and/or
  • the sweep gas present in the reactor reduces the organic vapour's partial pressure, and favours the vaporization of the lighter organic fractions, for example gasoil and naphtha, in the feed and products; this also reduces over cracking in the lighter fraction and increases the stability of the bio-oil liquid products, and/or
  • the sweep gas helps to stabilize the pressure in the reactor, and/or - when steam or nitrogen are used, the sweep gas reduces the risk of fires in the event of a leak in the reactor or in the downstream equipment; it will disperse the combustible vapours escaping and, hopefully, keep the combustible vapours from igniting, even if they are above their auto-ignition point, and/or
  • Spraying means means configured for moving in a mass of dispersed droplets or fine parti cules to a reaction's surface i.e. a surface of a plate that is preferably hot.
  • a first object of the invention is a stationary reactor and its internals for thermal processing of a mixture, said reactor comprising plates and at least one plate(s) supporting and/or guiding mean(s) configured to allow sliding of a plate on the upper surface of plate(s) supporting and/or guiding means, a plate sliding from an upper position of the reactor to a lower position of the reactor, said reactor being further characterized in that the at least one plate(s) supporting and/or guiding means is preferably inclined and in that at least part of the surface of said plates being used to performed said thermal processing of the mixture.
  • said stationary reactor comprises:
  • - one or several plate(s) displaceable inside the stationary reactor from an internal position of the reactor to a lower internal position of the reactor; - at least one plate(s) supporting mean positioned inside the stationary reactor and configured to allow sliding down of a plate on the upper surface of the at least one plate supporting mean(s);
  • At least one plate(s) guiding mean positioned inside the stationary reactor and configured to allow sliding down of a plate in the guides of the at least one guiding mean;
  • the stationary reactor have walls defining an intemal part called reaction's zone of the stationary reactor and comprisies:
  • said stationary reactor being further characterized in that the at least one plate(s) supporting and/or in that the at least one guiding means is preferably inclined; and wherein said stationary reactor optionally comprises, preferably in its bottom part, an entry for feeding the reaction's zone with a gaseous stream resuting from the incomplete pyrolysis reaction of a feed that is preferably essentially made of hydrocarbons.
  • the stationary reactor comprises at least one of the following features:
  • a plate entry preferably positioned in the upper part of the stationary reactor, and allowing the loading of the plates in the upper part of the stationary reactor
  • a plate exit preferably positioned in the lower part of the stationary reactor and allowing the exit of the plates from the lower part of the reactor after falling down from the lowest supporting and/or guiding mean
  • an internal elevator configured to deplace a plate from the internal lower part of the stationary reactor to the internal upper part of the stationary reactor
  • an external elevator preferably closely postioned to or adjacent to an external wall of the stationary reactor and configured to:
  • deplacement means for inititiating sliding of the plates on the at least one supporting and/or on the at least one guiding means.
  • the thermal processing of the mixture is performed on at least part of the surface of a plate in movement, is of the pyrolysis type and is more preferably of the flash cracking type;
  • At least 10 %, preferably at least 30 %, more preferably at least 60% of the plates present in the reactor are involved in the thermal processing of the mixture.
  • at least one of the surface of the plates is cleaned by cleaning means such as scraping device, said cleaning means being positioned :
  • Reactor of the invention is particularly suited for performing a pyrolysis of a mixture: when heating means are present inside the stationary reactor and/or inside the elevator, by spraying said mixture on the upper and/or on the lower and/or on at least one of the lateral surface of a plate; and/or when heating means are different from those of the combustion type, for example when heating means are of the induction's type, by depositing and/or by spraying the mixture on the upper, and/or on the lower and/or on one of the lateral surface of a plate , and wherein:
  • heating means are configured for heating at least part of the reaction support and /or without inducing overheating of the reaction surface, the reaction's support i.e. the surface of the plate wherein pyrolysis reaction takes place; heating means are preferably closely positioned to the surface of a plate to be heated; heating means are preferably induction means, IR and hot gases, advantageously the heating means are positioned inside the enclosure, more advantageously heating means are positioned- in a zone of the enclosure;
  • the reduced oxygen content that is preferably less than 1 % oxygen, and/or
  • the internal and/or external heating means are configured to heat the surface of the reaction's support at a temperature ranging: - in the case of particulates, advantageously over 120 Celsius degrees, preferably over 140 Celsius degrees, more preferably from 200 to 525 Celsius degrees, even more preferably from 350 to 570, still even more preferably from 400 to 500 Celsius degrees, and more advantageously about 450 Celsius degrees; and - in the case of a liquid feed, advantageously over 120 Celsius degrees, preferably over 140 Celsius degrees, more preferably from 200 to 525 Celsius degrees, advantageously from 300 to 450 Celsius degrees, preferably ranging from 325 to 425 Celsius degrees, and more advantageously at a temperature about 400 Celsius degrees.
  • plates contribute to the uniformity of temperatures conditions in said stationary reactor.
  • heating means are of the combustion's type, plates contribute to heat transfer from the heat sources to the reaction chamber.
  • the stationary reactor is connected through connecting means with a combustion chamber, positioned external to the reaction's chamber of the stationary reactor, said combustion chamber being configured for :
  • a non-combustion heating system such as an induction source, infra-red, micro-waves ... , positioned preferably outside the reaction's zone of the stationary reactor but preferably inside the stationary reactor.
  • the bottom of the stationary reactor is connected to the bottom of the plates elevator by connecting means, such as a tube, allowing the transfert of plates from the upper closest supporting and/or guiding to the bottom part of the elevator; and/or
  • the top of the stationary reactor is connected to top of the plates elevator by connecting means, such as a tube, allowing the feeding of the upper part of the stationary reactor by plates coming from the upper part of the elevator; and/or
  • separation means are preferably seals, doors, inet gas and overpressure.
  • the stationary reactor is preferably connected to a plate elevator in a way that at least one of the following features is present:
  • the stationary reactor is positioned vertical or slanted
  • connecting means are a top pressurised chamber preventing flow of vapour produced in the reactor chamber to enter upper part of the plates elevator and/or to enter combustion heating chamber, saif connecting means being positioned preferably between the reaction chamber of the stationary reactor and the combustion chamber; a bottom pressurised chamber, preferably positioned at the bottom of the elevator, preventing flow of vapour from the stationary reactor to enter the bottom part of the elevator; at least one solid/vapour separator such as a filter, spunch oil column, a liquid wash column or a cyclone and/or such as a deplegmator, preferably positioned outside the reaction chamber, to remove solid material from the vapour-solid mixture exiting the top of the stationary reactor; a reactor feeding tube for feeding the stationary reactor with mixture to be thermally processed inside the stationary reactor, preferably the feeding tube is a multi branched feeding tube configured to feed the stationary reactor at different eigth, simultaneously or alematively, or according to a
  • spraying nozzles preferably positioned vertical and/or above and/or under and/or laterally to the guiding and/or supporting means, said spraying nozzles being configured to spray mixture on the surface of at least one plate;
  • the guiding and/or supporting means are slanted and the angle in respect of the horizontal advantageously ranges from 10 to 60 Celsius, preferably ranges from 15 to 45, more preferably is about 20 degrees when stainless steel is used;
  • the stationary reactor is compact and is a mobile reactor, preferably fitting of a standart container or fitting a high cube container;
  • the stationary reactor is for example one of those repesented in the Figures.
  • a second object of the present invention is constituted by a system comprising:
  • d. means, such as spray nozzles, for directing the mixture to be thermally processed to the surface of at least part of the plates;
  • the stationary reactor in the system has preferably a form that is about parallelipepedic or reactor has the form of a cylinder.
