Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS, SYSTEM, AND METHOD FOR PROCESSING MATERIALS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to US Provisional Patent
Application No.
61/785,220 filed on March 14, 2013 and entitled APPARATUS AND METHODS OF
PROCESSING MATERIALS, the contents of which are incorporated by reference in
their
entirety herein.
TECHNICAL FIELD
[0002] The present disclosure relates to an apparatus, system, and method
for
processing materials.
BACKGROUND
[0003] Disposal of residential, commercial, and industrial waste in an
environmentally friendly and cost-efficient manner continues to be a problem
for which
current solutions have one or more disadvantages associated therewith.
[0004] Disposal in a landfill creates a multiplicity of problems, such as,
for example,
selecting a site for disposal, transport of material to and from the site,
potential pollutions
problems in the nearby soil, groundwater, and air, and issues associated with
the lack of
recycling when materials are disposed of in a landfill.
[0005] Other methods for waste disposal include recycling materials such as
plastics,
but the same logistics problems associated with transport to and from a
landfill are present,
and current methods of recycling are not energy or cost efficient. In
addition, many
commercial and industrial providers are charged a service or tonnage charge
for materials that
they recycle, which creates an incentive to avoid recycling.
[0006] Pyrolysis may be used to dispose of certain plastic wastes, however,
conventional pyrolysis methods are not energy or cost efficient.
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[0007] Accordingly, a method, good, or product that is configured to
address these
disadvantages is needed.
SUMMARY
[0008] This Summary is provided to introduce in a simplified form concepts
that are
further described in the following detailed descriptions. This summary is not
intended to
identify key features or essential features of the claimed subject matter, nor
is it to be
construed as limiting the scope of the claimed subject matter.
[0009] According to one or more embodiments, a refinery system is provided.
The
system includes a feedstock supply line, a first endothermic chamber that
receives feedstock
from the feedstock supply line and processes the feedstock under elevated heat
during a first
time period, a second endothermic chamber that receives feedstock from the
feedstock supply
line under elevated heat during a second time period, and a refining processor
downstream
and in communication with each of the first chamber and the second chamber.
[00010] According to one or more embodiments, the feedstock is one of
mostly
polymers, contaminated soil, and animal processing byproducts.
[00011] According to one or more embodiments, the system includes
respective first
and second catalyst chambers downstream from the first and second endothermic
chambers
but upstream from the refining processor.
[00012] According to one or more embodiments, a common line is downstream
of the
first and second endothermic chambers and in communication with the refining
processor
downstream.
[00013] According to one or more embodiments, syngas is formed in the
respective
first and second catalyst chambers, and further wherein, syngas formed in the
first and second
catalyst chambers is used to heat one of the first and second endothermic
chambers.
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[00014] According to one or more embodiments, the catalyst chambers include
a
catalyst selected from the group consisting of Acidic catalysts, Silica-
Alumina, PZMSM-5
Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-Zeolite, Faujasite
Zeolite (y-
Zeolite), Clinoptilolite, MCM-41, and SBA-15, ZnO, CaO, K20, and combinations
thereof
[00015] According to one or more embodiments, the first and second time
periods do
not substantially overlap.
[00016] According to one or more embodiments, the first time period is
between about
two hours and about fifteen hours.
[00017] According to one or more embodiments, the feedstock is processed
until the
oxygen level is below about 10%.
[00018] According to one or more embodiments, the feedstock is processed
until the
oxygen level is below about 5%.
[00019] According to one or more embodiments, the system includes a third
endothermic chamber that receives feedstock from the feedstock supply under
elevated
during a third time period.
[00020] According to one or more embodiments, the first endothermic chamber
and
the second endothermic chamber are configured to supply a continuous amount of
processed
feedstock to the refining processor.
[00021] According to one or more embodiments, the refining processor
includes a
crude oil refining system that includes an oil and water separator and one or
more condensers
for separating syngas.
[00022] According to one or more embodiments, the refining processor
includes a
crude oil refining system that includes a catalyst chamber and a condenser for
separating
syngas and leaving a biodiesel source.
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[00023] According to one or more embodiments, each of the first and second
endothermic chambers are sealed after feedstock is provided therein.
