STATIONARY REACTOR AND ITS INTERNALS FOR PRODUCING LIQUID FUEL FROM WASTE HYDROCARBON AND/OR ORGANIC MATERIAL AND/OR CONTAMINATED OILS, THERMAL PROCESSES, USES AND MANAGING SYSTEMS THEREOF

REACTEUR STATIONNAIRE ET SES ELEMENTS INTERNES POUR PRODUCTION DU COMBUSTIBLE LIQUIDE A PARTIR DE GAZ D`HYDROCARBURES RESIDUELS ET/OU DE MATIERES ORGANIQUES ET/OU D`HUILES CONTAMINEES, PROCEDES THERMIQUES, UTILISATIONS ET SYSTEMES DE GESTION ASSOCIES

English Abstract

There is provided a stationary reactor and its internals for thermal
processing of a
mixture. The 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. The 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. Processes for producing liquid fuels from starting material
and
managing systems allowing continuous optimisation of processes are also
disclosed.

Claims

CLAIMS
1. 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 caracterized 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.
2. A stationary reactor and its internals for thermal processing of a mixture,
according
to claim 1, said stationary reactor comprising:
- one or several plate(s) displaceable inside the stationary reactor from an
upper
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 for the sliding down of a plate on the upper surface
of
the at least one plate supporting mean(s); and/or
- 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
plate guiding means;
- feeding means for bringing the mixture on at least part of the surface of
said
at least one plate being used to perform the thermal processing of the
mixture;
- exit means for existing gaseous, liquid and solid materials, formed during
the
thermal treatment, outside the stationary reactor; and
-internal and/or external heating means for heating at least one plate and
preferably all plates.
3. A stationary reactor and its internals, according to claim 2, for thermal
processing
of a mixture, said stationary reactor having walls defining an internal part
called
reaction's zone of the stationary reactor and comprising:
100

- internal and/or external heating means for heating the stationary reactor

and/or for heating its internals and/or for heating the at least one plate(s)
supporting means and/or for heating the at least one guiding mean(s); and
- feeding means for spraying the mixture on at least part of the surface of
said
at least one plate being used to perform the thermal processing of the mixture

in the reaction's zone,
wherein said stationary reactor being further caracterized in that the at
least one
plate supporting means 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 resulting
optionnally
with solids from the incomplete pyrolysis reaction of a feed that is
preferably
essentially made of hydrocarbons.
4. Stationary reactor and its internals according to claim 3, for thermal
processing of a
mixture, said reactor comprising 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 means;
- an elevator closely positioned inside or close to the reaction's zone of
the
stationary reactor, and configured to displace a plate from the internal lower

part of the stationary reactor to the internal upper part of the stationary
reactor;
and
- optionally, displacement means for initiating the sliding of a plate on
the at
least one supporting means and/or on the at least one guiding means.
101

5. Stationary reactor and its internals, according to any one of claims 2 to
4, wherein:
- 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; and/or
- sliding of the plates in the reaction's zone is generated by gravity
and/or by
mechanical means and/or by sliding means.
6. Stationary reactor and its internals, according to any one of claims 2 to
6, configured
in order that:
- at least 10%, preferable at least 20%, more preferably at least 70%, even
more
preferably at least 90 % of the surface of the plates present inside the
stationary
reactor is used for performing the thermal processing of the mixture; and/or
- 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.
7. Stationary reactor, according to any one of claims 2 to 8, wherein at least
one of the
surfaces of the plates is cleaned by cleaning means such as scraping devices,
said
cleaning means being positioned:
- inside the reaction's zone, also named reaction chamber, of stationary
reactor,
preferably close to the surface of the plate wherein thermal processing
occurs;
and/or
- outside the reaction's zone of the stationary reactor; and/or
- in the internal and/or in the external elevator when an elevator is
present.
8. Stationary reactor, according to any one of claims 2 to 6, wherein
pyrolysis of said
mixture is performed by spraying, contacting and depositing said mixture on
the upper
and/or on the lower and/or on at least one of the lateral surfaces of a plate;
wherein:
- internal and/or external 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;
102

- heating means are preferably closely positioned to the surface of a plate
to be
heated when heating means are induction means or Infra-Red; advantageously
the heating means are positioned inside the enclosure, more advantageously
heating means are positioned in a zone of the enclosure;
- heating means are positioned outside the reaction's zone in a combustion
chamber, when heating means are of the combustion type; more advantageously
in the case of IR or convection heating means said heating means are
positioned
above or under the plate when sliding on the supporting means and/or when
sliding on a guiding means;
- the reaction's zone may be traversed by an inert gas; and
- the reaction's zone has reduced oxygen content that is preferably less
than 1
% oxygen, and
advantageously 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.
9. Stationary reactor, according to any one of claims 2 to 8, wherein,
particularly when
heating means are of the combustion type, plates contribute to the uniformity
of
temperature conditions in said stationary reactor.
10. Stationary reactor, according to any one of claims 2 to 9, wherein,
particularly
when heating means are of the combustion type, plates contribute to the heat
transfer
from the heat sources to the reaction chamber.
103

11. Stationary reactor, according to any one of claims 2 to 9, connected
through
connecting means to a combustion chamber, positioned external to the
reaction's
chamber of the stationary reactor, said combustion chamber being configured
for:
- reheating a plate after pyrolysis reaction took place on the surface of the
plate;
and/or
- burning coke formed on the surface of a plate by the pyrolysis reaction
occurring on the surface of the plate; and/or
- producing hot exhaust gases that may be used to warm up theexternal
enclosure of the stationary reactor warm air that is fed into the reaction's
zone
of the stationary reactor.
12. Stationary reactor, according to any one of claims 2 to 10, wherein the
stationary
reactor is not connected to a combustion chamber and the reheating of plates
is
performed by a non-combustion heating system, such as an induction source,
infra-red
and micro-waves, positioned preferably outside the reaction's zone of the
stationary
reactor but preferably inside the stationary reactor.
13. Stationary reactor, according to any one of claims 3 to 12, wherein:
- the bottom of the stationary reactor is connected to the bottom of the
plates
elevator by connecting means, such as a tube, allowing the transfer of plates
from
the upper closest supporting and/or guiding means 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;
- connecting means between the combustion chamber and the stationary reactor
preferably have separation means configured to avoid contamination of the gas
and steam, produced by the thermal processing performed in the reaction
chamber,
with oxygen from the combustion chamber, separation means are preferably
seals,
doors, inert gas and/or overpressure.
14. Stationary reactor, according to any one of claims 3 to 13, wherein the
stationary
reactor is connected to a plate elevator in a way that at least one of the
following
features is present:
104


- the stationary reactor is positioned vertical or slanted;
- the plate elevator is positioned vertical or slanted;
- connecting means are a top pressurised chamber preventing the flow of
vapour produced in the reaction chamber to enter the upper part of the
plates elevator and/or to enter the combustion heating chamber, said
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 the 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 dephlegmator, 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 heights, simultaneously or alernatively, or according to
a predetermined sequence;
- a reactor exit tube, preferably positioned on the top of the reaction
chamber
of the stationary reactor, to allow the flow of products resulting from the
thermal processing to stream out the reactor;
- at least one reactor sweep gas entrance, preferably positioned within or
close to the feeding tube or on a side wall of the reaction chamber;
- flippers, preferably mounted on a rotational axis about perpendicular to
the
plates displacement direction in the reaction chamber, to flip the plates
before said plates slides down and fall from one supporting and/or guiding
means (such as a tray) to another;
- flipping trays, preferably positioned about parallel to and directly
above the
supporting and/or guiding means, for preventing the plates from falling

105

from one supporting and/or guiding means (such as a tray) to another,
before a certain percentage of the length of the plates passes the extremity
of the tray directly below the flipping tray;
- curved tray that catches the plates which hang at an angle that allows the
plate to flip upon falling from one tray to another;
- lifter that is the element of the elevator which move upwards and catches

the plates as they slide off the, preferably pressured, connection means;
- scraping means, such as:
- those of the static scraper bars type and/or brushes, that scrape the
bottom and/or the top and/or a lateral surface of the plates while said
plates slide on the one sliding and/or guiding means (such as a tray) to
which the scraper bar is attached, and
- those of the rotating chains type that are preferably attached to a wall
in the lower part of the stationary reactor;
- 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 the 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 degrees, preferably
ranges from 15 to 45, advantageously is about 30 degrees, more preferably
is about 20 degrees when stainless steel is used;
- the stationary reactor is compact and is a mobile reactor, preferably
fitting
in a standard container or fitting a high cube container;
- the pyrolysis reaction occuring only on the surface of a plate and being
exclusively of the flash craking type; and
- the stationary reactor is for example one of those repesented in the
Figures
part.
106