  • the means for directing the mixture to be thermal processed on at least part of the surface of the plates bring said mixture on the surface of at least more than 20% of the plates, preferably on the surface of at least more than 50% of the plates, and more advantageously on between 75 and 85 % of the surface of plates present in said reactor.
  • the pyrolysis system, of the invention is particularly suited when:
  • the mixture is liquid, gas and/or solid and/or is a mixture of at least two of these;
  • said mixture and said gaseous stream comprises mostly organic compounds that may be transformed by thermal processing.
  • the pyrolysis system of the invention is used to treat :
  • - a mixture comprises at least 80 % of organic compounds that may be transformed by thermal processing; and/or - a gaseous stream is obtained by at least one of following treatments: thermochemical biomass transformation, pyrolysis of organic material biomass, anaerobic digestion of organic waste material and composting of organic waste material.
  • the mixture preferably contains at least about 95% of organic compounds that may be transformed by thermal processing.
  • the mixture may comprise other components that are not organic compounds and/or that may not be transformed by thermal processing.
  • the other components are advantageously selected among: water, steam, nitrogen, sand, earths, shale, metals, inorganic salts, inorganic acids, lime, organic gas that won't be transformed in the reactor and among combination of at least two of these components.
  • the mixture is advantageously composed of organic compounds that may be transformed by thermal processing in: a liquid phase, a gaseous phase, a solid phase, or in a combination of at least two of these phases.
  • the mixture is mostly composed of organic compounds that may be transformed by thermal processing to at least a liquid phase, a gaseous phase and a solid phase or in a combination of at least 2 of the latter phases.
  • the mixture may be selected among the family of mixtures of plastics, wood chips, used oils, mixtures of waste oils, ship fuels and the mixtures of at least two of these mixtures.
  • the pyrolysis system is configured to be operated in the absence, in the reactor, of a substantial organic solid, liquid and of a slurry phase and/or in less than 30% vol., preferably in less than 5% vol. of an organic solid, and/or of liquid and/or of a slurry phase.
  • the pyrolysis system is configured to be operated in the presence or absence of a liquid and or slurry phase.
  • the plates of the stationary reactor may be directly and/or indirectly heated, and advantageously the inside of the stationary reactor is directly and/or indirectly heated.
  • the heat source may be generated by electricity, IR or convection a hot oil and/or gas stream, or obtained from the combustion of gas, naphtha, reaction' products, other oily streams, coke, coal, or organic waste or by a mixture of at least two of these.
  • the inside of the stationary reactor may be indirectly heated by an electromagnetic field (such as induction and/or infrared sources and/or microwaves).
  • an electromagnetic field such as induction and/or infrared sources and/or microwaves.
  • the plates may be directly heated by a hot gas, liquid or solid stream, electricity or partial combustion of the feedstock, coke, products or by-products.
  • the pyrolysis system comprises at least one heating system external to the walls of the stationary reactor, for example in a case of an indirectly fired kiln.
  • the heating means are advantageously configured in order the external walls of the stationary reactor are advantageously heated at a temperature exceeding temperature of the dew point of the vapours thereby produced, such as when having the reactor walls in contact with the combustion chamber.
  • the walls of the stationanry reactor are surrounded electrical wires or by a fire box, and said fire box is stationary and contains one or more burners.
  • one or more of the supporting and/or guiding means are attached to the internal walls of the stationary reactor and/or to subsections of the stationary reactor walls and/or on self supporting stands.
  • the supporting and/or guiding means are attached to the wall of the stationary reactor in a way allowing for the thermal expansion with minimum stress on the reactor wall and the supporting and/or sliding means.
  • the supporting and/or sliding mean(s) is (are) symmetrically attached to the internal wall of said reactor.
  • supporting and/or guiding mean(s) is (are) attached to the internal wall in a designed and/or random pattern.
  • the number of supporting and/or guiding means(s) that is (are) disposed, per square meter of the internal surface of the stationary reactor, on the internal wall of said reactor ranges advantageously from 0,1 to 20, preferably from 0,2 to 3.
  • the number of supporting and/or guiding mean(s) that is (are) disposed, per square meter of the internal surface of the reactor, on the internal wall of the stationary reactor is morre preferably about 2.
  • the number of supporting and/or sliding means depends advantageously on the weight of the plates and/or on the material the supporting and/or guiding means and plates are made of and/or of the angle made by the supporting and/or sliding means in respect of the horizontal and/or of the shape of the plates and/or of the friction coefficient of the plate and/or of the thermal expansion coefficient of the material constituting the plates and/or of the guides and/or if the reactor is designed for allowing or not the flip of the plates when leaving the supporting and/or sliding means.
  • the distance spacing two supporting and/or guiding means represents advantageously from 0,1 to 20% of the higth of the reactor.
  • the distance spacing two supporting and/or sliding means represents preferably from 0,2 to 2 % of the eigth of thestationary reactor.
  • the form of the supporting and/or guiding means is selected in the group constituted by flat or straigth forms.
  • the supporting and/or sliding means are about parallell straight guides.
  • the height and/or the width of the supporting and/or sliding means is calculated and depends on at least one of the following parameters: the space between the supporting and/or sliding means, the material the supporting and/or sliding means are made of and the weight of the plates, the sliding angle and the number of supporting and/or sliding means by square meter of the reactor's wall.
  • the height or width of the supporting means ranges from 1 mm to the width of the plate.
  • the height or width of the supporting and/or guiding means as representing 1 to 100 % of the width of the plates, and preferably 5% of the width of the plates.
  • the width and the height of the supporting and/or sliding means are advantageously selected in order for the supporting and/or sliding means to be able to retains at least one and preferably 2 or 3 plates.
  • the shape of the plates of the charge is advantageously selected among the group of parallelograms, discs, elipsoids and ovoids.
  • the plates of the charge may alos be rectangular, triangular, hexagonal or octagonal.
  • the shape of the plates of the charge is advantageously about perfect.
  • all the plates present in the stationary reactor have about the same size and shape.
  • the volume of the plates of the charge present in the reactor represents from 1% to 40% of the internal volume of the said reaction chamber.
  • the volume of the plates of the charge present in the reactor represents advantageously from 2 to 5 % of the internal volume of the stationary reactor.
  • the charge of the stationary reactor is constituted by flat and/or slightly curved metal plates of consistent thickness and shape.
  • the plates have a melting point which is advantageouslyat least of 100 degrees Celsius, and more preferably is of at least 150 degrees Celsius above the stationary reactor wall maximum operating temperature in the thermal processing zone and/or in combustion chamber.
  • the plates are heavy enough in order its sliding movment not to be substantially stop by the scraper(s), and more preferably in order not to reduce for more than 70%, preferably not for more than 30% the sliding speed.
  • Each plate has advantageously, a density that is superior to 2,0 g/cm 3 , preferably superior to 2,0 g/cm 3 and more preferably the density of a plate is comprised between 5,5 g/cm 3 and 9,0 g/cm 3 .
  • the means advantageously used for bringing the mixture in contact with at least part of the surfaces of the plates are spraying means that are advantageously spray nozzles that spray the mixture onto the surface of the plates when feedstream/mixture is liquid and/or mixture of liquid and/or gas and/or lquids and fine solids.
  • the spraying means are advantageously positioned above, under or laterally in respect of an horizontal plate; the spraying direction being perpendicalar or slanter in respect of a surface of a plate.
