Note: Descriptions are shown in the official language in which they were submitted.
~08V147
The present invention relates generally to the converting of
organic waste material into clean fuels and other useful products, and more
particularly to a novel method and apparatus for obtaining liquid and gaseous
hydrocarbons and a solid carbonaceous material from used rubber tires and
industrial and residential trash containing r~latively large amounts of plas-
tic material.
At the present time, there is considerable concern in all high-
ly industrialized countries regarding the disposal problems occasioned by the
accumulation of large quantities of used automobile tires, industrial waste
and residential trash ... much of the latter containing non-degradable plas-
tic materials. In previous years, such waste materials were disposed of
primarily by burning, but the enactment of air-pollution laws in st major
countries now prohibit this method of disposalO
Also, at the present time, many of the so-called oil-consuming
countries are concerned about the increased cost and unavailability of import-
ed petroleum, and the dwindling supplies of natural gas.
Because of the af~rementioned problems, there has been and now
is an increased interest in the converting of industrial waste, residential
; trash, and ordinary garbage into products which can be used to produce heat
or as the feed stock for various industrial processes.
The extraction of hydrocarbon materials from organic waste by
the use of high temperatures has been known for many years. However, the
known processes and apparatus have serious disadvantages. For example, grad-
ual!lheating of the waste materials to the desired temperature results in cross-
chemical reactions of the reactants and products and the loss of useful pro-
~ducts.
Also~ the use of atmospheric and above-atmospheric pressures
in the heating vessel causes the gases and vapors to slowly diffuse through
the solid mass of materials and to thereby cause side reactions and cross-
reactions among product species, which results in a very inefficient conversion
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`` 1080147
process.
And, the prolonged heating of the gases and vapor products in
the heat-ing vessel causes recomb m ations, ~epol~merizations, and condensation
of some of th3 products, ~h~ch resu~ts m the ormati~n o hlgh molecul æ
weight tars and hydrocarbons and t-hereby reduces the yield o the useful pro-
ducts. In alditaon, s~me of these high molecular welght tars and hydrocarbans
form surface coat mgs on the feed materials and thereby block the relea æ of
new gases and vapors from the unreacted fe d materials.
This mvention æeks to provide a novel method and apparatus
for oonverting organic waste materials into clean uels and other useul hydro-
carbon products. Mbre pæ ticulælv, th~s ~nvention seeks to provide a novel
method and apparatus for obtainLng useful hydrocarbon products from u æd
rubker tires and waste plastic materia~s.
In an alternative aspect, this invention seeks to provide a
novel method and apparatus for obtaining from used rub~er tires and waste
plastic materials, a hydrocarbon feed stock for petrochemical plants.
In an altexnative aspect, this invention seeks to provide a
novel method and app æatus for abtaim ng from usod rubber tires and waste
plastic materials, a carbonaceous char which can be readily canverted to act-
ivated cæbon, or used as a smokeless fuel, or used as an asph~lt and chemical
iller.
I have discovered that the above objects and advantages a~e
achieved by continuously moving a mass of shredded rubber tires, industrial
trash, ar residential trash including the steps of: moving the material
through an elongated tubular member maintained at a temperature between about
800F and about 1500F, in the substantial abænce of oxygen; and withdraw mg
gases and vapor~ from the tubular member at a vacuum o fram tw~ to six inches
of mercury h~low ambient abmospherlc pressure. T~ increase the production rate,
a plurality of such tubular members can be provided in the same heatin~ ves-
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10 8~ 14~7
sel in a side~by-side relationship, and/or the diameter of the tubular mem-
bers can be increased in size with accompanying provisions for maintaining
a substantially constant temperature throughout the mass of material being
processed.
By this phrase "a vacuum of from about two inches to five inches
of mercury~ in this specification and claims is meant a pressure of from about
two inches to six inches of mercury below ambient atmospheric; that is, tak-
ing atmospheric pressure as approximately 30 inches of mercury, pressures of
from about 24 inches of mercury to about 28 inches of mercury are used.