15. A pyrolysis system for thermal processing of a mixture, said system
comprising:
a) a stationary reactor as defined in any one of claims 1 to 14;
b) an intemal or extemal heating system;
c) a charge of plates of consistent shapes;
d) 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;
means for recovering the reaction and straight run products; and
g) means for venting the gas obtained by the thermal processing outside the
stationary reactor zone.
16. Pyrolysis system, according to claim 15, wherein the stationary reactor
has a form
that is about parallelepipedic or cyclindrical.
17. Pyrolysis system, according to claim 15 or 16, wherein the means for
directing the
mixture to be thermally 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.
18. Pyrolysis system, according to any one of claims 15 to 17, wherein:
- the mixture is liquid, gas, solid or is a mixture of at least two of
these; and/or
- the gaseous stream resulting from the incomplete pyrolysis reaction of
celullosic material and/or of a mixture comprising more than 10 weight percent

of long chain hydrocarbons, such as a mixture of cellulosic materials and of
long chain hydrocarbons such as used oils.
19. Pyrolysis system, according to any one of claims 15 to 18, wherein said
mixture
and said gaseous stream comprises mostly organic compounds that may be
transformed by thermal processing.
107

20. Pyrolysis system, according to any one of claims 15 to 19, wherein said:
- mixture comprises at least 80 % of organic compounds that may be
transformed by thermal processing; and
- 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.
21. Pyrolysis system, according to claims 20, wherein said mixture contains at
least
about 95% of organic compounds that may be transformed by thermal processing.
22. Pyrolysis system, according to any one of claims 15 to 21, wherein the
mixture
may comprise other components that are not organic compounds and/or that may
not be transformed by thermal processing.
23. Pyrolysis system, according to any one of claims 15 to 22, wherein said
other
components are 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.
24. Pyrolysis system, according to any one of claims 15 to 23, wherein said
mixture is
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.
25. Pyrolysis system, according to any one of claims 15 to 24, wherein said
mixture is
mostly composed of organic compounds that may be transformed by thermal
processing to at least a liquid phase, a gaseous phase, a solid phase or in a
combination
of at least two of the latter phases.
26. Pyrolysis system, according to any one of claims 15 to 25, wherein said
mixture is
selected among the family of mixtures of plastics, wood chips, used oils,
mixtures of
waste oils, ship fuels or a mixture of at least two of these mixtures.
27. Pyrolysis system, according to any one of claims 15 to 26, operating in
the absence,
in the reactor, of a substantial organic solid, liquid or of a slurry phase.
108

28. Pyrolysis system, according to any one of claims 15 to 27, operating in
less than
30% vol., preferably in less than 5% vol. of an organic solid, and/or of a
liquid and/or
of a slurry phase.
29. Pyrolysis system, according to any one of claims 15 to 28, operating in
the presence
or absence of a liquid and/or slurry phase.
30. Pyrolysis system, according to any one of claims 15 to 29, wherein the
plates of
said reactor are directly and/or indirectly heated.
31. Pyrolysis system, according to any one of claims 15 to 30, wherein the
inside of
the stationary reactor is directly and/or indirectly heated.
32. Pyrolysis system, according to any one of claims 15 to 31, wherein the
heat source
is generated by electricity, a hot oil and/or a gas stream, or obtained from
the
combustion of gas, naphtha, reaction's products of the pyrolysis, other oily
streams,
coke, coal, organic waste or by a mixture of at least two of these.
33. Pyrolysis system, according to any one of claims 15 to 32, wherein the
inside of
the stationary reactor is indirectly heated by an electromagnetic field (such
as induction
and/or infrared sources and/or microwaves).
34. Pyrolysis system, according to any one of claims 15 to 33, wherein the
plates are
directly heated by a hot gas, liquid or solid stream, electricity or partial
combustion of
the feedstock, coke, products or by-products.
35. Pyrolysis system, according to any one of claims 15 to 34, wherein the
heating
means comprises at least one heating system external to the walls of the
stationary
reactor, for example in a case of an indirectly fired kiln.
36. Pyrolysis system, according to any one of claims 15 to 35, wherein the
external
walls of the stationary reactor are 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.
37. Pyrolysis system, according to any one of claims 15 to 36, wherein the
walls of the
stationanry reactor are surrounded by a fire box, and said fire box is
stationary and
contains one or more burners.
109

38. Pyrolysis system, according to any one of claims 15 to 37, wherein 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.
39. Pyrolysis system, according to any one of claims 15 to 38, wherein 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 guiding means.
40. Pyrolysis system, according to any one of claims 15 to 39, wherein the
supporting
and/or guiding mean(s) is (are) symmetrically attached to the internal wall of
said
reactor.
41. Pyrolysis system, according to any one of claims 15 to 40, wherein the
supporting
and/or guiding mean(s) is (are) attached to the internal wall in a designed
and/or
random pattern.
42. Pyrolysis system, according to any one of claims 15 to 41, wherein 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
from 0,1 to 20, preferably from 0,2 to 3.
43. Pyrolysis system, according to claim 42, wherein 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 about 2.
44. Pyrolysis system, according to any one of claims 15 to 43 wherein the
number of
supporting and/or guiding means depends 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 guiding means in respect of the horizontal
and/or
of the shape of the plates and/or of the friction coefficient of the plates
against the
supporting and/or guiding means, 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 flipping of the plates when leaving the supporting
and/or
guiding means.
110

45. Pyrolysis system, according to any one of claims 15 to 44, wherein the
distance
spacing two supporting and/or guiding means represents from 0,1 to 20% of the
height
of the reactor.
46. Pyrolysis system, according to claim 45, wherein the distance spacing two
supporting and/or guiding means represents from 0,2 to 2 % of the height of
the
stationary reactor.
47. Pyrolysis system, according to any one of claims 15 to 46, wherein the
form of the
supporting and/or guiding means is selected in the group constituted by flat
or straight
form s.
48. Pyrolysis system, according to any one of claims 15 to 47, wherein the
supporting
and/or guiding means are about parallel straight guides.
49. Pyrolysis system, according to any one of claims 15 to 48, wherein the
height
and/or the width of the supporting and/or guiding means is calculated and
depends on
at least one of the following parameters: the space between the supporting
and/or
guiding means, the material the supporting and/or guiding means are made of
and the
weight of the plates, the sliding angle and the number of supporting and/or
guiding
means by square meter of the reactor's wall.
50. Pyrolysis system, according to any one of claims 15 to 49, wherein the
height or
width of the supporting means ranges from the width of the plate to 1 mm,
preferably
to the width of the plate plus 1 cm.
51. Pyrolysis system, according to any one of claims 15 to 50, wherein 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.
52. Pyrolysis system, according to any one of claims 15 to 51, wherein the
width and
the height of the supporting and/or guiding means are selected in order for
the
supporting and/or guiding means to be able to retains at least one,
advantageously
between 3 and 6, and preferably 2 or 3 plates.
53. Pyrolysis system, according to any one of claims 15 to 52, wherein the
shape of
the plates of the charge is selected among the group of parallelograms, discs,
elipsoids
and ovoids.
1 i

54. Pyrolysis system, according to any one of claims 15 to 53, wherein the
plates of
the charge are rectangular, triangular, hexagonal or octagonal.
55. Pyrolysis system, according to any one of claims 15 to 54, wherein the
shape of
the plates of the charge is about perfect.
56. Pyrolysis system, according to any one of claims 15 to 55, wherein all the
plates
present in the stationary reactor have about the same size and shape.
57. Pyrolysis system, according to any one of claims 15 to 56, wherein the
volume of
the plates of the charge present in the reactor represents from 1% to 40% of
the internal
volume of the reaction chamber.
58. Pyrolysis system, according to claim 57, wherein the volume of the plates
of the
charge present in the reactor represents from 2 to 5 % of the internal volume
of the
stationary reactor.
59. Pyrolysis system, according to any one of claims 15 to 58, wherein the
charge of
the stationary reactor is constituted by flat and/or slightly curved metal
plates of
consistent thickness and shape.
60. Pyrolysis system, according to any one of claims 15 to 59, wherein the
plates have
a melting point which is at least 100 degrees Celsius, and more preferably is
at least
150 degrees Celsius above the stationary reactor wall maximum operating
temperature
in the thermal processing zone and/or combustion chamber.
61. Pyrolysis system, according to any one of claims 15 to 60, wherein the
plates are
heavy enough in order its sliding movement to not be substantially stopped by
the
scraper(s), and more preferably in order to not be reduced by more than 70%,
preferably not by more than 30% of the sliding speed of the plates.
62. Pyrolysis system, according to any one of claims 15 to 61, wherein each
plate has
a density that is superior to 2,0 g/cm3, preferably superior to 3,0 g/cm3 and
more
preferably the density of a plate is comprised between 5,5 g/cm3 and 9,0
g/cm3.
63. Pyrolysis system, according to any one of claims 15 to 62, wherein the
means for
bringing the mixture in contact with at least part of the surfaces of the
plates are
pouring means; dumping, means or spraying means such as spray nozzles.
112