  • the means for bringing the solids outside the stationary reactor is (are) advantageously entrainment with the product gas, scoop(s), screw convey or(s) and/or propeller and/or rotating fins and/or blower(s); and/or gravity and/or pumps and/or compressors and/or vacuum pumps.
  • the means for bringing the solid outside the said reactors advantageously comprise an exit hopper arrangement attached to the solids exit tube, or ascrew conveyer or simply gravity.
  • the stationary reactor has two exits: one for the solids and one for the gas/vapours and entrained solids obtained.
  • the gas/vapours obtained may contain entrained solids.
  • the stationary reactor is advantageously equipped with means for avoiding accumulation of solid in the reactor and/or for plugging of any of the exits.
  • Those means are preferably a screw conveyor in the solids exit tube, or a slanted solids exit tube preferably positioned at the bottom part of the stationary vertical reactor.
  • the reactor feed is made laterally trough at least one entry positioned between the top and the bottom of the stationary reactor and/or wherein the exit of the vapor is positioned on the top of the stationary reactor.
  • Pyrolysis systems of the invention having of a particular interest are those wherein:
  • cleaning means are positioned advantageously at least temporary in contact with the superior surface of the reaction support wherein pyrolyze reaction takes place
  • cleaning means are preferably configured to clean at least part of the surface of the moving reaction's supports after pyrolysis reaction took place, said cleaning means preferably additionally comprising: - at least one rake in permanent or temporary in contact with at least part of the surface of a reaction's supports wherein pyrolysis takes place, and/or
  • - feeding means is are advantageously feeding line mounted with spray nozzle's, said spray nozzles, depending on the physical nature of the feeding material, are:
  • said spray nozzle are configured to spray, only the surface of the reaction's support:
  • - particulates having an average size less than 3 mm, preferably less than 2 mm, more advantageously the average size ranging from 0,5 to 1,5 mm; and/or
  • feeding means is a feeding line mounted with spray nozzle's, spray nozzles being positioned to spray feeding oily feed material essentially on the superior and/or the inferior surface of a reaction's support; and/or preferably, feeding means is a feeding line mounted with spray nozzle's, spray nozzles being configured for spraying, on demand, a specific amount of feeding material, in order substantially or in order no liquid film would be able to form from the individual drops reaching the surface of the reaction's supports; and/or wherein particulates and/or drops of the feeding material are preferably sprayed to the reaction's surface at a controlled pressure.
  • a third object of the present invention is constituted by the use of a stationary reactor as defined in the first object or of the pyrolysis system as defined in the second object of the invention, for the thermal processing of :
  • organic mixtures comprising for examples mixtures of used oils, waste oils, heavy oils and plastics, and preferably substantially in the absence of an organic, liquid and/or slurry phase;
  • the use of the stationary reactor and its internals and of the pyrolysis system may be in a continuous thermal process.
  • a fourth object of the present invention is a process for thermal processing a mixture comprising organic compounds, which process comprises the steps of:
  • step b) said part is the part of the mixture that will be thermally processed during the process.
  • the process of the invention is particularly suited for thermally processing a mixture comprising organic compounds, wherein the part of the mixture that will be thermally processed is the heavy part of the mixture and may eventually contain additives commonly used in this field (and in particular in the field of lubricating oils) and their degradation by-products.
  • the mixture advantageously comprises organic compounds having the following thermodynamic and physical features: a specific gravity as per ASTM D-4052 for used oils between 0.75 and 1.1 and/or for oily stream distillation temperatures between 20 degrees Celsius, for plastics a specific gravity ranging from 0.3 to 1.5 ( in liquid or in solid form) as per ASTM 792, and for organic liquids or mixtures a specific gravity ranging from 0.7 to 1.3 as per ASTM D 4052.
  • a specific gravity as per ASTM D-4052 for used oils between 0.75 and 1.1 and/or for oily stream distillation temperatures between 20 degrees Celsius
  • plastics a specific gravity ranging from 0.3 to 1.5 ( in liquid or in solid form) as per ASTM 792
  • organic liquids or mixtures a specific gravity ranging from 0.7 to 1.3 as per ASTM D 4052.
  • - a) is, when no gas stream resulting from incomplete pyrolysis of hydrocarbons is injected in the reaction's zone of the stationary reactor, comprised between 1 seconds to 10 hours, preferably between 30 seconds and 2 hours, and more preferably is between 90 seconds and 10 minutes; and
  • the heating temperature in the stationary reactor ranges from 120°C to 800°C or 350°C to 750°C.
  • the heating temperature of the plates in the reactor advanatgeously ranges froml50°C to 560°C, preferably 200°C to 525°C, more preferably 400°C to 460°C, even more preferably 200°C to 460°C, still more preferably from 420°C to 455°C and, more advantageously, is about 425°C, particularly when used lube oils are treated.
  • the heating temperature in the stationary reactor ranges from 500°C to 520°C, an is preferably about 505°C, more preferably about 510°C, particularly when shredded tires, bitumen, heavy oils, contaminated soils or oil sands or soil contaminated with heavy oils are treated.
  • the pressure in the vertical stationary reactor ranges from 0 to 5, preferably from 1 to 2, more preferably range from 1,2 to 1,3.
  • a sweet gas is in introduced in the stationary reactor in amount representing up to 30 % or up to 80 % of the volume of the gas produced during the pyrolysis transformation in the reaction's zone of the stationary reactor.
  • the various fractions generated by the thermal processing are recovered as follow:
  • the solid fraction is recovered for example in cyclones, a solids recovery box, a scrubber, liquid wash column, spring oil, and/or a refluxing condenser and/or a dephlegmator and/or in a filter and/or in a condensator.
  • the process of the invention is of a particular interest when :
  • the amount of the recovered liquid fraction represents between 75% and 100% weight of the organic reactor feed
  • the amount of the recovered gaseous fraction represents between 0% weight and 20% weight of the reactor feed
  • the amount of the recovered solid fraction represents between 0% weight and 25% weight
  • the feedstock is used lubricating oil and a gaseous stream resuting from the incomplete pyrolysis reaction of a mixture of hydrocarbon, thus the amount of the recovered liquid fraction and the amount of the recovered gaseous fraction represents at least 105 % of the amount obtained in a).
  • the process may also be operated in a continuous or in a batch mode.
  • wastes oils such as used lubricating oils, form oils, metal treating oils, refinery or transportation oil tank bottoms; and/or
  • the process of the invention is of particular interest when used for treating used oils and to prepare:
  • a fuel or a component in a blended fuel, such as a home heating oil, a low sulphur marine fuel, a diesel engine fuel, a static diesel engine fuel, power generation fuel, farm machinery fuel, off road and on road diesel fuel; and/or
  • drilling mud base oil or component a drilling mud base oil or component
  • a fifth object of the present invention is a manufacturing process for fabricating the stationary reactor and its internals and for fabrication the corresponding pyrolysis system, that comprises the assembly, by known means, of the constituting elements of said reactor.
  • Known assembling means may comprise screwing, jointing, riveting and welding.
  • a sixth object of the present invention is a process for producing liquid fuels from starting material, that is organic material, in a form of agglomerates, said starting material, preferably with a reduced content in water, metal, glass and/or rocks, being thermally liquefied and further dewatered; the thereby obtained liquid fraction being thereafter submitted to a pyrolysis treatment, performed in a vertical stationary kiln, preferably of the type described in the first object of the present invention, and resulting in a solid gas fraction exiting the reactor, said solid gas fraction allowing the recovering of a liquid fuels after a controlled liquid solid separation treatment.