[00024] According to one or more embodiments, one of the first endothermic
chamber
and the second endothermic chamber is at a preferred operating temperature
(POT) at all
times during processing.
[00025] According to one or more embodiments, the feedstock is algae.
[00026] According to one or more embodiments, the feedstock includes a
polymer.
[00027] According to one or more embodiments, the feedstock includes animal
byproducts.
[00028] According to one or more embodiments, the refining processor
processes
syncrude and syngas.
[00029] According to one or more embodiments, processed feedstock is
removed from
the first endothermic chamber while feedstock is loaded into the second
endothermic
chamber.
[00030] According to one or more embodiments, a method of generating a
resource is
provided. The method includes receiving a feedstock in a first endothermic
chamber,
processing the feedstock in the first endothermic chamber during a first time
period under
heating, receiving a feedstock in a second endothermic chamber, processing the
feedstock in
the second endothermic chamber during a second time period under heating, and
receiving, in
a single downstream refining processor, the processed feedstock from each of
the first
endothermic chamber and the second endothermic chamber for further processing.
[00031] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about two hours and about 15 hours.
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[00032] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about four hours and about 13 hours.
[00033] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about six hours and about 11 hours.
[00034] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about eight hours and about 9 hours.
[00035] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock from ambient temperature to about 900 degrees C during the first
time period.
[00036] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock from ambient to about 50 degrees C.
[00037] According to one or more embodiments, the method includes
processing the
feedstock in a respective first and second catalyst chamber downstream from
each of the first
and second endothermic chambers and upstream of the single downstream refining
processor.
[00038] According to one or more embodiments, processing the feedstock in a
respective first and second catalyst chamber includes introducing a catalyst
consisting of
Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite,
Mordenite
ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and
SBA-15, ZnO,
CaO, K20, and combinations thereof
[00039] According to one or more embodiments, the first time period and the
second
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time period do not substantially overlap.
[00040] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber comprises
heating the
feedstock until the oxygen levels are below about 10%.
[00041] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock until the oxygen levels are below about 5%.
[00042] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock until the feedstock is reduced to primarily a light weight gas, a
heavy weight gas,
and carbon char.
[00043] According to one or more embodiments, the carbon char is removed
from each
of the first endothermic chamber and the second endothermic chamber.
[00044] According to one or more embodiments, the light weight gas is
syngas, the
method further comprising isolating the syngas and using the syngas to heat
either of the first
and second endothermic chambers during a subsequent processing step.
[00045] According to one or more embodiments, during receiving, in a single
downstream refining processor, the processed feedstock from each of the first
endothermic
chamber and the second endothermic chamber for further processing includes
receiving a
continuous supply that is alternated from the first endothermic chamber and
the second
endothermic chamber.
[00046] According to one or more embodiments, during the processing of
feedstock,
one of the first endothermic chamber and the second endothermic chamber is
maintained at a
preferred operating temperature ("POT") at all processing times.
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[00047] According to one or more embodiments, a method of generating a
resource
includes at a first time, receiving a feedstock in a first endothermic
chamber, processing the
feedstock in the first endothermic chamber under heating to an elevated
processing
temperature in which light weight heating gas is produced, and at a second
time, receiving a
feedstock in a second endothermic chamber, and processing the feedstock in the
second
endothermic chamber under heating to an elevated processing temperature in
which light
weight heating gas is produced. One of the first and second endothermic
chambers maintains
the elevated processing temperature during a processing period of time, the
processing period
of time including at least one heating period for each of the first and second
endothermic
chambers.
[00048] According to one or more embodiments, a refinery system includes a
feed
stock supply line, a first endothermic chamber that receives feedstock from
the feedstock
supply and processes the feedstock under elevated heat during a first time
period, a second
endothermic chamber that receives feedstock from the feedstock supply under
elevated heat
during a second time period, a refining processor downstream and in
communication with
each of the first chamber and the second chamber, and a control module
configured to direct a
heating source to apply heat to the first endothermic chamber during the first
time period,
monitor the oxygen level in the first endothermic chamber to determine a
desired oxygen
level in the feedstock, upon determining a desired oxygen level in the
feedstock of the first
endothermic chamber, direct a heating source to apply heat to the second
endothermic
chambering during the second time period, monitor the oxygen level in the
second
endothermic chamber to determine a desired oxygen level in the feedstock, and
upon
determining a desired oxygen level in the feedstock of the second endothermic
chamber,
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direct a heating source to apply heat to one of the first endothermic chamber
or a third
endothermic chamber.