64. Pyrolysis system, according to any one of claims 15 to 63, wherein the
means for
bringing the mixture in contact with at least part of the surfaces of the
plates are spray
nozzles that spray the mixture onto at least part of the surfaces of the
plates of the
charge when the feedstream is liquid and/or a mixture of liquid and/or gas
and/or fine
solids.
65. Pyrolysis system, according to any one of claims 15 to 64, wherein the
spraying
means are positioned above, under or laterally in respect of a horizontal
plate; the
spraying direction being perpendicular or slanted in respect of a surface of a
plate.
66. Pyrolysis system, according to any one of claims 15 to 65, wherein the
means for
bringing the solids outside the stationary reactor is (are) entrainment with
the product
gas, scoop(s), screw conveyors and/or gravity and/or pumps and/or compressors
and/or vacuum pumps.
67. Pyrolysis system, according to any one of claims 15 to 66, wherein the
means for
bringing the solids outside said stationary reactor comprises an exit hopper
arrangement attached to the solids exit tube, or a screw conveyor or simply
gravity.
68. Pyrolysis system, according to any one of claims 15 to 67, wherein said
reactor has
two exits: one for the solids and one for the gas/vapours and entrained solids
obtained.
69. Pyrolysis system, according to any one of claims 15 to 68, wherein the
gas/vapours
obtained contain entrained solids.
70. Pyrolysis system, according to any one of claims 15 to 69, wherein said
reactor is
equipped with means for avoiding accumulation of solids in the reactor and/or
for
avoiding plugging of any of the exits.
71. Pyrolysis system, according to claim 70, wherein the means for avoiding
accumulation are rotating tins, propellers(s), blowers(s) and/or 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.
72. Pyrolysis system, according to any one of claims 15 to 71, wherein 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.
113

73. Pyrolysis system, according to any one of claims 14 to 72, wherein at
least one of
following features is present:
- cleaning means are positioned advantageously at least temporary in contact
with the superior surface of the reaction support wherein pyrolysis 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 contact with at least part
of the surface of a reaction's supports wherein pyrolysis takes place,
and/or
- at least one rotating flail chain in permanent or temporary contact
with at least part of the surface of the reaction's support wherein
pyrolysis takes place, and/or
- at least one ultrasonic means in permanent or temporary contact with
at least part of the surface of the reaction's support wherein pyrolysis
takes place, and/or
- at least one directed blow means blowing air, with low content in
oxygen. or an inert gas in permanent or temporary contact with at
least part of the surface of a reaction's support wherein pyrolysis takes
place; and/or
- feeding means are advantageously feeding line mounted with spray nozzles,
said spray nozzles, depending on the physical nature of the feeding material,
are:
- of the liquid feed type, and/or
- of the solid feed in form of small particulates type, and/or
- of the feeding stream liquid but containing solid particulates type;
advantageously, said spray nozzles are configured to spray only the surface of

the reaction's support:
114

- drops of the liquid feeding oily stream having an average drop size of
less than 10 mm, preferably of less than 5 mm, and more
advantageously lower than 2 mm, and/or
- 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
- a mixture of liquid and particulates with a ratio particulates/liquid
being in weight percent ranging from 5 to 95 %, preferably from 15 to
75 %,
preferably, feeding means is a feeding line mounted with spray nozzles, 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 nozzles, spray
nozzles being configured for spraying, on demand, a specific amount of
feeding material, in order substantially 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.
74. Use of the stationary reactor and its internals, according to any one of
claims 2 to
14 or of the pyrolysis system according to any one of claims 15 to 73, 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; and/or
- gaseous stream resuting from the incomplete pyrolysis reaction of a
mixture of
cellulosic material.
75. Use of the reactor and its internals, according to claim 74 in a
continuous process.
76. Process for thermally processing a mixture comprising organic compounds,
which
process comprises the steps of:
115

- a) feeding a stationary reactor and its internals as defined in any one of
claims
2 to 14 with:
- said mixture being sprayed or poured or dumped on at least part of the
plates surfaces during sliding of the plates on the supporting and/or
guiding means, and
- optionally, a gaseous stream resuting from the incomplete pyrolysis
reaction of a mixture of cellulosic materaial;
- b) heating the plates of said stationary reactor and its internals at a
temperature
corresponding to the thermal processing temperature of part of the mixture;
and
- c) recovering of the products resulting from the vaporizing and/or thermal
processing and for their elimination from said reactor;
wherein the mixture to be thermally processed is brought in contact with at
least
part of the surfaces of the plates of the charge and results in a reaction
and/or
vaporization of the feed and products allowing the removal of the mixture in
the
gas and solids phases, and
wherein at least part of the plates of the charge moves during the process,
and
wherein the gaseous stream resulting from the incomplete pyrolysis reaction of
a
mixture of celluosic material is brought in contact with at least part of the
surface
of the plates of the charge and results in a reaction and/or vaporization of
the feed
and products allowing the removal of the mixture in the gas and solids phases,
and
wherein at least part of the plates of the charge moves during the process.
77. Process, according to claim 76, for thermal processing a mixture
comprising
organic compounds wherein in step b) said part is the part of said mixture
that will be
thermally processed during the process.
78. Process, according to claim 76 or 77, 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 (and
116

in particular those additives used in the field of lubricating oils) and their
degradation
by-products.
79. Process, according to any one of claims 76 to 78, wherein the mixture
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.
80. Process, according to any one of claims 76 to 79, wherein the average
residence
time in the stationary reactor:
- 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
- b) has a value, when a gas stream resulting from incomplete pyrolysis of
hydrocarbons is injected in the reaction's zone of the stationary reactor,
reduced by at least about 10 % when compared with the average residence time
according to a).
81. Process, according to any one of claims 76 to 80, wherein the heating
temperature
in the reactor ranges from 120°C to 800°C or 350°C to
750°C.
82. Process, according to claim 81, wherein the heating temperature of the
plates in
the reactor ranges from 150°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.
83. Process, according to claim 82, wherein the heating temperature in the
reactor
ranges from 500°C to 520°C, and is preferably about
505°C, more preferably about
1 17

510°C, particularly when shredded tires, bitumen, heavy oils,
contaminated soils, or
oil sands naturally contaminated with heavy oils, are treated.
84. Process, according to any one of claims 76 to 97, wherein the pressure in
the
vertical stationary reactor ranges from 0 to 5, preferably from I to 2, more
preferably
range from 1.2 to 1.3 atmospheres.
85. Process, according to any one of claims 76 to 84, wherein a sweep gas is
in
introduced in the stationary reactor in an 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.
86. Process, according to any one of claims 76 to 85, wherein the various
fractions
generated by the thermal processing are recovered as follows:
- the liquid fraction is recovered by distillation;
- the gaseous fraction is recovered by distillation; and
- 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 condensor.
87. Process, according to claim 86, wherein :
a) when the feedstock is solely used lubricating oil:
- the amount of the recovered liquid fraction represents between 75%
and 100% weight of the reactor feed; and/or
- the amount of the recovered gaseous fraction represents between 0%
weight and 20% weight of the reactor feed; and/or
- the amount of the recovered solid fraction represents between 0%
weight and 25% weight of the reactor feed, and
b) when the feedstock is used lubricating oil and a gaseous stream resuting
from the incomplete pyrolysis reaction of a mixture of hydrocarbons, 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).
88. Process according to any one of claims 76 to 87, wherein said process is
operated
in a continuous or in a batch mode.
118