  • the feed can be in a form of pellets, granules and/or powder.
  • the agglomerates have, after drying and filtering, at least one of the following features: a humidity content lower than 75 %, a content in metal and stones/glass representing both together less than 25 % weight percent of the total amount of agglomerates; and a total carbon content of at least 30 % by weight and at least 90% by weight.
  • the agglomerates are in the preferably in the form of pellets with an average weight ranging from 1 to 500 grams. More preferably, the agglomerates are in the form of pellets with a total carbon content ranging from 30 % to 75 % and wherein pellets have a humidity content less than 60 %, preferably ranging from 5 to 65 %.
  • the liquid fuel recovered has a low sulfur content that is, according to ASTM D7544 - 12, comprised between 0,03 % and 5 %, preferably lower than 0,05 %, more preferably lower than 0,03 %, and advantageously lower than 0,01 %.
  • a seventh object of the present invention is a process for producing liquid fuels from starting material, that are waste hydrocarbons and/or organics material or a mixture of the two, such as municipal waste material, said process includes:
  • a pressure that is preferably ranging from 0,05 to 1 atmosphere and, more preferably, this pressure is about absolute, and preferably is about 0,5 atmosphere, and
  • step b) recovering of the liquid fraction resulting from step b), said liquid fraction can contain solid matters in suspension;
  • - liquid fraction obtained in step b) or c) is treated in a stationary reactor, preferably of the type described in the first object of the invention or is treated in a pyrolysis system as described in the second object of the invention, and preferably under positive pressure and/or preferably in the presence of a sweep gas, that is preferably an inert gas, - reaction and straight run products are recovered from the stationary reactor as solids and as a solid-gas mixture;
  • a sweep gas that is preferably an inert gas, - reaction and straight run products are recovered from the stationary reactor as solids and as a solid-gas mixture;
  • a post treatment step wherein solid-gas mixture exiting the stationary reactor is submitted to a solid-gas separation allowing the recovering of substantially clean vapours and solids; f) a condensation and/or fractionation step to obtain liquid fuel and gas, and wherein part of the heavy bio-oil and/or heavy hydrocarbon fraction recovered from pyrolysis step may be incorporated in liquid fraction resulting from step c), preferably in order to adjust solid liquid ratio in the liquid feed stream entering the reactor.
  • the present invention also relates to a process is advantageously used for producing liquid fuels from starting material, that are waste hydrocarbons and/or organics material or a mixture of the two, such as municipal waste material, said process includes:
  • an absolute pressure that is preferably ranging from 0,05 to 1 atmosphere and more preferably this pressure is ranging from about 0,5 to 1,5 atmospheres, and
  • step e) mixing the fluid fraction obtained in step b) and the solid fraction resulting from grinding in a proportion that does not substantially affect the thermodynamic properties of the liquid fraction, the mixing results in a liquid containing solids in suspension;
  • step c) or e is treated in a stationary reactor, preferably of the type described in the first object of the invention or is treated in a pyrolysis system as described in the second object of the invention, advantageously under positive pressure and/or preferably in the presence of a sweep gas, that is preferably an inert gas, and
  • step c) wherein, in the case wherein liquefaction in step c) is incomplete, the remaining unliquified solid fraction is incorporated in the liquid obtained in step c) preferably before entering the pyrolysis stationary reactor and at concentration and/or particle size that does not affect significantly the physico-dynamic properties of the liquid entering the stationary reactor;
  • step c wherein heavy hydrocarbon and/or heavy bio-oil fraction recovered from pyrolysis step is incorporated in liquid fraction resulting from step c), preferably in order to adjust the solid-liquid ratio in the liquid feed stream entering the reactor.
  • a further object of the invention is a process for producing liquid fuels from starting material, that are waste hydrocarbons and/or organics material or a mixture of the two, in a form of agglomerates, such as municipal waste material, said process includes: a) a pre-treatment step wherein agglomerates, such as pellets and/or powder, are made from the starting material;
  • agglomerates obtained in the pre-treatment step is(are) or coming from the market and/or waste collection are dried to a water content lower than 55% weight percent;
  • a thermal step wherein at least partial liquefying and at least partial dewatering of the agglomerates obtained in previous steps a) and/or b) occurs;
  • a pyrolysis step wherein:
  • o liquid obtained in step c) is treated in a stationary kiln, preferably of the type described in the first object of the invention or in a pyrolysis system as described in the second object of the invention, and preferably under positive pressure and/or preferably in the presence of a sweep gas, that is preferably an inert gas, and
  • step f) a condensation and/or fractionation step to obtain liquid fuel and gas, and wherein, in the case wherein liquefaction in step c) is incomplete, the remaining unliquified solid fraction is incorporated in the liquid obtained in step c), preferably before entering the stationary reactor and at concentration and/or particle size that does not affect significantly the physico-dynamic properties of the liquid entering the stationary reactor.
  • starting material that are used in the process are waste hydrocarbons and/or organics material or a mixture of the two, wherein:
  • - agglomerates are made of at least 75% by weight of organics or hydrocarbons mixed with water;
  • the water content in the starting material is less than 87% as during the (agglomeration) pelletizing part the water was taken out;
  • the solid content of the agglomerates (preferably pellets) preferably before entering the second stage of the drying/liquefying step has been increased to 15 to 30 % in a mill of the dry "Hammermill" type (for example of the Wackerbauer type); and/or
  • the solid content is further increased, in a screw press, up to 50 to 60 %, eventually, with special system, such as separation mill, turbo dryer, high efficiency dryer, press or filter, raised up to 85%; and/or
  • step c) of said process the partially dewatered and pre-treated feedstock is heated in a vessel at conditions of temperature and pressure allowing to: evaporate part of the water still present;
  • the water and lighter materials eventually include cracked material, such as proteins, fats and/or plastics, that are separated from the heavier portion that is at a liquid stage at operating temperature, allowing to eliminate water and to recover lighter products which can be further separated into gas and liquid with low solid content and used in a previous or in a subsequent step to further dry and or crack the feed stock and/or as fuel of any heating system and/or to be sold in a liquid form as a liquid fuel.
  • cracked material such as proteins, fats and/or plastics
  • the thermal separation treatment is performed in a vessel, at temperature to liquefy the most of the hydrocarbons and/or organics and at a pressure that is preferably below the atmospheric pressure.
  • step c) the recovered lighter material is separated in two fractions: the first fraction that is a heavy bio-oil fraction that falls back in the vessel wherein step c) is performed; and the remaining fraction that is the light fraction of the lighter material is also separated in 2 liquid fractions (with remaining solid) and a gaseous fraction or in at least 3 subfractions: respectively in an aqueous, oil and a gaseous fraction.
  • step d means for bringing the mixture of the liquefied and entrained solids resulting from step c) to be thermally processed on the surface of at least part of the plates;
  • At least one step performed in the stationary reactor operating under positive pressure managing system e. optionally, at least one step performed in the stationary reactor operating under positive pressure managing system; and/or f. at least one step performed in a stationary reactor wherein a sweep gas is injected in the stationary vertical reactor or in the feed stream entering the stationary vertical reactor, g. means for removing solids from the reactor, preferably either through entrainment with the exiting vapours, or through a separate solid exit, or both;
  • h. means for recovering the reaction and straight run products; and i. means allowing the exit vapours to be directed to a post-treatment module for performing a solid-gas separation on the solid-gas mixture exiting the central module, the transfer is done ensuring that the walls of the post-treatment modules are 10 degrees above the condensation point of the vapours and below the cracking point of the vapours.