Based upon present information, it appears that the relatively
high temperature adjacent the inlet of the tubular member (and throughout its
length) and the constant stirring or turning of the material so as to continu-
ously expose it to the heated surface or surfaces of the tubular member,
causes the gases and vapors to literally "explode" from the material, and the
relatively high vacuum throughout the length of the tubular member causes the
vapors and gases to be quickly withdrawn before they can repolymerize or con-
dense onto the feed material.
In the drawings:
Figure ] is a schematic elevational view, partially in cross-
section and somewhat in the nature of a flow diagram, illustrating one form
of apparatus for practicing the teachings of the present invention.
Pigure 2 is an enlarged elevational view, partially in cross-
section, showing an alternative form of heating vessel containing a plurality
of tubular members of increased diameter, in order to increase the capacity r
of the system, and
Figure 3 is a vertical, sectional view taken on the line 3 - 3
in Figure 2.
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n
1~80147
:
Referring to the drawings more particularly by refer-
ence numerals, and specifically to Figure 1, the number 10 indi-
cates one form of apparatus for practicing the teachings of the
present invention, which includes a storage bin 12 from which
the starting material "M" can be discharged into a hopper 14.
Positioned beneath the hopper 14 is an air-tight in-
let chamber 16 which has an inlet 18 for admitting a charge of
material into the chamber, and an outlet 20 for discharging the
material therefrom. Each inlet and outlet is provided with a
sliding door movable between an open position and a
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108V147
closed position, responsive to signals from an automated control 22 transmitted
through control lines 24 and 26, respectively. The specific means for control-
ling the movement of said doors is a matter of choice and can be either elec-
trical, hydraulic or pneumatic.
Extending between the inlet chamber 16 and the control 22, is
a first purging conduit 28, which can be selectively placed in communication
with a container 30 of purging ~as such as nitrogen, through a pipe 32 which
contains a valve 34.
The reactor system includes an insulated heating vessel 36
through which extends an elongated pipe ~to tube 38 and which contains an in-
let 40 and an outlet 42. I have used a 6 inch diameter stainless steel tube
in the prototype apparatus.
A source of heat such as a gas burner 44 is provided in the
heating vessel 36 beneath the tube 38, and a vent or chimney 46 is provided
at the top of the vessel for the discharge of the products of combustion
therefrom.
A screw conveyor 48, which is driven by an electric motor 50
extends through the tube 38 from adjacent the inlet 40 to adjacent the outlet
42, for moving the material through the tube at a uniform rate of speed with
a churning or stirring vement, whereby to continuously expose all of the
chunks or particles of material to the heat at the surface of the tube 380
A product outlet pipe 52 is in communication with a connector
pipe 54 and with the interior of the tube 38 adjacent to its outlet end, the
outlet pipe being within the heating vessel so as to be exposed to the heat
therein. Stating it somewhat differently, the product outlet pipe 52 should
be maintained at a relatively high temperature so that the hydrocarbon products
being removed from the tube B8 as gases or vapors remain in such state, as
will be described more fully hereinafter.
Adjacent the outlet 42 of the tube 38 is an air-tight outlet
chamber 56 ~lich is similar in construction to the inlet chamber 16 previous-
~08014~7
ly describedO Thus, it contains an inlet 58 and an outlet 60, each of which
is provided with a sliding door movable between an open position and a closed
position responsive to the automated control 22 which is ir communication
therewith through control lines 62 and 64, respectivelyO
A second purging conduit 66 extends between the outlet chamber
56 and the automated control 22 and is in selective communication with the
container 30 of purging gasO
Positioned beneath the outlet chamber 56 is a char collection
container 68.
The product recovery system includes a heat exchanger 70 which
contains a coolant ;nlet 72 and a coolant outlet 74 for causing cooling fluid
to pass therethrough. The heat exchanger 70 also includes a product inlet
pipe 76 which is connected to the connector pipe 54, and a product outlet
pipe 78 which is connected to the inlet of a condenser 80. The outlet of the
condenser is connected through a pipe 82 with the inlet of a liquid storage
tank 84 which has a drain pipe 86 at the bottom thereof, the drain pipe 86
being provided with a valve 88 for selectively draining liquid products there-
from.