[00049] According to one or more embodiments, the first and second time
periods are
about the same.
[00050] According to one or more embodiments, a refinery system includes a
feedstock supply line, a first endothermic chamber that receives feedstock
from the feedstock
supply and processes the feedstock under elevated heat during a first time
period and a first
catalyst chamber for interacting with syncrude from the first endothermic
chamber, a second
endothermic chamber that receives feedstock from the feedstock supply under
elevated heat
during a second time period and a second catalyst chamber for interacting with
syncrude from
the second endothermic chamber, and a refining processor downstream and in
communication with each of the first chamber and the second chamber, the
refining processor
receiving a generally continuous supply of syncrude from one of the first
catalyst chamber
and the second catalyst chamber during a manufacturing process.
[00051] According to one or more embodiments, the refining processor
processes
syncrude and syngas.
[00052] According to one or more embodiments, a method of generating a
resource is
provided. The method includes at a first time, receiving a feedstock in a
first endothermic
chamber, processing the feedstock in the first endothermic chamber under
heating to an
elevated processing temperature to produce a product for downstream
processing, at a second
time, receiving a feedstock in a second endothermic chamber, processing the
feedstock in the
second endothermic chamber under heating to an elevated processing temperature
to produce
a product for downstream processing, and providing a product for downstream
processing in
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a generally continuous manner from one of the first endothermic chamber and
the second
endothermic chamber.
[00053] According to one or more embodiments, the method includes
processing the
product for downstream processing in a catalyst chamber.
[00054] According to one or more embodiments, a method of generating an oil
byproduct is provided. The method includes providing a feedstock into a first
endothermic
chamber in communication with a first catalytic chamber, applying heat to the
first
endothermic chamber in order to process the feedstock into a processed
syncrude,
transporting the processed syncrude from the first endothermic chamber into
the downstream
processor, providing feedstock into the second endothermic chamber in
communication with
a second catalytic chamber, wherein each of the first and second endothermic
chambers are in
communication with a single downstream processor that processes the oil
byproduct,
applying heat to the second endothermic chamber from the second endothermic
chamber in
order to process the feedstock into a processed syncrude, and transporting the
processed
syncrude into the downstream processor.
BRIEF DESCRIPTION OF THE DRAWINGS
[00055] The previous summary and the following detailed descriptions are to
be read
in view of the drawings, which illustrate particular exemplary embodiments and
features as
briefly described below. The summary and detailed descriptions, however, are
not limited to
only those embodiments and features explicitly illustrated.
[00056] FIG. 1 illustrates a system diagram of a portion of a processing
system
according to one or more embodiments disclosed herein;
[00057] FIG. 2 illustrates a system diagram of a portion of a processing
system
according to one or more embodiments disclosed herein;
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[00058] FIG. 3 illustrates a system diagram of a portion of a processing
system
according to one or more embodiments disclosed herein;
[00059] FIG. 4 illustrates one or more methods of processing waste
materials
according to one or more embodiments disclosed herein; and
[00060] FIG. 5 illustrates temperature versus time charts of respective
first and second
endothermic chambers according to one or more experiments according to the one
or more
methods disclosed herein.
DETAILED DESCRIPTIONS
[00061] These descriptions are presented with sufficient details to provide
an
understanding of one or more particular embodiments of broader inventive
subject matters.
These descriptions expound upon and exemplify particular features of those
particular
embodiments without limiting the inventive subject matters to the explicitly
described
embodiments and features. Considerations in view of these descriptions will
likely give rise
to additional and similar embodiments and features without departing from the
scope of the
inventive subject matters.