  • - temperature range from 200 to 750 degrees Celsius
  • - residence times ranges from 1 second to 2 hours, preferably 5 seconds to 10 minutes, preferably about 3 minutes;
  • the height of the shelves of the vertical reactor is versus the thickness of the plates range from 6 and 1 (6 plates for 1 shelf to 1 plate for 1 shelf).
  • the post treatment module is advantageously configured to perform the solid-gas separation, substantially without any condensation of the gas present in the solid gas-mixture exiting the central module;
  • the post treatment module has preferably at least one cyclone and preferably two cyclones
  • solids are further separated in a self-refluxing condenser and/or in a equipement changing steam direction, a diverter and/or a wash column;
  • vapours are condensed and separated either in a distillation column or multiple condensers and/or in a flash drum.
  • liquid fuels thereby obtained present at least one of the following features that are dependent upon the kind of upgrading performed on the bio-oil (hydrodeoxygenation, use of catalysts, etc ):
  • Bio-diesel and/or heavy hydrocarbon and/or heavy bio-oil fraction recovered from the solid vapour fraction exiting the pyrolysis step, is(are) advantageoussly added to the feeding stream before entering the stationary reactor.
  • Bio-diesel is advantageously added in the feed material resulting from step b) or from step c) at a rate ranging from 0 to 90 % of the feed mass flow rate entering the stationary reactor, preferably less than 50 % of the feed mass flow rate entering the stationary reactor, more preferably less than 25%, advantageously ranging from 5 to 20 % by weight or 10 to 20 % by weight of the feed mass flow rate entering the stationary reactor.
  • a weak organic acid may be added in the feeding stream before the pyrolysis treatment, preferably before entering the vertical stationary reactor and/or wherein solid fraction recovered from step c) is submit to a preliminary treatment in order to at least partially destructurize cellulose present in said recovered fraction.
  • the weak organic acid preferably a carboxylic acid such as a formic acid and/or carboxylic acid, is used in the preliminary treatment.
  • the amount of weak acid added in the feeding stream represents from 0 to 50 weight percent of the feed material.
  • the feeding stream is submitted to a physical and/or microwave and/or to a chemical treatment allowing, before the feeding stream to be spread on a sliding plate, to at least partially destructurize cellulosic material present in the feed stream.
  • the temperature of the feeding stream used in the pyrolysis step is preferably adjusted to a temperature ranging from 80 to 400 degrees Celsius before entering the stationary vertical reactor, more preferably this temperature ranges from ranges from 100 to 350 degrees Celsius, 200 to 250 degrees Celsius or 100 to 300 degrees Celsius, more preferably about 180 degrees Celsius.
  • the processe of the invention may be performed in a continuous, semi-continuous or batch mode.
  • the fraction recovered by performing aprocess of the invention is preferably the heavy oil.
  • the stationary reactor used in the proces of the invention preferably comprises plates and at least part of the surface of said plates being used to performed said thermal processing.
  • thermal processing being performed on at least part of the surface of said plates in movement.
  • Thermal processing is advantageously performed on at least 1%, preferably on at least 5%, more preferably on 10 % of the surface of said plates and/or on at least 5%, preferably on at least 10% of the plates.
  • the plates advantageously contribute to the uniformity of temperatures conditions in said reactor. And/or the plates contribute to heat transfer from the heated sources to the surface of said plates and to the feed material to process.
  • the plates also advantageously contribute to the heat transfer taking place from the heated walls to the surface of said plates.
  • the mixtures that may be treated during the pyrolysis reaction occuring on the surface of the plates by using the processes of the invention are advanatgeoisly mixtures that comprise mostly organic compounds and/or hydrocarbon that may be transformed by thermal processing.
  • the mixture comprises at least 80%, preferably at least 90% of organic compounds that may be transformed by thermal processing.
  • the mixtures advantageously comprises at least about 95% of organic compounds that may be transformed by thermal processing.
  • the mixtures may comprise other components that are not organic compounds and/or that may not be transformed by thermal processing.
  • the other components are advantageously selected among:, water, steam, ash, nitrogen, sand, earths, shale, metals, inorganic salts, inorganic acids, lime, organic gas that won't be transformed in the reactor and among mixtures of at least two of these components.
  • the mixtures are advanatgeously composed of organic compounds that may be transformed by thermal processing in: a liquid phase, a gaseous phase, a solid phase, or in a combination of at least two of these phases.
  • the mixture is mostly composed of organic compounds that may be transformed by thermal processing, in at least a liquid phase, a gaseous phase and a solid phase.
  • the plates are heated in a specific internal zone of the stationary reactor.
  • the plates are advantageously heated along a side, preferably along a vertical side, of the stationary reactor.
  • the heat source may be generated by electricity, IR or convection, a hot oil and/or bio-oil and/or gas stream, or obtained from the combustion of gas, naphtha, other oily streams, coke, coal, or organic waste or by a mixture of at least two of these.
  • the inside of the reactor may be indirectly heated by an electromagnetic field, microwaves and/or infra-rouge.
  • the inside of the stationary reactor may also be directly heated by a hot gas, liquid or solid stream, electricity or partial combustion of the feedstock, coke, products or by-products.
  • the extemal walls of the stationary reactor are advantageously at least partially surrounded by one or more burners and/or exposed to combustion gas and/or hot solids.
  • the walls of the stationary reactor may be surrounded by a fire box, and said fire box is stationary and contains one or more burners.
  • the supporting and/or guiding means are advantageously attached to the internal wall in a designed and/or random pattern of said reactor .
  • the thickness of the plates advantageously ranges from 0,05 to 8 cm, preferably from 0,1 to 5 cm and more preferably from 0,3 to 0,4 cm.
  • the shape of the plates of the charge is advantageously selected among the group of parallelograms, such as triangles, squares, rectangles, lozenges, or trapezes.
  • the plates of the charge are preferably rectangular.
  • the shape of the plates of the charge may be imperfect and/or all the plates present in the reactor my have about the same size and shape.
  • the plates advantageously have a melting point which is at least of 100 degrees Celsius, and more preferably that is of at least 150 degrees Celsius above the reactor wall maximum operating temperature in the thermal processing zone and/or the combustion chamber.
  • the plates are preferably heavy enough to scrape coke off other plates and/or to have coke scraped off it bymoving over scrapping mechanism without loosing more than 90 % or 70 % of initial velocity of a plate when sliding or when falling.
  • each plate has a density that is superior to 2.0 g/cm 3 , preferably superior to 7.5 g/cm 3 and more preferably comprised between 5.5 g/cm 3 and 9.0 g/cm 3 .
  • the means for bringing the mixture in contact with at least part of the surfaces of the plates are advantageously spraying means of the nozzle type or pouring means; or dumping means.
  • spray nozzles spray the mixture onto the surface of the plates of the charge when the feed stream is liquid and/or mixture of liquid and/or gas and/or entrained solids.
  • the means for bringing the solids outside the stationary reactor is (are) entrainment with a product gas, scoop(s), screw conveyors and/or gravity and/or comprise an exit hopper arrangement attached to the solids exit tube.
  • the stationary reactor has preferably two exits: one for the solids and one for the gas/vapours and entrained solids obtained.
  • the gas/vapours obtained may contain entrained solids.
  • the stationary reactor may be equipped with means for avoiding accumulation of solid in the staationary reactor and/or for plugging of any of the exits, those means are advantageously rotating fins, propellers(s), blowers(s) and/or screw conveyor in the solids exit tube, or a slanted solids exit tube; said means may also be positioned in the bottom part of the vetical stationary reactor.