89. Use of a process, according to any one of claims 76 to 88, for:
- treating cellulosic material such as waste papers, wood chips, sawdust;
- treating plastics, Municipal Solid Wast;
- treating agricultural wast such as straw, corn stalks;
- treating wastes oils such as used lubricating oils, form oils, metal
treating oils,
refinery or transportation oil tank bottoms; and/or
- destroying hazardous and/or toxic products; and/or
- reusing waste products in an environmentally acceptable form and/or way;
and/or
- 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.
90. Use of a process, according to claim 89 for treating organics to prepare
fules and
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 d;esel fuel and on road diesel
fuel; and/or
- solid fuel; 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 wide range diesel; and/or
- a clarified oil; and/or
- a component in asphalt blends; and/or
- a component of drilling fluids; and/or
- a component of flotation oils; and/or
- a component of dedusting oils.
119

91. A manufacturing process for fabricating the stationary reactor and its
internals for
thermal processing, according to any one of claims 1 to 14, which process
comprise
assembly, by known means, of the constituting elements of said reactor.
92. A manufacturing process, according to claim 91, for fabricating the
stationary
reactor and its internals for thermal processing, wherein known assembling
means
comprise screwing, jointing, riveting and welding.
93. 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 claims 2 to 14, 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.
94. A Process, according to claim 93, for producing liquid fuels, wherein the
feed
can be in a form of pellets, granules and/or powder.
95. A Process, according to claim 93 or 94, for producing liquid fuels,
wherein 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 preferably at least

90% by weight.
96. A Process, according to any one of claims 93 to 95, for producing liquid
fuels,
wherein the agglomerates are in the form of pellets with an average weight
ranging
from 1 to 500 grams.
97. A Process, according to claim 95 or 96, for producing liquid fuels,
wherein the
agglomerates are in the form of pellets with a total carbon content ranging
from 30 %
120

to 90, preferably % 30 % to 75 %, and wherein pellets have a humidity content
less
than 60 %, preferably ranging from 1 to 65 % weight, preferably 5 to 65 %
weight.
98. A Process, according to any one of claims 93 to 97, wherein the recovered
liquid
fuel has a low sulfur content that is, according to ASTM D7544, ASTM
preferably
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 %
weight.
99. 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) an optional preliminary step wherein water content of the starting
material is
reduced preferably to a value lower than 55 % and/or wherein particulate size
has been reduced to a size ranging from 0,1 mm to 5 mm;
b) a thermal step wherein at least partial liquefying and at least partial
dewatering of the starting material, eventually obtained in previous steps a)
occurs, wherein starting material is heated under:
- 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
- at a temperature that is preferably lower than 300 degrees Celsius;
c) recovering of the liquid fraction resulting from step b), said liquid
fraction can
contain solid matters in suspension;
d) a pyrolysis step wherein:
- liquid fraction obtained in step b) or c), is treated in a stationary
reactor, preferably of the type described in claims 1 to 14 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,
- preferably, with a reduced amount of oxygen present in the
stationary reactor; and
121

e) a post treatment step wherein the solid-gas mixture exiting the stationary
reactor is submitted to a solid-gas separation allowing the recovery of
substantially clean vapours and solids;
0 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 the liquid fraction resulting from step
c),
preferably in order to adjust solid liquid ratio in the liquid feed stream
entering the
reactor.
100. 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) an optional preliminary step wherein water content of the starting
material is
reduced preferably to a value lower than 55 % and/or wherein stone and/or
metallic content is reduced below 10 weight percent;
b) a thermal step wherein at least partial liquefying and at least partial
dewatering of the starting material eventually obtained in previous steps a),
occurs and wherein starting material is heated under:
- 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
- at a temperature that is preferably lower than 250 degrees Celsius;
c) recovering of the liquid fraction resulting from step b);
d) recovering unliquified solid fraction from step b);
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; and
0 a pyrolysis step wherein:
- liquid obtained in step c) or e), is treated in a stationary reactor,
preferably of the type described in claims 1 to 13, advantageously
122

under positive pressure and/or preferably in the presence of a sweep
gas, that is preferably an inert gas, and
- reaction and straight run products are recovered from the vertical
rotating reactor as solids and as a solid-gas mixture; and
g) a post treatment step wherein solid-gas mixture exiting the vertical
stationary
reactor is submitted to a solid-gas separation allowing the recovering
of substantially clean vapours and solids; and
h) 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 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; and
- 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.
101. 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;
b) an optional drying step, wherein agglomerates obtained in the pre-treatment

step and/or coming from the market and/or waste collection are dried to a
water content lower than 55% weight percent;
c) 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;
d) a pyrolysis step, wherein:
.circle. liquid obtained in step c), is treated in a stationary reactor,
preferably
of the type described in claims 2 to 13 and preferably under positive

123

pressure and/or preferably in the presence of a sweep gas, that is
preferably an inert gas, and
.circle. reaction and straight run products are recovered from the stationary
reactor as solids and as a solid-gas mixture;
e) a post treatment step wherein solid-gas mixture exiting the stationary
reactor
is submitted to a solid-gas separation allowing the recovery of substantially
clean vapours and solids; and
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 un-
liquefied 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.
102. Process, according to any one of claims 93 to 101, for producing liquid
fuels
from starting material that are waste hydrocarbons and/or organics material or
a
mixture of the two, wherein;
- solids present in starting material are broken into small pieces below
20 mm; and/or
- agglomerates are made of at least 75% by weight of organics or
hydrocarbons mixed with water; and/or
- metals and rocks have been sorted out from the agglomerates,
preferably by gravity and/or by magnetic separation; and/or
-the water content in the starting material is less than 87 weight % as,
during the (agglomeration) pelletizing part, the water was taken out;
and/or
- 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 weight % 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
weight %, eventually, with a special system, such as separation mill,
turbo dryer, high efficiency dryer, press or filter, raised up to 85
weight %; and/or

124

- dewatering is done with drum dryers or belt dryers or settler to get to
a lower water content.
103. Process, according to claim 102, for producing liquid fuels from starting

material that is waste hydrocarbons and/or organic materials or a mixture of
the two,
wherein in 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; and
- liquefy more than 50 % of the heavier hydrocarbons and/or organics
present
in the starting material,
while managing cracking of the feedstock under treatment.
104. Process, according to claim 103, for producing liquid fuels from starting

material that is waste hydrocarbons and/or organic materials or a mixture of
the two,
wherein in step c): the water and lighter materials eventually including
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 to be used as fuel of any heating system
and/or to
be sold in a liquid form as a liquid fuel.
105. Process, according to claim 104, for producing liquid fuels from starting

material that is waste hydrocarbons and/or organic materials or a mixture of
the two,
wherein in step c), 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.
106. Process, according to claim 105, for producing liquid fuels from starting

material that is waste hydrocarbons and/or organic materials or a mixture of
the two,
wherein in 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

125

- the remaining fraction that is the light fraction and that 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 gaseous fraction.
107. Process, according to claim 106, for producing liquid fuels from starting

material that is waste hydrocarbons and/or organic materials or a mixture of
the two,
wherein in step c): the water and lighter materials and lighter portion, only
present if
some material cracks, are separated from the heavier portion allowing to
eliminate
water and to recover lighter products which can be further separated and used
as fuel.
108. Process, according to any one of claims 100 to 107, for producing liquid
fuels
from starting material that is waste hydrocarbons and/or organic materials or
a
mixture of the two, wherein in step d): the liquefied materials and entrained
solids
(resulting of step c) are directed to the vertical stationary reactor,
preferably with
added sweep gas, and/or preferably with an inert gas, preferably directly in
the piping
or conduit to treat them in a, preferably indirectly fired, stationary reactor
operating
preferably under positive pressure and/or preferably with a pressure control
system;
said indirectly fired stationary reactor having:
a. a heating system;
b. at least one plate moving inside the stationary reactor;
c. a charge of plates of consistent shapes;
d. means for bringing the mixture of the liquefied materials and
entrained solids resulting from step c) to be thermally processed on
the surface of at least part of the plates;
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 the 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