POLYMER AS A FEEDSTOCK
[00062] FIG. 1 illustrates a portion of a system, where the portion is
generally
designated 10A. Portion of system 10A works in conjunction with portion of
system 10B
illustrated in FIG. 2 and portion of system 10C illustrated in FIG. 3 to form
an entire system
that processes materials, such as, for example, plastics and the like. System
10A includes
feedstock supplies 11A and 11B. While illustrated in the system diagram as
being separate
feedstocks, the feedstock supply may be one in the same for supplying
feedstock to
endothermic chambers 12A and 12B. The feedstock supplies 11A and 11B may
include any
waste material. In one or more embodiments, the waste material may include
waste plastics
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and other polymers from postindustrial manufacturing, municipal waste
collections, or any
other source of waste plastics. The waste plastics may include plastics 1
through 7 and 9. The
plastics may be bailed, bundled, shredded, or otherwise processed or
unprocessed.
[00063] The waste material is transferred from storage using any
appropriate material
handler, such as a tractor, to a staging or loading area. The waste material
is then loaded onto
a conveyor loader, hydraulic loader, or carried by hand, or other appropriate
manner, and is
then supplied to the endothermic chambers 12A and 12B. This is preferably done
during
alternating time periods, though may be done at the same time. The endothermic
chambers
12A and 12B are loaded with the feedstock material. Downstream from the
endothermic
chambers 12A and 12B are respective catalytic chambers 14A and 14B. Catalytic
chambers
14A and 14B each have a catalyst compound loaded therein.
[00064] The catalyst compound used herein may include, but is not limited
to, Acidic
catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite,
Mordenite ZSM-5
x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15,
and
combinations thereof The catalysts may also be alkaline catalysts such as ZnO,
CaO, K20,
and combinations thereof
[00065] The polymer feedstock may include, but is not limited to, #1 PET
(Polyethylene terephthalate), #2 HDPE (High-density polyethylene); #3 PVC
(Polyvinyl
chloride); #4 LDPE (Low-density polyethylene); #5 PP (Polypropylene); #6 PS
(Polystyrene); #7 Other; and #9 or ABS.
[00066] In one or more processes, endothermic chamber 12A is sealed after
the
feedstock is provided therein. Next, processing occurs of the feedstock in the
endothermic
chamber. This occurs by subjecting the feedstock to a heating process where
the temperature
of the feedstock is raised from ambient to about 50 degrees C in a first
heating step. The
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temperature of the feedstock is then raised from about 50 degrees C to about
900 degrees C
over less than about a 12 hour period. In one or more embodiments, the
elevated temperature
may be higher or lower than about 900 degrees C. For example, in one or more
embodiments, the elevated final temperature may be between about 450 and 550
degrees C.
During the process of applying heat to the endothermic chamber 12A, the oxygen
level
therein is reduced during the heating process until it is at a suitably low
level. In one or more
embodiments, the oxygen level may be about 10 percent. In one or more
embodiments, the
oxygen level may be about 5 percent. In one or more embodiments, the oxygen
level is
below about 5 percent after final processing within the endothermic chamber
12A.
[00067] The endothermic chamber 12A is in fluid communication with catalyst
chamber 14A. The catalyst chamber 14A includes a catalyst to aid in reacting
with gases
formed in the endothermic chamber 12A. The catalyst may include Acidic
catalysts, Silica-
Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy Zeolite, Mordenite ZSM-5 x-
Zeolite,
Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-41, and SBA-15, and
combinations
thereof The catalysts may also be alkaline catalysts such as ZnO, CaO, K20,
and
combinations thereof Gases are formed in endothermic chamber 12A when a
chemical
reaction of the feedstock occurs. Specifically, the chemical reaction may be
cracking where
long chain molecules in the feedstock are broken down into shorter chain
molecules that
generally form into a light weight gas, which may be syngas, a heavy gas,
which may be
syncrude, and a carbon char.
[00068] During cracking, the gases are formed and they flow out of the
endothermic
chamber 12A into the catalyst chamber 14A. The gases, collectively the syngas
and
syncrude, may further react with a catalyst.