A vacuum system 90 has the inlet thereof connected to the upper
portion of the liquid storage tank through a pipe 92, and the outlet of the
vacuum system is connected through a pipe 94 and valve 95 with the inlet of a
gas tank 96 which has a discharge pipe 98 adjacent the upper end thereof, the
discharge pipe being provided with a discharge valve 100.
Connected to the bottom of the gas tank 96 is a fuel pipe 102
which has a valve 104 positioned therein, and which pipe is connected to the
gas burner 44 positioned in the bottom portion of the heating vessel 36 be-
neath the tubular member 38.
In oPeration, the material '~"..~which can be shredded rubber
tires or crushed industrial or residential waste which has metal and other
inorganic materials removed therefrom, as will be described more fully here- -
1~0~7
inafter...is discharged from the storage bin 12 and into the hopper 14.
me automated control 22 is adjusted so that with the outlet
20 of the inlet chamber 16 in the closed position, the inlet 18 is opened to
permit a measured charge of material to enter into the inlet chamber 16.
mereafter, the inlet 18 is closed and a charge of purging gas such as nitro-
gen is admitted into the inlet chamber 16 through the conduit 28, whereby to
displace all of the air from the inlet chamber 16.
With the inlet 18 closed, the outlet 20 of the chamber 16 is
opened, whereby the material '~" passes through the inlet 40 of the tube 38
and is carried through the tube by means of the screw conveyor 48.
The opening and closing of the inlet 18 and outlet 20 and the
purging of the inlet chamber 16 with a gas such as nitrogen, occurs at rela-
tively short intervals of time, whereby there is practically a continuous
flow of material into the inlet end of the tube 38.
The char which remains after the vapors and gases are removed
from the material, passes through the outlet 42 of the tube and into the out-
let chamber 560 The outlet chamber 56 function9 in a manner similar to the
inlet chamber 16, Witll the outlet 60 being closed and the inlet 58 being opened
to permit a charge of char to pass into the outlet chamber, with the inlet 58
then being closed and the outlet 60 opened to discharge the char into the
container 68. me outlet 60 is then closed, and with both the inlet and out-
let in the closed position, purging gas is admitted into the outlet chamber
through the conduit 66, so as to purge any air from the outlet chamberO
Thereafter, the inlet 58 is opened to permit another charge of char to enter
the outlet chamber, and the sequence is again repeated to discharge the char
into the container 680 As mentioned hereinabove, the opening and closing of
the inlet 58 and the outlet 60, and the purging of the outlet chamber 56,
occur at relatively short intervals of time, whereby there is substantially a
continuous flow of char from the outlet 42 of the tube 38 and into the contain-
er 68.
~080147
As will be explained more fully hereinafter, I have learnedthat the temperature in the heating vessel 36 should be at least 800 F~ and
preferably as high as 1500F~ depending upon the proportions of gases desired.
Also, that the vacuum within the tube 38 should be from about four inches to
about six inches of mercuryO The diameter of the tube 38 and the speed at
which the material is moved through the tube 38 by the conveyor 48 should be
such that the temperature of the material being processed reaches the mean
temperature in the retort within a few feet of the side of the retort adjacent
the inlet 40. m us, it appears that the sudden increase in the temperature of
the material to no less than about 800Fo by the time it has moved a few feet
into the vessel, causes a sudden "shock" heating which, together with the
vacuum in the tube, causes the vapors and gases to literally "explode" from
the chunks or particles and the vacuum causes them to be carried away from
the churning, turning mass of material before they can repolymerize or condense
upon the remaining solid material.
Turning to the operation of the product recovery system, the
~ases and vapors which are produced and/or liberab~d in the tubular member 38~ ~ r
pass through the product outlet pipe 52 and the pipes 54 and 76, and through
the heat exchanger 70, whereby the vapors are condensed and the gases are
cooled.
From the condensor 80, the gases and liquid pass through the
pipe 82 and into the upper end of the tank 84, with the water and oil remain-
ing in the tank and the gases passing through the pipe 92, the vacuum system
90, and the pipe 94.00into the gas tank 96.
The fuel gas thus produced can flow through the pipe 102 to the
burner 44 and be used to heat the vessel 36, or can be discharged through the
outlet pipe 98 and valve 100 for other purposes.