126

of the post-treatment modules are at least 10 degrees Celsius above
the condensation point of the vapours and below the cracking point of
the vapours.
109. Process, according to any one of claim 93 to 108, for producing liquid
fuels
from starting material that is organic materials such as waste hydrocarbons,
wherein
the transformation conditions in the vertical stationary reactor are at least
one of the
followings:
- temperature range from 200 to 750 degrees Celsius;
- pressure lower than 5 atmospheres, preferably below 2 atmospheres, more
preferably about l .1 atmospheres;
- residence times ranges from 1 second to 2 hours, preferably 5 seconds to
10
minutes, preferably about 3 minutes; and
- the height of the shelves of the vertical reactor, versus the thickness
of the
plates, ranges from 6 to 1 (6 plates for 1 shelf to 1 plate for 1 shelf).
110. Process, according to claims 93 to 109, for producing liquid fuels from
starting
material that is organic materials such as waste hydrocarbons, wherein in step
e),
- 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; and/or
- the post treatment module has preferably at least one cyclone and
preferably
two cyclones; and/or
- solids are further separated in a self-refluxing condenser and/or in a
equipement changing steam direction, such as a diverter, and/or a wash
column; and/or
- thereafter, the vapours are condensed and separated either in a
distillation
column or in multiple condensers and/or in a flash drum.
111. A process, according to any one of claims 93 to 110, wherein the thereby
obtained liquid fuels 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..... ):
- viscosity as per ASTM D445 below 80, advantageoulsy 40 cSt @ 40°C,
more preferably below 20 cSt @ 40°C, more preferably below 10 cSt @

127

40°C, more preferably below 5 cSt g 40°C, more preferably below
3 cSt @
40°C;
- flash point as per ASTM D92 or D93 over 40 °C (preferably after
fractionation);
- flash point over 55 °C for medium fraction (preferably after
fractionation);
and
- water content, as meseaured by ASTM D1533, below 25 weight %, more
preferably below 15 weight %, more preferably below 5 weight % after
fractionation.
112. A process, according to any one of claims 93 to 111, wherein bio-diesel
and/or
heavy hydrocarbons and/or heavy bio-oil fraction, recovered from the solid-
vapour
fraction exiting the pyrolysis step, is(are) added to the feeding stream
before entering
the stationary reactor.
113. A process, according to claim 112, wherein bio-diesel is added in the
feed
material resulting from step b) or from step c) at a rate ranging from 0 to 90
weight %
of the feed mass flow rate entering the stationary reactor, preferably less
than 50
weight % of the feed mass flow rate entering the stationary reactor, more
preferably
less than 25 weight %, advantageously ranging from 5 to 20 weight % or 10 to
20
weight % of the feed mass flow rate entering the stationary reactor.
114. A process, according to any one of claims 93 to 113, wherein a weak
organic acid
is 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 submitted to a preliminary treatment in order to at least partially
destructurize
cellulose present in said recovered fraction.
115. A process, according to claim 114, wherein a acid, that advantageously a
weak
organic acid, preferably a carboxylic acid such as a formic acid and/or
carboxylic acid,
is used in the preliminary treatment.
116. A process, according to claims 115, wherein the amount of weak acid added
in
the feeding stream represents from 0 to 50 weight percent of the feed
material.
117. A process, according to any one of claims 93 to 116, wherein the feeding
stream,
is submitted to a physical and/or microwave and/or chemical treatment
allowing,

128

before the feeding stream is sprayed on a sliding plate, to at least partially
destructurize
cellulosic material present in the feed stream.
118. A process, according to any one of claims 93 to 117, wherein the
temperature of
the feeding stream used in the pyrolysis step is adjusted to a temperature
ranging from
80 to 400 degrees Celsius before entering the stationary vertical reactor,
more
preferably this temperature ranges from 100 to 350 degrees Celsius, 200 to 250
degrees
Celsius or 100 to 300 degrees Celsius, more preferably about 180 degrees
Celsius.
119. A process, according to any one of claims 93 to 118, performed in a
continuous,
semi-continuous or batch mode.
120. A process, according to any one of claims 93 to 119, wherein at least one
of the
following components is used to reduce solid content in the feed stream:
gaseous
and/or liquid fraction recovered at the exit of the stationary reactor in
operation
121. A process, according to any one of claim 120, wherein said recovered
fraction is
the heavy oil.
122. A process, according to any one of claims 93 to 121, wherein said reactor

comprises plates and at least part of the surface of said plates is used to
perform said
thermal processing.
123. A process, according to claim 122, wherein thermal processing being
performed
on at least part of the surface of said plates in movement.
124. A process, according to claim 122 or 123, for thermal processing of a
mixture,
wherein thermal processing being 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.
125. A process, according to any one of claims 122 to 124, wherein said plates

contribute to the uniformity of temperature conditions in said stationary
reactor.
126. A process, according to any one of claims 122 to 125, for thermal
processing of
a mixture, wherein said plates contribute to heat transfer from the heated
sources to
the surface of said plates and to the feed material to process.

129

127. A process, according to any one of claims 122 to 126, wherein said plates

contribute to the heat transfer taking place from the heated walls to the
surface of
said plates.
128. A process, according to claim 127, wherein said mixture comprises mostly
organic compounds and/or hydrocarbon that may be transformed by thermal
processing.
129. A process, according to claim 128, wherein said mixture comprises at
least 80
weight %, preferably at least 90 weight % of organic compounds that may be
transformed by thermal processing.
130. A process, according to claim 129, wherein said mixture comprises at
least about
95 weight % of organic compounds that may be transformed by thermal
processing.
131. A process, according to any one of claims 126 to 130, wherein the mixture
may
comprise other components that are not organic compounds and/or that may not
be
transformed by thermal processing.
132. A process, according to claim 131, wherein said other components are
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.
133. A process, according to any one of claims 126 to 132, wherein said
mixture is
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.
134. A process, according to claim 133, wherein said 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.
135. A process, according to any one of claims 126 to 134, wherein the plates
are
heated in a specific internal zone of the stationary reactor.
136. A process, according to any one of claims 126 to 135, wherein the plates
are
heated along a side, preferably along a vertical side, of the stationary
reactor.

130

137. A process, according to 135 or 136, wherein the heat source is 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 a mixture of at least two of these.
138. A process, according to claim 137, wherein the inside of the reactor is
indirectly
heated by an electromagnetic field, micro-waves and/or infra-red.
139. A process, according to claim 138, wherein the inside of the reactor is
directly
heated by a hot gas, liquid or solid stream, by electricity or by partial
combustion
of the feedstock, coke, products or by-products.
140. A process, according to claim 139, wherein the external walls of the
reactor are
at least partially surrounded by electrical wires by one or more burners
and/or
exposed to combustion gas and/or hot solids.
141. A process according to any one of claim 139 or 140, wherein the walls of
said
reactor are surrounded by electrical wires or by a fire box, and said fire box
is
stationary and contains one or more burners.
142. A process, according to any one of claims 139 to 141, wherein the
supporting
and/or guiding means are attached to the internal wall in a designed and/or
random
pattern of said reactor.
143. A process, according to any one of claims 121 to 142, wherein the
thickness of
the plates ranges from 0,05 to 8 cm, preferably from 0,1 to 5 cm and more
preferably
from 0,3 to 0,4 cm.
144. A process, according to any one of claims 126 to 143, wherein the shape
of the
plates of the charge is selected among the group of parallelogram, such as
triangles,
squares, rectangles, lozenges, or trapezes.
145. A process, according to claim 144, wherein the plates of the charge are
rectangular.
146. A process, according to any one of claims 126 to 145, wherein the shape
of the
plates of the charge is imperfect and/or wherein all the plates present in the
reactor
have about the same size and shape.

131

147. A process, according to any one of claims 126 to 146, wherein the plates
have a
melting point which is at least about 100 degrees Celsius, and more preferably
is at
least 150 degrees Celsius above the reactor wall maximum operating temperature

in the thermal processing zone and/or combustion zone.
148. A process, according to any one of claims 126 to 147, wherein the plates
are
heavy enough to scrape coke off other plates and/or to have coke scraped off
it by
moving over scraping mechanisms without loosing more than 90 % or 70 % of
initial velocity of a plate when sliding or when falling.
149. A process, according to claim 148, wherein each plate has a density that
is
superior to 2.0 g/cm3, preferably superior to 7.5 g/cm3 and more preferably
comprised between 5.5 g/em3 and 9.0 g/cm3.
150. A process, according to any one of claims 126 to 149, wherein the means
for
bringing the mixture in contact with at least part of the surfaces of the
plates are
spraying means of the nozzle type.
151. A process, according to claim 150, wherein the means for bringing the
mixture in
contact with at least part of the surfaces of the plates are spray nozzles
that 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.
152. A process, according to any one of claims 126 to 151, wherein the means
for
bringing the solids outside the reactor is (are) entrainment with the product
gas,
scoop(s), screw conveyor(s) and/or propeller and/or rotating fins and/or
blower(s)
and/or gravity and/or comprise an exit hopper arrangement attached to the
solids
exit tube.
153. A process, according to claim 152, wherein said reactor has two exits:
one for the
solids and one for the gas/vapours and entrained solids obtained.
154. A process, according to any one of claims 126 to 153, wherein the
gas/vapours
obtained contain entrained solids.
155. A process, according to any one of claims 126 to 154, wherein said
reactor is
equipped with means for avoiding accumulation of solid in the reactor and/or
for
avoiding plugging of any of the exits and/or wherein the means for avoiding