  • the feeding tube of the mixture is advantaeously positioned on the top of the reactor or is at equal distance of each end of the stationary reactor and the exit of the solids is on the bottom of the stationary reactor.
  • the part of the mixture that will be thermally processed is the heavy part of the mixture and may eventually contain additives commonly used in this field and their degradation by-products.
  • the mixture may comprise organic compounds having the following thermodynamic and physical features: a specific gravity as per ASTM D-4052 range from 0.5 and 2.0, and/or distillation temperatures between 20°C and 950°C as per ASTM D-1160.
  • the average residence time in the stationary reactor is usually between 1 seconds to 10 hours, preferably between 30 seconds and 2 hours, and more preferably is between 90 seconds and 10 minutes.
  • the heating temperature in the stationary reactor advantageously ranges from 50°C to 750°C, preferably froml00°C to 650°C and more preferably from 250°C to 450°C .
  • the heating temperature in the stationary reactor ranges from 140 to 550 °C or 200°C to 555°C, 370°C to 525°C, more preferably from 420°C and 500°C and, more advantageously, is about 420°C or about 470°C particularly when MSW combined with used lube oils are treated.
  • the heating temperature in the reactor ranges from 500°C to 520°C, an is preferably about 505°C, more preferably about 510°C when rubber is feed in the stationary reactor .
  • the stationary reactor used in the processs of the invention advantageously has, considering that plates are defined by L for length, W for width, T for thickness of a plate, at least one of the following features: the average width of the plate range from 4 to 30, preferably from 5 to 10 % the inner diameter of the stationary reactor, the average thickness of the plate must be less than or equal to 8 cm, the Ratio LAV is less or equal to 3; and the The length of a plate is at most 5 times the width of a plate.
  • the supporting and/or guiding means in the stationary reactor used in aprocess of the invention have the shape of a single rectangle and/or a series of rectangles and/or a series of rectangles with guides directly below them and/or a series of rectangle with guides attached to them and/or a series of pegs and/or a series of pegs with guides directly below them and/or a series of pegs with guides attached to them.
  • the solid-gas mixture exiting the vertical stationary reactor are directed to a post-treatment module for performing a solid-gas separation on the solid-gas mixture exiting the central module, wherein the post treatment module is configured to perform the solid-gas separation, substantially without any condensation of the gas present in the solid gas-mixture exiting the central module.
  • the post-treatment module is advantageously configured for keeping the solid-gas mixture at a temperature about the temperature of the gas at the exit of the central module, or at a temperature that is above the temperature at the exit of the central module but inferior to the cracking temperature of the gas present in the solid-gas mixture; preferably, the temperature of the solid-gas mixture in the post treatment module is higher than the temperature of the solid-gas mixture at the exit of the central module by no more than 5 degrees Celsius or is preferably greater than the temperature of the solid-gas mixture at the exit of the central module.
  • the difference between the temperature in the post-treatment module and the temperature at the exit of the central module preferably ranges from 0 to + or - 10 degrees Celsius.
  • the post-treatment module is advantageously being positioned close to the exit of the central module.
  • injection of steam inside the feed material and/or inside the feedstock, and/or inside the pre- treatment module and/or inside the central module are advantageously configured for allowing the thermal conversion to be performed with a residence time ranging from 1 seconds to 10 minutes.
  • the post-treatment module may comprise a transit line, directly connected to the gas- solid mixture exit of the central module, for bringing the gas-solid mixture into the also heated post-treatment module.
  • the post treatment module is advantageously equipped with:
  • an extension, of the central heated enclosure having the function of assuring the connection with an end of the transit line, said extension being also kept at or above the reactor outlet temperature and/or
  • the transit line between the two heated enclosures is advantageously kept at a temperature slightly above or below the temperature of the gas at the exit of the central module, preferably the two enclosures and the transit line are inside the same heating vessel.
  • the line between the two heated enclosures is equipped with an automatic or manual cleanout device, such as a door, provided on this line to remove deposits for example when the plant is shut down; and the sealing of the connection between the extension of the Central module and the end of the connection line being preferably assumed by a ring (preferably a metallic ring) and by a seal (preferably of the graphite type and of the asbestos's type).
  • the transit line is advantageously in the form of a cylinder, has a length L and an internal diameter D and the Ratio L/D is advantageously lower or equal to 2.
  • the length of the transit line is preferably lower or equal to 10 meters.
  • the stationary pyrolysis reactor used in the processes of the invention is advantageously about vertical and comports a first zone placed in a heated enclosure and a second zone that is outside the heated enclosure but insulated internally to keep the solid-gas mixture, produced in the first zone, hot until entering a solid-gas separation equipment.
  • the about vertical stationary pyrolysis reactor advantageously comports a first zone placed in a heated enclosure and a second zone that is outside the heated enclosure but insulated internally to keep the reactor products at a temperature higher that the temperature inside the first zone.
  • the solids resulting from the thermal processing in the vertical stationary reactor are advantageously separated from the vapours in gas- solids separation equipment, preferably in a box and/or in a cyclone, situated in a second heated enclosure placed downstrean upstream to the central module.
  • the temperature of the products at the exit of the separating equipment is advantageously kept at or above the reactor exit temperature.
  • the clean vapours exiting from the post treatment module are advantageously condensed and separated into products such as Wide Range Bio-Diesel being defined by reference to Number 1 to Number 6 diesels, and by reference to marine oil specifications and/or to heating oil specifications and/or alkene products such as kerosene.
  • the separating equipment is configured to be connected with an equipment of the distillation column type.
  • the vapours, exiting the gas-solids separating equipment is advantageously routed to an equipment of the flash drum type, said equipment of the flash drum type having preferably a self-refluxing condenser mounted above it to scrub the reactor products and to remove residual solids.
  • the clean vapours exiting from the post treatment module are advantageously condensed and separated in an equipment of the distillation column type.
  • the average residence time in the vertical stationary reactor preferably ranges from 1 seconds to 2 hours, advantageously from 3 seconds to 15 minutes, preferably from 50 seconds to 15 minutes, and more preferably from 90 seconds to 10 minutes.
  • the heating temperature in the stationary reactor depending of the feed material and of the product desired in the stationary reactor ranges from 140°C to 575°C, 300°C to 420°C or 350°C to 550°C, preferably from 390°C to 460°C or 510°C to 520°C, more preferably from 420°C and 455°C and, more advantageously, is about 425°C, about 510°C or about 520°C.
  • the various fractions generated by the cracking are preferably recovered as follow: the liquid fraction is recovered by distillation, the gaseous fraction is recovered by distillation and/or partial condensation, and the solid fraction is recovered for example in wash column, cyclones, a solids recovery box, a scrubber, and/or a refluxing condenser.
  • the amount of the recovered liquid fraction represents preferably between 30% and 90% weight of the reactor feed; and/or - the amount of the recovered gaseous fraction represents between 1 % weight and 30% weight of the reactor feed; and/or
  • the amount of the recovered solid fraction represents between 1% weight and 40% weight
  • the amount of the recovered liquid fraction, preferably, of the recovered diesel represents between 50 % and 90 % weight of the reactor feed;
  • the amount of the recovered gaseous fraction i.e. of the recovered vapours represents between 1 to 10 % weight and the amount of the recovered naphtha represents between 2 and 15 % weight of the reactor feed;
  • the amount of the recovered solid fraction i.e of recovered coke represents between 2 and 40 % weight.