[00069] Towards the conclusion of processing of the feedstock in the
endothermic
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chamber 12A, feedstock 11A is loaded into endothermic chamber 12B in the same
manner as
it is loaded into endothermic chamber 12A. In this manner, during the time
period P1 in
which endothermic chamber 12A is processing, feedstock in endothermic chamber
12B is
also being processed in the same manner. This has the advantage of maintaining
a continuous
supply of syngas, Syncrude, and carbon char from processed feedstock to be
used for
downstream processing. In this manner, inefficiencies associated with starting
and stopping a
pyrolysis system as new processed feedstock becomes available are eliminated.
This has the
advantage of increasing production uptime and it has been determined to yield
higher
efficiency in recycling feedstocks, and additionally only requires single
downstream
processing equipment. Endothermic chamber 12A may be loaded by about between
10 and
90 percent by volume with feedstock.
[00070] Feedstock is then processed in endothermic chamber 12B according to
the
same manner as that which is processed in endothermic chamber 12A while
endothermic
chamber 12A cools. During this cooling period, char is removed from the
endothermic
chamber 12A, as well as any other contaminants or materials such as metal.
These materials
may then be further processed or sold for industrial use.
[00071] During processing of feedstock in either of the endothermic
chambers 12A and
12B, syngas travels into a flue 16. The syngas may then further go through a
filtering process
to remove any dust or other contaminants in a filter 44 or 46. A compressor 20
may then
compress the syngas before it is stored in a storage tank 22 where it is later
used for providing
heat treatment to each of the endothermic chambers 12A and 12B. In this
manner, the
majority of the energy used in the portion 10A is from syngas made from
recycled materials.
[00072] Char removed from either of endothermic chambers 12A and 12B may be
subject to further processing FP, which may include any suitable processing
for those
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materials. Syncrude may be pumped or otherwise transferred into a portion 10B
of the
system for further processing. A separator 24 separates oil and water in the
crude oil.
[00073] The crude oil then travels through one or more condensers 34, 36 in
order to
cool the crude oil down to less than about 350 degrees C. Syngas is separated
from crude oil
during this process, and may be stored in tank 22 for further use. A
transition tank 42 may
contain the processed crude oil which will later be processed in a further
processing step. A
backpressure module 40 may be provided in communication with condensers 34, 36
in order
to reduce any backpressures in the system.
[00074] During the portion 10B, solids from air may be processed in filters
44 and 46.
Steam from the refining process of 10A is processed through filter 44 and then
into filter
module 46 for capturing any remaining steam and contaminants. A buffer tank 30
and
pressure module 26 may be provided for storing processed materials during any
of the
processes.
[00075] Portion 10C of the system may be further provided for additional
processing.
Specifically, an oil flow pump 44 may be provided for pumping the crude oil to
a
thermochemical distillation chamber 46. In this chamber, the crude oil is
heated for further
processing. The oil is then transferred to a catalyst chamber 50 for
additional processing. A
syngas filter 52 filters out any syngas, which is then filtered in filter 54
and filter 56. Steam
from this portion of the refining process is processed through the dust filter
54 and then
passed through the hydro filter module 56, capturing the remaining steam and
contaminants.
The collection of contaminants is then processed through the chamber 12A or
12B to convert
from a liquid into a solid.
[00076] The remaining oil then goes through condenser 60 to form a diesel
grade
material that is collected within tank 62. Another condenser 64 condenses the
remaining oil
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into a distillates collection tank 66. A back pressure module 70 may be in
communication
therewith, with buffer tank 72 and negative pressure module 74.
[00077] Oil from the diesel collection tank 62 is transferred to a diesel
measurement
tank 76 that is in communication with a distillates measurement tank 80. An
oil flow pump
82 provides pumping forces to pump oil to an acidic wash tank 84. An oil flow
pump 86
further provides pumping forces to pump oil to an alkali wash tank 90 where
sulfur is cleaned
from the fuel, completing the refining process and resulting in transportation
grade ultra-low
biodiesel fuel D2. The biodiesel fuel is then transferred to a transition tank
92 where further
testing may be completed before transport to a transfer fuel trailer or other
storage tank.