132

accumulation are a 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.
156. A process, according to any one of claims 126 to 155, wherein the feeding
of the
mixture is on the top of the reactor or is at about equal distance of each
end,
preferably vertical end of the stationary reactor.
157. A process, according to any one of claims 126 to 156, wherein the exit of
the
solids is on the bottom of the reactor.
158. A process, according to any one of claims 126 to 157, 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 their degradation by-products.
159. A process, according to claim 158, wherein the mixture comprises organic
compounds having the following thermodynamic and physical features: a specific

gravity as per ASTM D-4052 ranging from 0.5 to 2.0, and/or distillation
temperatures between 20°C and 950°C as per ASTM D-1160.
160. A process, according to claims 158 or 159, wherein the average residence
time in
the stationary reactor is between 1 seconds to 10 hours, preferably between 30

seconds and 2 hours, and more preferably is between 90 seconds and 10 minutes.
161. A process, according to any one of claims 158 to 160, wherein the heating

temperature in the reactor ranges from 50°C to 750°C, preferably
from100°C to
650°C, more preferably 200°C to 550°C, and even more
preferably from 250°C to
450°C.
162. A process, according to claim 161, wherein the heating temperature in the
reactor
ranges from preferably 140°C to 550°C, more preferably
370°C to 525°C, even
more preferably from 420°C and 500°C and, more advantageously,
is about 420°C
or 470°C particularly when MSW combined with used lube oils are
treated.
163. A process, according to claim 160, wherein the heating temperature in the
reactor
ranges from 500°C to 520°C, and is preferably about
505°C, more preferably about
510°C when rubber is fed in the stationary reactor.

133

164. A process, according to any one of claims 158 to 163, wherein the
stationary
reactor 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 plates of a guiding and/or of a sliding means is
larger
than the width by 0 to 30, advantageously by 2 to 15 % , preferably by 5 to 10
%, more
preferably is about 3 %; the inner length of the stationary reactor or the
inner
diameter when the stationary reactor is a cylinder;
- the average thickness of the plate must be less than or equal to 8 cm;
- the Ratio L/W is less than or equal to 3; and
- the length of a plate is at most 5 times the width of a plate.
165. A process, according to any one of claims 158 to 164, wherein the
supporting
and/or guiding means 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
rectangles 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.
166. A process, according to any one of claims 158 to 165, wherein 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.
167. A process, according to claim 166, wherein the post-treatment module is
configured for keeping the solid-gas mixture at a temperature that is 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.

134

168. A process, according to claim 167, wherein the difference between the
temperature in the post-treatment module and the temperature at the exit of
the
central module ranges from 0 to + or - 10 degrees Celsius.
169. A process, according to any one of claims 167 or 168, comprising means
for
injecting inert gaz such as nitrogen, recycled gaz and/or steam inside the
feed
material and/or inside the feedstock, and/or inside the pre-treatment module
and/or
inside the central module.
170. A process, according to any one of claim 167 to 169, wherein the post-
treatment
module being positioned close to the vapour exit of the central module.
171. A process, according to any one of claims 167 to 170, configured for
allowing
the thermal conversion to be performed with a residence time ranging from 1
seconds to 10 minutes.
172. A process, according to any one of claims 167 to 171, wherein the post-
treatment module comprises 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.
173. A process, according to any one of claims 167 to 172, wherein the post
treatment module is equipped with:
- a transit line connecting the two heated enclosures constituting of the
central
module and of the post-treatment module; and/or
- 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
- an extension of the combustion chamber surrounding the pyrolysis reactor
being connected with the post-treatment module, preferably by means of heat
transfer line(s).

135

174. A process, according to claim 167 or 173, wherein the transit line
between the
two heated enclosures is also 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.
175. A process, according to claims 167 to 174, wherein:
- 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' type).
176. A process, according to any one of claims 167 to 175, wherein the transit
line is
permanently heated when in operation.
177. A process, according to claim 176, wherein the length of the transit line
is lower
or equal to 10 meters.
178. A process, according to any one of claims 167 to 177, wherein the
pyrolysis
vertical reactor comprises 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.
179. A process, according to any one of claims 167 to 178, wherein the
vertical
pyrolysis reactor module 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.
180. A process, according to any one of claims 167 to 179, wherein the solids
resulting from the thermal processing in the vertical stationary reactor are
separated
from the vapours in gas-solids separation equipment, preferably in a box
and/or in a

136

cyclone, situated in a second heated enclosure placed downstream or upstream
to the
central module.
181. A process, according to claims 167 to 180, wherein the temperature of the

products at the exit of the separating equipment is kept at or above the
reactor exit
temperature.
182. A process, according to any one of claims 167 to 181, wherein the clean
vapours exiting from the post treatment module are 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.
183. A process, according to claim 182, wherein the separating equipment is
contigured to be connected with an equipment of the distillation column type.
184. A process, according to claim 183, wherein the vapours, exiting the gas-
solids
separating equipment is routed to an equipment of the flash drum type, said
equipment of the flash drum type having preferably a refluxing condenser
mounted
above it to scrub the reactor products and to remove residual solids.
185. A process, according to claim 184, wherein the clear vapours, exiting
from the
post treatment module, are condensed and separated in an equipment of the
distillation column type.
186. Process, according to claims 184 or 185, wherein the average residence
time in
the vertical stationary reactor 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.
187. Process, according to claims 186, wherein the heating temperature,
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.

137

188. Process, according to any one of claims 185 to 187, wherein the various
fractions generated by the cracking are 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 in cyclones.
189. Process, according to any one of claims 167 to 188, wherein:
- the amount of the recovered liquid fraction represents between 30% and
90%
weight of the reactor feed; and/or
- the amount of the recovered gaseous fraction represents between 1% and
30%
weight of the reactor feed; and/or
- the amount of the recovered solid fraction represents between 1% and 40%
weight of the reactor feed, and
when applied to plastic:
- the amount of the recovered liquid fraction, preferably, of the recovered

diesel represents between 50 % and 90 % weight of the reactor feed; and/or
- the amount of the recovered gaseous fraction i.e. of the recovered
vapours
represents between 1 to 10 % weight of the reactor feed and the amount of the
recovered naphtha represents between 2 and 15 % weight of the reactor feed;
and/or
- the amount of the recovered solid fraction i.e of recovered coke
represents
between 2 and 40 % weight of the reactor feed.
190. A process, according to any one of claims 126 to 189, wherein the
vertical
stationary reactor 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 stationary reactor to a post-treatment module configured to
separate gas
and solids present in the solid-gas mixture.
191. A process, according to claim 190, wherein the stationary reactor 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 stationary
reactor to a

138

post-treatment module configured to at least partially separate solids present
in the
solid-gas mixture.
192. Process, according to any one of claims 172 to 191, wherein the various
fractions generated by the thermal processing are recovered as follow:
- the liquid fraction is recovered by distillation;
- the gaseous fraction is recovered by distillation; and
- the solid fraction is recovered for example in wash column, filters,
cyclones, a
solids recovery box, a scrubber, and/or a refluxing condenser.
193. Process, according to claim 192, wherein
- the amount of the recovered liquid fraction represents between 30% and 80%
weight of the organic reactor feed; and/or
- the amount of the recovered gaseous fraction represents between 30% weight
and 60% weight of the reactor feed; and/or
- the amount of the recovered solid fraction represents between 0% weight and
20% weight of the reactor feed,
when the feedstock is organic waste material.
194. Use of a process, according to any one of claims 171 to 192 for treating
municipal
waste material such as municipal solid or liquid waste, biomass, plastic
and/or
tires.
195. Use of the process, according to claim 194, 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 diesel fuel and/or 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

139

- 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 additive to animal feed; and/or
- an insulator; and/or
- a humidity regulator; and/or
- an air decontaminator; and/or
- a protective element against electromagnetic radiation; 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 detoxification agent; and/or
- a carrier for active pharmaceutical ingredients; and/or
- an exhaust filter; and/or
- a semiconductor; and/or
- a therapeutic bath additive; and/or
- a skin cream additive; and/or
- a soap additive; and/or
- a solid fuel; and/or
- a substitute for lignite; and/or
- a filling for mattresses and/or pillows; and/or
- an ingredient in food; and/or
- a bio-oil for combustion; and/or
- chemicals such as acids, alcohols, aromatics, aldehydes, esters, ketones,

sugars, phenols, guaiacols, syringols, furans, alkenes; and/or
- emulsification agent for fuels; and/or

140

- refining secondary feeds et dedusting oils; and/or
- a feed for steam reforming.
196. 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 feed:ag stream in a liquid or in a
semi liquid stage and/or
heterogeneous state before entering the
vertical 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 preferably a pretreatment vessel, and/or to adjust
solid content in the feed stream to the vertical stationary reactor.
197. Managing system, according to claim 196, wherein feed stream solid
content is
adjusted by at least one of the following means for:
- injecting in the feed stream a weak organic acid;
- injecting in the feed stream a diesel, preferably a heavy diesel, product
oil or
used lubricating oils; and/or
- adjusting pressure at positive or negative value; and
- adjusting temperature of the feeding stream in the range from 25 to 350
Celsius degrees.