  • the vertical stationary reactor when used in the processes of the invention, is configured in a way that the extension is connectable with a transit line that is advantageously heatable and configured to bring solid-gas mixtures exiting the rotating kiln to a post-treatment module configured to separate gas and solids present in the solid-gas mixture.
  • the rotating kiln is configured in a way that the extension is connectable with a transit line that is advantageously heatable and configured to bring solid-gas mixtures exiting the rotating kiln to a post-treatment module configured to at least partially separate solids present in the solid-gas mixture.
  • the amount of the recovered liquid fraction advantageously represents between 30% and 80% weight of the organic reactor feed and/or the amount of the recovered gaseous fraction advantageously represents between 30% weight and 60% weight of the reactor feed and/or the amount of the recovered solid fraction represents advantageously between 0% weight and 20% weight,
  • the processes of the invention may be used for treating waste material, such as waste materail, biomass, plastic and/or tires.
  • the processes may additionnaly be used for treating MSW and/or organic matter and/or used oils and to prepare:
  • a fuel, or a component in a blended fuel such as a home heating oil, a low sulphur marine fuel, a diesel engine fuel, a static diesel engine fuel, power generation fuel, farm machinery fuel, off road and on road diesel fuel; and/or - a cetane index enhancer; and/or a drilling mud base oil or component; and/or a solvent or component of a solvent; and/or a diluent for heavy fuels, bunker or bitumen; and/or a light lubricant or component of a lubricating oil; and/or - a cleaner or a component in oil base cleaners; and/or a flotation oil component; and/or a wide range diesel; and/or a clarified oil; and/or a component in asphalt blends; and/or a soil amendment; and/or
  • an element to decontaminate soil and/or water and/or a biomass additive; and/or a biogas slurry treatment; and/or an element for paints and/or food colorants; and/or
  • a eigth object of the present invention is a managing system allowing continuous optimisation of a process as defined in any one of the preceeding process-claims for producing fuel from waste hydrocarbon and/or organic material, said system comprising at least one captor for measuring at least one of the following parameters: humidity in the agglomerates, rate of cellulosic material present in the feed stream before entering the vertical stationary reactor, brix index and/or temperature of the feeding stream in a liquid or in a semi liquid stage and or heterogeneous state before entering thevertical stationary reactor,temperature and/or pressure in the vessel and/or in the vertical stationary reactor, a storage unit for storing data collected by sensors of the system, and calculation unit configured to adjust solid content present in the feed stream to the vessel, and/or to adjust solid content in the feed stream to the vertical stationary reactor.
  • feed stream solid content is advantageously adjusted by at least one of the following means: injection a weak organic acid in the feed stream, injection of a diesel having preferably following feature in the feed stream, adjustment of the pressure at a positive or negative value, and adjustment of the temperature of the feeding stream in the range from 25 to 350 Celsius degrees.
  • liquid feed comprised mainly of a
  • stream liquid may also
  • Trays (11) may be left wall plates can bounce off of 2 attached. Plates (10) when transitioning may bounce off when between trays. Trays transitioning may be attached between trays
  • Trays (11) may be right wall plates can bounce off of 2 attached. Plates (10) when transitioning may bounce off when between trays. Trays transitioning may be attached between trays
  • Reactor Allows plates to pass Near the top of 10, TC, Allows plates (10) to entrance through the door from the reactor, VR, 16, exit the top door the top pressurised directly next to 21 pressurised chamber chamber into the and/or above (TC) and enter the reactor. It also scrapes the top-most vertical reactor (VR). the surface of the plates tray. Scrapes the surface which pass through it. of said plates which
  • Seen in Figure may remove at least 4 part of the solid material (16) on said surface. Rotates along the reactor entrance door axis of rotation (21)
  • the and enter the vertical plates slide on the reactor by passing bottom pressurised through the top chamber floor (40) pressurised chamber and the top exit door, which may pressurised chamber remove at least part of floor (49), which the solid material may scrape the located on the top surface of the plate surface of said plates. sliding on said floor.
  • the plates slide material (16) on said downwards on tray(s) surface may be and may have at least remove from said part of the solid material surface.
  • Object which apart from one towards the reactor consists of at least one another such exit door (12) and/or guide on which plates that there is slide downwards can slide and two guide space for within the one piece walls which prevent the plates to fall reactor (OPR) plates sliding on said from one tray liquid feed stream 49, 3, 4, formed on the and/or is formed during VR, surfaces of the plates thermal reactions.
  • Reactor Has a different angle Top-most tray 10, VR, Allows plates (10) to entrance than the top-most tray located 9 slide into the vertical tray within the vertical directly next to reactor (VR) after reactor to facilitate the or below the passing through the entrance of a plate into reactor reactor entrance door said reactor entrance door. (9).
  • Reactor Allows the reactor Located at the 9 Allows the rotation entrance entrance door to rotate top of the of the reactor door axis when a plate pushes on reactor entrance door (9) of rotation said door. Through this entrance door.
  • Flipper Flips the plates as they Located at the 10, 22, Flips plates (10) by transition between trays. bottom-most 26 the rotating extremity of a movement of the tray. Not flipper arms (22). located on the Rotates along the bottom-most flipper axis of tray. rotation (26)
  • Flipping Prevents the plates from Located 10, 11 Prevents the plates tray falling before a certain directly above (10) from falling percentage of the length each tray, before a certain of the plates pass the except for the percentage of the bottom-most extremity bottom-most length of the plates of the tray directly tray. Attached passes the extremity below the flipping tray. to at least one of tray (11) directly By preventing the plates reactor wall. below the flipping from falling, they hang tray (23), thus at an angle which allows Seen in Figure allowing them to flip them to flip as they fall 13 as they transition onto the curved tray between trays.
  • Curved Catches plates which are Attached to 10, 23, Catches plates (10) tray flipped by flipping trays the top-most 11 which are flipped by and allows them to slide part of each flipping trays (23) onto the next tray.
  • the tray except for and allows them to curved shape of the tray the top-most slide onto the next allows the plates which tray. Attached tray (11). fall on it to slide to at least one
  • Inductive Protects the inductive Between the 66 Protects the inductive heater heater from contact with conveyor belt heater (66) protective plates and/or hot and the
  • Tube chamber can increase Seen in Figure
  • Elevator If elevator does not have Seen in Figure 10, 42, Plates (10) scrape left wall an inductive heater, the 3 73 along the elevator elevator left wall allows left wall (42) when plates to lean against ascending the said wall while elevator and said ascending the elevator, wall prevents pates thus allowing the angle from falling off the of the plates to change elevator system (73) during said ascent
  • Elevator Allows the solids within Location on
  • Elevator Allows flow of solids Located at the
  • Top Allows for more room Located 10 Does not interfere slanted for the plates which directly above with the plates (10) elevator slide off the lifters and the top-most movement wall supports onto the top end of the top
  • Top Allows the flow of Located within G, TC Allows the passage pressurise sweep gas into the top the top of sweep gas (G) into d chamber pressurised chamber so pressurised the top pressurised sweep gas that the pressure within chamber. chamber (TC) entrance said chamber can
  • Support Outer chain of the Located along 53, 120 Carries the supports outer chain elevator system which and in between (53) upwards. Is carries the supports the top and moved by pegs of a around the pulleys. bottom pulley (120).
  • Support Inner chain of the Located along 53, 120 Carries the supports inner chain elevator system which and in between (53) upwards. Is carries the supports the top and moved by pegs of a around the pulleys. bottom pulley (120).