[00078] Collectively, portions 10A, 10B, and 10C form a system 10 that is
capable of
converting plastic waste into a highly efficient recycling process producing
syngas for
heating during the processing step, biodiesel for use as a fuel source, and
char for further
processing as desired. A control module 94 may be in communication with one or
more or all
of the elements described herein for monitoring one or more aspects of the
refining process.
For example, the endothermic chambers 12A and 12B may have one or more sensors
in
communication therewith that monitor, for example, temperature, pressure,
oxygen levels,
and any other desired characteristic. The control module 94 may then be
configured to
monitor the one or more characteristics, and direct additional elements to
carry out one or
more portions of the process disclosed herein. As the control module 94
detects a release in
negative pressure from system 10A, particularly the refining of oil of the
first feedstock from
the endothermic chamber 12A, the control module directs the oil pump 44 to
pump oil from
endothermic chamber 12B to thereby cause a continuous flow of oil in the
refining process.
In this manner, system uptime is maximized and the system 10 is almost always
running at
operating temperatures and pressures, thereby increasing efficiency in the
recycling process
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by eliminating the inefficiencies associated with startup when temperatures
and pressures are
not at operating ranges. The control module 94 is configured to monitor a
decrease in gas
flow into the catalyst chamber 14A in order to direct heating of endothermic
chamber 12B.
EXPERIMENTAL RESULTS FOR PROCESSING OF POLYMER MATERIALS
[00079] In one or more experiments, the system 10 utilized the processes
disclosed
herein to produce syngas, biodiesel, and char. In the one or more experiments,
each of the
first endothermic chamber 12A and the second endothermic chamber 12B had about
the same
amount of feedstock haying about the same characteristics applied therein. The
first
endothermic chamber 12A was sealed and heat was applied according to the
following
schedule shown in TABLE I.
TABLE I
OXYGEN
TIME __________________ TEMP. ____ LEVEL ___ GASIFICATION
0:00 21C 21% 0%
0:30 150C 16% 0%
1:00 250C 10% 0%
1:30 350C 5% 40%
2:00 450C 2% 76%
2:30 450C 2% 76%
3:00 500 C 2% 69%
3:30 500 C 2% 69%
4:00 520C 2% 60%
4:30 520C 2% 60%
5:00 550 C 2% 47%
5:30 520C 2% 60%
6:00 500 C 2% 69%
6:30 350C 5% 40%
7:00 250C 10% 0%
7:30 150 C 16% 0%
8:00 32C 21% 0%
8:30 21 C 21% 0%
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[00080] At about time 4:30 during the heating and processing of the first
endothermic
chambers 12A, the second endothermic chamber 12B was loaded with feedstock and
the
heating process began. In this manner, at about 7:00, the feedstock in the
second
endothermic chamber 12B starts a gasification flow. At about 7:00, heat is no
longer applied
to endothermic chamber 12A and ambient air is introduced to decrease pressure
and increase
the cooling rate. At about 8:30, the endothermic chamber 12A is rotated to
increase the
cooling rate. At about 9:30, a chamber door is opened on the endothermic
chamber 12A,
thereby allowing an increased cooling rate. The heating process for the second
endothermic
chamber 12B was carried out to have consistent time measurements as the
heating process for
the first endothermic chamber 12A. At about 10:30, the char is removed from
the
endothermic chamber 12A. Feedstock may then be loaded into chamber 12A for
heating and
processing at a later date. Maximum pressure was found to be about 500 pounds
per square
inch.
[00081] After the first endothermic chamber 12A has cooled, the syngas,
crude oil, and
char material are then processed according to the one or more processes
disclosed herein.
[00082] FIG. 5 illustrates graphs plotting temperature of each endothermic
chamber
12A, 12B relative to processing time. As illustrated, by having alternating
endothermic
chambers 12A, 12B provides for a continuous supply of processed feedstock at a
preferred
operating temperature ("POT") of about at least 425 degrees C, which has been
shown to
create optimum processing conditions for increased efficiency and improved
processed stock.
In one or more embodiments,
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CONTAMINATED SOIL AS A FEEDSTOCK
[00083] In one or more embodiments, feedstocks 11A and 11B may be petroleum
contaminated soils from, but not limited to, fuel spills, fuel tank leakage,
petroleum beach
wash, refining spills, fuel line spills, petroleum laden spills, and sands
residue from
separation washing.