141

Description

STATIONARY REACTOR AND ITS INTERNALS FOR PRODUCING
LIQUID FUEL FROM WASTE HYDROCARBON AND/OR ORGANIC
MATERIAL AND/OR CONTAMINATED OILS, THERMAL PROCESSES,
USES AND MANAGING SYSTEMS THEREOF
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to International Patent Application No

PCT/CA2018/051178 filed on September 20, 2018. This document is hereby
incorporated by reference in its entirety.
FIELD OF THE INVENTION
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 thermal processusing astaionary reactor or a
pyrolysis system of the invention.
CA 3019711 2018-10-02

PRIOR ART
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.
There was also a need for an efficient equipment, with a simple and compact
mechanical structure that can be easily fabricated at low costs, dismounted
and
mounted on a remote site and allowing the efficient producing of mixtures easy
to
separate in an efficient way and with reduced maintenance of the equipment.
SUMMARY
According to one aspect, there is provided 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
caracterized in that the at least one plate(s) supporting and/or guiding means
is
2
CA 3019711 2018-10-02

preferably inclined and in that at least part of the surface of said plates
being used to
performed said thermal processing of the mixture.
According to another aspect, there is provided a pyrolysis system for thermal
processing of a mixture, said system comprising:
a. a stationary reactor as defined in the present invention;
b. an internal or external heating system;
c. a charge of plates of consistent shapes;
d. 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;
f. means for recovering the reaction and straight run products; and
g. means for venting the gas obtained by the thermal processing outside the
stationary reactor zone.
According to a further aspect, there is provided a process for thermally
processing a
mixture comprising organic compounds, which process comprises the steps of:
- a) feeding a stationary reactor and its internals as defined in the present
invention with:
- said mixture being sprayed or poureds or dump on at least part of the
plates surfaces during sliding of the plates on the supporting and/or
guiding means, and
- optionally, a gaseous stream resuting from the incomplete pyrolysis
reaction of a mixture of cellulosic materaial;
- b) heating the plates of said stationary reactor and its internals at a
temperature
corresponding to the thermal processing temperature of part of the mixture;
and
- c) recovering of the products resulting from the vaporizing and/or thermal
processing and for their elimination from said reactor;
wherein the mixture to be thermally processed is brought in contact with at
least
part of the surfaces of the plates of the charge and results in a reaction
and/or
3
CA 3019711 2018-10-02

vaporization of the feed and products allowing the removal of the mixture in
the
gas and solids phases, and
wherein at least part of the plates of the charge moves during the process,
and
wherein the gaseous stream resulting from the incomplete pyrolysis reaction of
a
mixture of celluosic material is brought in contact with at least part of the
surface
of the plates of the charge and results in a reaction and/or vaporization of
the feed
and products allowing the removal of the mixture in the gas and solids phases,
and
wherein at least part of the plates of the charge moves during the process.
According to another aspect, there is provided 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.
According to another aspect, there is provided 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) an optional preliminary step wherein water content of the starting
material is
reduced preferably to a value lower than 55 A and/or wherein particulate size
has been reduced to a size ranging from 0,1 mm to 5 mm;
b) a thermal step wherein at least partial liquefying and at least partial
dewatering of the starting material, eventually obtained in previous steps a)
occurs, wherein starting material is heated under:
- 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
- at a temperature that is preferably lower than 300 degrees Celsius;
4
CA 3019711 2018-10-02

c) recovering of the liquid fraction resulting from step b), said liquid
fraction can
contain solid matters in suspension;
d) a pyrolysis step wherein:
- 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,
- reaction and straight run products are recovered from the stationary
reactor as solids and as a solid-gas mixture,
- preferably, with a reduced amount of oxygen present in the
stationary reactor; and
e) a post treatment step wherein the solid-gas mixture exiting the stationary
reactor is submitted to a solid-gas separation allowing the recovery of
substantially clean vapours and solids;
t) 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 the liquid fraction resulting from step
c),
preferably in order to adjust solid liquid ratio in the liquid feed stream
entering the
reactor.
According to another aspect, there is provided 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) an optional preliminary step wherein water content of the starting material
is
reduced preferably to a value lower than 55 % and/or wherein stone and/or
metallic content is reduced below 10 weight percent;
b) a thermal step wherein at least partial liquefying and at least partial
dewatering of the starting material eventually obtained in previous steps a),
occurs and wherein starting material is heated under:
- 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
- at a temperature that is preferably lower than 250 degrees Celsius;
5
CA 3019711 2018-10-02

c) recovering of the liquid fraction resulting from step b);
d) recovering unliquified solid fraction from step b);
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; and
0 a pyrolysis step wherein:
- liquid obtained in 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
- reaction and straight run products are recovered from the vertical
rotating reactor as solids and as a solid-gas mixture; and
g) a post treatment step wherein solid-gas mixture exiting the vertical
stationary
reactor is submitted to a solid-gas separation allowing the recovering
of substantially clean vapours and solids; and
h) 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 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; and
- 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.
According to another aspect, there is provided 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;
6
CA 3019711 2018-10-02

b) 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;
c) 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;
d) a pyrolysis step, wherein:
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
o reaction and straight run products are recovered from the rotating kiln
as solids and as a solid-gas mixture;
e) 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; and
0 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.
According to another aspect, there is provided 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;
7
CA 3019711 2018-10-02

- 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.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are presented as non-limitative examples.
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.
8
CA 3019711 2018-10-02

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 bottom-
most 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.
9
CA 3019711 2018-10-02

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
to
CA 3019711 2018-10-02

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
II
CA 3019711 2018-10-02

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
12
CA 3019711 2018-10-02

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
13
CA 3019711 2018-10-02

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 flip.
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
14
CA 3019711 2018-10-02

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
CA 3019711 2018-10-02

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.
16
CA 3019711 2018-10-02

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.
17
CA 3019711 2018-10-02

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 4813 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 49A.
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 50A.
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 51A.
Figure 51C represents a right-side view of the tray described in Figure 51A.
18
CA 3019711 2018-10-02

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 53A.
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 MC 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.
19
CA 3019711 2018-10-02

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 5813 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
63A.
CA 3019711 2018-10-02

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.
21
CA 3019711 2018-10-02

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.
22
CA 3019711 2018-10-02

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 4th, 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
23
CA 3019711 2018-10-02

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.
24
CA 3019711 2018-10-02

DETAILLED DESCRIPTION OF THE INVENTION
The following examples are presented in a non-limitative maner
Preliminary definitions:
Municipal solid waste (MSW) and/or plastics, commonly known as trash or
garbage
in the United States and as refuse or rubbish in Britain, is a waste type
consisting of
everyday items that are discarded by the public. 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.;
- inert waste: construction and demolition waste, dirt, rocks, debris, ;
- electrical and electronic waste (WEEE) - electrical appliances, light
bulbs,
washing machines, TVs, computers, screens, mobile phones, alarm clocks,
watches, etc.;
- composite wastes: 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;
and
- toxic waste including pesticides, herbicides, and fungicides.
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.
CA 3019711 2018-10-02

Contaminants: In MSW, the contaminants are non-combustible material and/or non-

organic 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 MSW 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.
Internals: any element that is in the general inside the enclosure of the
reactor.
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 (UL0): are oils or greases that were used as lubricants,
usually
in engines, and were discarded. Examples would include car engine oils,
compressor
26
CA 3019711 2018-10-02