  • Lifter Outer chain of the Located along 54 Carries the lifters outer chain elevator system which and in between (54) upwards. Is carries the lifters around the top and moved by pegs of a the pulleys. The lifter's bottom lifter pulley (120).
  • Lifter Inner chain of the Located along 54 Carries the lifters inner chain elevator system which and in between (54) upwards. Is carries the lifters around the top and moved by pegs of a the pulleys. The lifter's bottom lifter pulley (120).
  • Bottom Bottom-most pulley Located within 55, 56 Pulley which pulls on support which rotates and pulls the elevator, the support inner pulley the inner and outer below the chain (56) and support chains, thus bottom-most support outer chain moving the supports part of the (55).
  • Bottom Bottom-most pulley Located within 57, 58 Pulley which pulls on lifter which rotates and pulls the elevator, the lifter inner chain pulley the inner and outer lifter below the (58) and lifter outer chains, thus moving the bottom-most chain (57).
  • Top Top-most pulley which Located within 55, 56 Pulley which pulls on support rotates and pulls the the elevator, the support inner pulley inner and outer support above the topchain (56) and chains, thus moving the most part of support outer chain supports through the the top (55).
  • Top lifter Top-most pulley which Located within 57, 58 Pulley which pulls on pulley rotates and pulls the the elevator, the lifter inner chain inner and outer lifter above the top(58) and lifter outer chains, thus moving the most part of chain (57).
  • Burner Consumes oxygen and a Located along X, 10, E Consumes the carbonaceous fuel to the elevator oxygen and a produce thermal energy. right wall. carbonaceous fuel to This thermal energy produce thermal heats the plates which Seen in Figure energy to heat the are carried upwards 9 plates (10). Produces through the elevator. exhaust which leaves the elevator (E) with the exhaust stream (X)
  • Elevator Turns above the elevator Located 16, 46 Pushes the screw screw floor and within the directly above conveyor solid conveyor elevator solid exit tube the elevator material (16) out of to push solids out of the floor and the elevator solid exit elevator. within the tube (46).
  • the inductive heater is between the
  • cylindrical coil but may heater
  • inductive heater and Seen in Figure Protects the inductive from the plates and/or 10 heater from plates vapours and/or gasses and/or vapours and/or solid material and/or gasses and/or and/or heat from other solid material (16) sources while allowing and/or heat from the inductive heater to other sources while heat the plates. allowing the inductive heater (66) to heat the plates.
  • Outer coil Serves as an enclosure Located to the 66 Serves as an wall for the inductive heater left of both the enclosure for the inner coil wall inductive heater (66) and the
  • Top Allows the top Located at the 64 Allows the rotation pressurise pressurised chamber top of the top of the bottom d chamber exit door to rotate when pressurised pressurised chamber exit door a plate pushes on said chamber exit exit door (64) axis of door. Through this door.
  • tray Prevents plates from walls of the and prevents plates falling through the tray.
  • tray from falling through May scrape the bottom preferably said trays. May surface of the plates and along said scrape the bottom remove at least part of walls. surface of the plates the solid material from and remove at least said surface. Seen in Figure part of the solid
  • Scraper Bar which scrapes the Located in 10, 92, Scrapes the bottom bar bottom surface of the between the 16 surface of the plates plates while said plates guides of the (10) sliding over the slide on the tray to tray, scraper bar (92) to which the scraper bar is preferably remove at least part attached. perpendicular of the solid material to said walls, (16) from said and spaced out surface.

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Combustion & Propulsion (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • General Health & Medical Sciences (AREA)
  • Automation & Control Theory (AREA)
  • Processing Of Solid Wastes (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

L'invention concerne un réacteur fixe et ses éléments internes pour le traitement thermique d'un mélange. Le réacteur comprend des plaques et au moins un moyen de support et/ou de guidage d'une ou plusieurs plaques conçu pour permettre le glissement d'une plaque sur la surface supérieure du moyen de support et/ou de guidage d'une ou plusieurs plaques, une plaque glissant d'une position supérieure du réacteur vers une position inférieure du réacteur. Le réacteur est en outre caractérisé en ce que le moyen de support et/ou de guidage d'une ou plusieurs plaques est de préférence incliné et en ce qu'au moins une partie de la surface desdites plaques est utilisée pour effectuer ledit traitement thermique du mélange. L'invention concerne également des procédés pour la production de combustibles liquides à partir de matière de départ et des systèmes de gestion permettant l'optimisation continue des procédés.
PCT/CA2018/051234 2017-09-20 2018-10-02 Réacteur fixe et ses éléments internes pour la production de combustible liquide à partir d'hydrocarbures résiduels et/ou de matière organique et/ou d'huiles contaminées, procédés thermiques, utilisations et systèmes de gestion s'y rapportant WO2019056138A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
CA2979651A CA2979651A1 (fr) 2017-09-20 2017-09-20 Reacteur stationnaire et ses dispositifs internes servant a produire un carburant liquide a partir d'hydrocarbure residuel ou de matiere organique ou de sols contamines, procedes thermiques, utilisation et systemes de gestion associes
CA2,979,651 2017-09-20
PCT/CA2018/051178 WO2019056110A1 (fr) 2017-09-20 2018-09-20 Réacteur stationnaire et ses éléments internes pour produire du combustible liquide à partir de déchets d'hydrocarbures et/ou de matières organiques et/ou d'huiles contaminées, processus thermiques, utilisations et systèmes de gestion associés
CAPCT/CA2018/051178 2018-09-20

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WO2019056138A1 true WO2019056138A1 (fr) 2019-03-28
WO2019056138A8 WO2019056138A8 (fr) 2019-04-18

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021211529A1 (fr) * 2020-04-13 2021-10-21 Eastman Chemical Company Pyrolyse de déchets plastiques dans un réacteur à film
CN115415046A (zh) * 2022-11-03 2022-12-02 南通世创机械有限公司 金属裁切废料处理装置

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2726996A (en) * 1950-04-28 1955-12-13 Phillips Petroleum Co Conversion of heavy oils by means of hot pebbles along a spiral path
US20080223268A1 (en) * 2007-03-16 2008-09-18 Gehring Michael W Freefall pyrolytic oven
CA2757061A1 (fr) * 2011-10-20 2013-04-20 Lucie B. Wheeler Usine mobile pour le traitement thermique de flux d'alimentation contamines ou non contamines, ses procedes et les utilisations des produits
US20170095790A1 (en) * 2010-05-18 2017-04-06 Envirollea Inc. Thermal processing reactor for mixtures, fabrication of the reactor, processes using the reactors and uses of the products obtained

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2726996A (en) * 1950-04-28 1955-12-13 Phillips Petroleum Co Conversion of heavy oils by means of hot pebbles along a spiral path
US20080223268A1 (en) * 2007-03-16 2008-09-18 Gehring Michael W Freefall pyrolytic oven
US20170095790A1 (en) * 2010-05-18 2017-04-06 Envirollea Inc. Thermal processing reactor for mixtures, fabrication of the reactor, processes using the reactors and uses of the products obtained
CA2757061A1 (fr) * 2011-10-20 2013-04-20 Lucie B. Wheeler Usine mobile pour le traitement thermique de flux d'alimentation contamines ou non contamines, ses procedes et les utilisations des produits

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021211529A1 (fr) * 2020-04-13 2021-10-21 Eastman Chemical Company Pyrolyse de déchets plastiques dans un réacteur à film
CN115415046A (zh) * 2022-11-03 2022-12-02 南通世创机械有限公司 金属裁切废料处理装置

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