[00084] The petroleum contaminated soils are transferred into the
endothermic
chambers 12A and 12B for processing. After the soil has been processed in the
endothermic
chambers 12A and 12B, the separated syngas and oil is sent for further
processing as
described herein with reference to other materials, and the soil and char is
removed from the
endothermic chambers 12A and 12B. A vacuum or similar apparatus may be used to
remove
the soils.
POULTRY, SWINE, BOVINE, AND FISH PROCESSING OFFAL AS A FEEDSTOCK
[00085] In one or more embodiments, feedstocks 11A and 11B may be poultry,
swine,
bovine, fish, or other animal processing byproducts. The animal processing
byproducts are
transferred into the endothermic chambers 12A and 12B for processing. Before
being placed
into endothermic chambers, the processing byproducts are preferably dewatered
or dried to a
moisture content of less than about 50%. After the byproducts have been
processed in the
endothermic chambers 12A and 12B, the separated syngas and oil is sent for
further
processing as described herein with reference to other materials, and the char
is removed
from the endothermic chambers 12A and 12B. A vacuum or similar apparatus may
be used to
remove the char and other materials. These materials have particular
applicability as a
fertilizer grade material.
[00086] One or more methods are illustrated in the flowchart of FIG. 4 and
generally
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designated 100. The one or more methods may include a method of generating a
resource.
The method may include receiving a feedstock \ in a first endothermic chamber
110,
processing the feedstock in a first endothermic chamber during a first time
period under
heating 112, receiving a feedstock in a second endothermic chamber 114,
processing the
feedstock in a second endothermic chamber during a second time period under
heating 116,
and receiving, in a single downstream refining processor, the processed
feedstock from each
of the first endothermic chamber and the second endothermic chamber for
further processing
120.
[00087] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about two hours and about 15 hours.
[00088] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about four hours and about 13 hours.
[00089] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about six hours and about 11 hours.
[00090] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock for a period of between about eight hours and about 9 hours.
[00091] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock from ambient temperature to about 900 degrees C during the first
time period.
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[00092] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock from ambient to about 50 degrees C in a first portion of the heating
process.
[00093] According to one or more embodiments, the method includes
processing the
feedstock in a respective first and second catalyst chamber downstream from
each of the first
and second endothermic chambers and upstream of the single downstream refining
processor.
[00094] According to one or more embodiments, processing the feedstock in a
respective first and second catalyst chamber comprises introducing a catalyst
comprising one
of Acidic catalysts, Silica-Alumina, PZMSM-5 Zeolite, HZSM-5 zeolite, Hy
Zeolite,
Mordenite ZSM-5 x-Zeolite, Faujasite Zeolite (y-Zeolite), Clinoptilolite, MCM-
41, and SBA-
15, and combinations thereof The catalysts may also be alkaline catalysts such
as ZnO, CaO,
K20, and combinations thereof
[00095] According to one or more embodiments, the first time period and the
second
time period do not substantially overlap. In this manner, only a portion of
the first and
second time period overlaps, yet the endothermic chambers continually provide
processed
feedstock for further downstream processing.
[00096] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber comprises
heating the
feedstock until the oxygen levels are below about 10%.
[00097] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
feedstock until the oxygen levels are below about 5%.
[00098] According to one or more embodiments, processing the feedstock in
either of
the first endothermic chamber or the second endothermic chamber includes
heating the
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feedstock until the feedstock is reduced to primarily a light weight gas, a
heavy weight gas,
and carbon char.
[00099] According to one or more embodiments, the carbon char is removed
from each
of the first endothermic chamber and the second endothermic chamber.
[000100] According to one or more embodiments, the light weight gas is
syngas and the
method further includes isolating the syngas and using the syngas to heat
either of the first
and second endothermic chambers during a subsequent processing step.
[000101] Particular embodiments and features have been described with
reference to the
drawings. It is to be understood that these descriptions are not limited to
any single
embodiment or any particular set of features, and that similar embodiments and
features may
arise or modifications and additions may be made without departing from the
scope of these
descriptions and the spirit of the appended claims.
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