For initially starting the system, the valve 95 is closed and
commercial fuel gas is a~mitted into the gas tank 96 through the pipe 98 and
valve 100. However, after the system is operating and fuel gas is being pro-
1080147
duced in sufficient quantities, th~ valve 95 is opened and the system becomes
self-sustaining insofar as the fuel gas is concerned. And, when it is nec-
essary or desirable to shut-down the system, valves 95, 100 and 104 can be
closed, thereby maintaining a "start-up" supply of fuel gas in the tank 96.
Obviously, if at any time not enough fuel gas is being produced in the system
to maintain the heating vessel 36 at the proper temperature, additional com-
mercial fuel gas can be admitted into the gas tank through the pipe 98 and
the valve 100.
As mentioned above, various materials can be processed using
the method and apparatus of the present invention, including shredded rubber
automobile tires from which metal has been removed, industrial waste plastic
materials, and residential trash from which metal and inorganic materials have
been removed and which consists primarily of plastic containers and wrappings. r
EXAMPLE NO. 1
Although residential trash from which metal and inorganic mat-
erials have been removed varies from city to city, and from one section of a
city to another section thereof, a typical physical composition of such dry
residential trash, which comprises primarily plastics, is as follows, by
weight:
Volatile Matter 75%
Fixed Carbon 11%
Ash 14%
The chemical composition of such "typical" dry residential
trash, is as follows, by weight:
Component Percenta~e
~Iydrogen 5.5
Carbon 46.0
Nitrogen 1.8
Oxygen !33 .2
Sulphur 0-5
1080~47
:
Component Percentage
Ash 16.0
- Using the apparatus previously described, and with a temperature
of the heating vessel at about 1100F. and with a vacuum between about four
inches and about six inches of mercury, the following listed yield was obtained
wherein the percentage of yield is by weight of dry feed material.
Product Percent Amount
.. .. _
Oil 40 2.7 bbl/ton
Gas 32 8,000 scf/ton
Char 16 320 pounds/ton
Water 12 240 pounds/ton
The char or solid residue was a black, powdery material, similar
in appearance to amorphous carbon, and consisted primarily of fixed carbon
and ash.
The gas which was produced had the following composition, by volume.
Product Percentage
Hydrogen 20
Nitrogen 10
Methane 21
20 Carbon Monoxide 2
Carbon Dioxide 6
Ethane 10
Ethylene 3 .
Propane and Higher Hydrocarbons 26
EFFECT OF TEMPERATURE ON GAS PRODUCED
.
; By changing the temperature of the heating vessel from 1100F. to
either 800F. or 1500F., the amounts of the various gases which are produced
can be varied to an appreciable extent, as shown by the following table in
which the gas composition is in percent by volume:
A'~
g
~0~0~7
Ex. 2 Ex. 1 Ex
Product 800F. llOO~F. 1500F.
Hydrogen 10 20 35
Nitrogen 12 10 8
Methane 16 21 18
Carbon Monoxide 8 2 2
Carbon Dioxide 18 6 7
Ethane 8 10 4
Ethylene 2 3 4
Propane and higher
Hydrocarbons 18 2620
EXAMPIES N0. 4 AND N0. 5
As previously mentioned, another type of waste material which
can be processed using the teachings of the present invention, to provide oil,
a carbonaceous char, and high quality fuel gas, comprises waste plastic mat-
erials obtained from manufacturing processes.
Two different mixtures of polypropylene and polystyrene, pro-
cessed at 1100 F. and with a vacuum between about four inches and six inches
of mercury, produced the following percentages of gases:
Ex. No. 4 Ex. No 5
Product Percenta~e Percenta~e
Nitrogen 12.2 11.4
Carbon Monoxide 1.3 1.0
Carbon Dioxide 3.8 3.5
Methane 8.3 7.0
Ethane 9-7 9-5
Propane 33.6 39.7
Butane 10~5 11.1
Hydrogen 7.4 5.0
The amount of gas produced in each of these examples was
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`-` 108(~147
about 1,500 cubic feet per ton of starting material~ and the oil was about
83 percent, by weight, and the char was about 7 percent, by weight, of the
starting material.
EXAMPLE N0. 6
Another starting material, which is in abundant supply in many
industrial countries, including the United States, Japan, and West Germany,
and which presents a serious disposal problem, is used rubber automobile
tires.
Such rubber tires which have the metal removed and which are
shredded into small pieces approximately three-fourth of an inch in length
and about one fourth inch in thickness, were processed using the apparatus
previously described, at a temperature of about 1100F. and with a vacuum
between about four inches and about six inches of mercury.
The products recovered, per ton of starting material, were as
follows:
Light oil 3 barrels
Gas 9000 cubic feet
Char 700 pounds
If it is desired to produce more gas and less oil and char, the
operating temperature should be increased above 1100F.
The char which was produced is a powdery carbon-black type of mater-
ial with a heating value of about 19,500 Btu per pound.
The gas which was produced had the following composition, by
volume:
Product Percentage
Hydrogen 6
Nitrogen 17
Carbon Monoxide 4
Methane 20
Carbon Dioxide 5
~C~801~7
:.;,
Product Percenta~e
Ethane 7
Propane and ~igher
~ydrocarbons 28
Because this gas obtained from used rubber tires contains in
excess of 55%, by volume of light molecular weight hydrocarbons, it has a
very high heating value, comparable to natural gas.
The yield of oil, by weight, according to the boiling point
range of the oil, was as follows:
Boilin~ Point Ran~e ( C) Yield (Wt.... %)
- 97 7.0
97 - 150 9.9
150 - 190 8.1
190 - 265 17.8
265 - 375 31.0
Residue 26~0
TERNATIVE FORM OF APPARATUS
As mentioned above, I have used a 9ix inch diameter stainless
steel pipe as the tubular member 38, in achieving the aforementioned results,
with the temperature gradient between the outer surface of the pipe and the
center of the pipe being about 10 F~
If it is desired to increase the capacity of the apparatus, ad-
ditional pipes or tubular members can be placed in the heating vessel in a
side-by-side relationship, and/or the diameter of the tubular members can be
increased.
Referring to Figures 2 and 3 which show one such alternative
form of apparatus, the single tubular member 38 is replaced with three tubular
members 138 of increased diameter, which are positioned in a spaced apart,
side-by-side relationship above the same gas burner 44. Each of the tubular
members 138 is provided with the same type of inlet 140 and outlet 142 as
1080147
previously described, and the controlled inlet and outlet chambers for exclud-
ing air, are the sameO
However, because of the increased diameter of the tubular mem-
bers and the desirability of maintaining approximately a 10Fo gradient be-
tween the outer surface of the tube and the center thereof, each of the tub-
ular members is provided with a hollow shaft through which hot gases can be
circulated.
Thus, each screw conveyor 148 has a hollow shaft 150 with an
inlet end 152 and an outlet end 154. The inlet end 152 extends beyond the
tubular member 138 and is in communication with and is rotatabl~ received in
a hollow, gas-tight fitting 156, the interior of which fitting is in commun-
ication with a pipe 158, which, in turn is connected to a pump 160 which has
an inlet 162 in communication with the interior of the heating vessel 36.
The outlet end 154 of the hollow shaft is connected to the
electric motor 50, and between the motor and the end of the tubular member
138 there is a plurality of openings or vents 164 to permit the passage of
hot gases~
Surrounding the vented end po~tion of the hollow shaft 150 in
relative rotational relationship therewith is a gas-type housing 166, the
interior of which housing is in communication with a pipe 168 which has its
outlet in communication with an opening 170 provided in the wall of the heat-
ing vessel 36.
Thus, hot gases which enter the inlet 162 of the pump 160,
flow through the pipe 158 and the fitting 156, into the interior of the hollow
shaft 150 so as to transmit heat to the center of the mass being conveyed
through the tubular member 138. The gases exit from the hollow shaft through
the openings 164, and then flow through the pipe 168 and return to the inter-
ior of the heating vessel 36.
It is to be understood that other means can be employed for
heating the hollow shaft 150 in order to obtain the same result, as for ex-
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108V147
ample, an electrical resistance coil can be positioned in the hollow center
of the shaft.
Thus, it is apparent that there have been provided a novel :
method and alternative forms of apparatus, which fulfill all of the objects
and advantages sought therefor.
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