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.
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. In the meaning of the invention, the expression consistent shapes also
means:
- a multiplicity of physical elements having substantially the same form;
27
CA 3019711 2018-10-02

- a multiplicity of physical elements having substantially the same form and
substantially the same size;
- a multiplicity of physical elements having substantially the same size,
provided those
forms are compatible in such an extent that are globally symmetrical and stay
substantially constant during rotation inside the rotating kiln; and
- a multiplicity of physical elements having shapes that permit that plates
sit upon each
other, preferably in such a way that there is no space or substantially no
space between
them.
Dynamical wall: the multiplicity of plates of consistent shapes results,
because of the
rotation, in a continuously reconstructing wall.
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. Examples of thermal processing include
evaporating,
cracking, condensing, solidifying, drying, pyrolyzing and thermocleaning. In
the
meaning of the invention 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.
It was
surprisingly found that such gas not only have as sweeping effect in the
reaction's
zone of rotating operating reactor, but may help control the pressure in the
reactor,
may increase the safety in plant operations, may help control the reactions in
the
reactor and globally may improve the efficiency of the process. For example,
the
sweep gas is a gas stream that may additionally serve in various the following
functions
such as:
- when injected into the reactor feed line, the sweep gas 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
28
CA 3019711 2018-10-02

- 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
- it reduces the organic vapour's and/or organic liquid's residence time in
the
reactor, by sweeping the organic vapours out of the reactor soon after they
are
formed, thereby reducing the incidence of secondary reactions, or over-
cracking, resulting in higher liquid yields and more stable liquid product bio-

oils, 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
- it can also be part of the stripping gas stream in the product
distillation unit.
Spraying means: means configured for moving in a mass of dispersed droplets or
fine
particules 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
caracterized 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.
Advantageously, said stationary reactor comprises:
- one or several plate(s) displaceable inside the stationary reactor from
an upper
internal position of the reactor to a lower internal position of the reactor;
29
CA 3019711 2018-10-02

- 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); and/or
- 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;
- feeding means for bringing the mixture on at least part of the surface of
said
at last one plate being used to perform the thermal processing of the mixture;
- exit means for existing gaseous, liquid and solids, formed during the
thermal
treatment, outside the stationary reactor.
Preferably, the stationary reactor have walls defining an internal part called
reaction's
zone of the stationary reactor and comprisies:
- internal and/or external heating means for heating the stationary reactor
and/or for heating its internals and/or for heating the at least one plate(s)
supporting and/or for heating the at least one guiding mean(s): and
- feeding means for spraying the mixture on at least part of the surface of
said
at last one plate being used to perform the thermal processing of the mixture
in
the reaction's zone,
wherein said stationary reactor being further caracterized 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.
According to aprefered embodiment of the invention, 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;
CA 3019711 2018-10-02

- 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:
- bring a plate from the lower part of the external elevator to the bottom
part of the external elevator,
- elevate a plate from the bottom part of the external elevator to the
upper part of the external elevator; and
- bring a plate from the internal upper part of the external elevator to
the upper internal part of the stationary reactor; and
- optionally, deplacement means for inititiating sliding of the plates on
the at
least one supporting and/or on the at least one guiding means.
Advantageously:
- 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; and/or
- sliding of the plates in the reaction's zone is generated by gravity and/or
by
mechanical means and/or by sliding means.
The stationary reactor and its internals is advantageously configured in order
that:
- at least 10%, preferable at least 20%, more preferably at least 70%, even
more
preferably at least 90 % of the surface of the plates present inside the
stationary
reactor is used for performing the thermal processing of the mixture; and/or
- at least 10 (Yo, 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.
31
CA 3019711 2018-10-02

Preferably, at least one of the surface of the plates is cleaned by cleaning
means such
as scraping device, said cleaning means being positioned :
- inside the stationary reactor, preferably close to the surface of plate
wherein
thermal processing occurs; and/or
- outside the stationary reactor; and/or
- in the internal and/or in the external elevator when an elevator is
present.
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:
internal and/or external 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;
- having a reduced oxygen content, the reduced oxygen content that is
preferably less than 1 % oxygen, and/or
- being traversed by an inert gas, more advantageously in the case of IR
or convection heating means said heating means are positioned above
32
CA 3019711 2018-10-02

or under the plate when sliding on the supporting means and/or when
sliding on a guiding means,
advantageously 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.
Particularly, when heating means are of the combustion's type, plates
contribute to the
uniformity of temperatures conditions in said stationary reactor.
Particularly, when heating means are of the combustion's type, plates
contribute to
heat transfer from the heat sources to the reaction chamber.
According to a preferred embodiment, 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:
- reheating a plate after pyrolysis reaction took place on the surface of a
plate;
and/or
- burning coke formed on the surface of a plate by the pyrolysis reaction
occurring on the surface of a plate; and/or
- producing warm air that is fed into the reaction's zone of the stationaray
reactor.
When the stationary reactor is not connected with a combustion chamber, the
reheating
of plates is performed by 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.
33
CA 3019711 2018-10-02

According to another preferred embodiment of the invention:
- 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
- connecting means between the combustion chamber and the stationary reactor
preferably have seperation means configured to avoid contamination of the gas
and steam, produced by the thermal processing performed in the reaction
chamber,
with oxygen from the combustion chamber, separation means are preferably
seals,
doors, met 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;
- the plate elevetor 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;
34
CA 3019711 2018-10-02

- 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 alernatively, or according to a
predetermined sequence;
- a reactor exit tube, preferably positioned on the top of
the reaction chamber
of the stationary reactor, to allow flow of products resulting from thermal
processing to stream out the reactor;
- at least one reactor sweep gas entrance, preferably positioned within or
close to the feeding tube or on a side wall of the reaction chamber;
- flippers, preferably monted on a rotational axis about
perpendicular to the
plates displacement direction in the reactio chamber, to flip the plates
before said plates slides down and fall from one supporting and/or guiding
means (such as a tray) to another;
- flipping trays, preferably positioned about parallel to and directly above
the
supporting and/or guiding means, for preventing the plates from falling
from one supporting and/or guiding means (such as a tray) to another,
before a certain percentage of the length of the plates passes the extremity
of the tray directly below the flipping tray;
- curved tray that catches the plates which hang at an angle that allows to
flip
upon faling from one tray to another;
- lifter that is the element of the elevator which move
upwards and catch the
plates as they slide off the, preferably pressured, reaction's chamber floor;
- scraping means, such as:
- those of the static scraper bars type or brushes, that scrap the bottom
and/or top and/or the lateral surface of the plates while said plates slide
on the one sliding and/or guiding means (such as a tray) to which the
scrapper bar is attached, and
- those of the chains rotatingtype that are preferably attached on a wall
in the lower part of the stationary reactor;
CA 3019711 2018-10-02

- 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 pyrolysis reaction occuring only on the surface of a
plate and beying
exclusively of the type flash craking type; and
- the stationary reactor is for example one of those
repesented in the Figures.
A second objet of the present invention is constituted by a system comprising:
a. a stationary reactor as defined in the present invention;
b. an internal or external heating system;
c. a charge of plates of consistent shapes;
d. means, such as spray nozzles, for directing 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;
f. means for recovering the reaction and straight run products; and
g. means for venting the gas obtained by the thermal processing outside the
stationary reactor zone.
The stationary reactor in the system has preferably a form that is about
parallelipepedic
or reactor has the form of a cylinder.
According to apreferred embodiment of the reactor, 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
36
CA 3019711 2018-10-02

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; and/or
- the gaseous stream resulting from the incomplete pyrolysis reaction of
celullosic material and/or of a mixture comprising more than 10 weigth percent

of long chain hydrocarbons, such as a mixture of cellusic materials and of
long
chain hydrocarbons such as used oils.
Advantageously, said mixture and said gaseous stream comprises mostly organic
compounds that may be transformed by thermal processing.
Preferably, 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.
37
CA 3019711 2018-10-02

Preferably, 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.
According to a preferred embodiment of the invention, 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.
According to another embodiment, 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).
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.
Advantageously, 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.
Advantageously , 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.
38
CA 3019711 2018-10-02

According to a preferred embodiment, 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. Advantageously, the supporting and/or

sliding mean(s) is (are) symmetrically attached to the internal wall of said
reactor.
Advantageously, 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.
According to a preferred embodiment of the pyrolysis system, the form of the
supporting and/or guiding means is selected in the group constituted by flat
or straigth
forms. Advantageously, the supporting and/or sliding means are about paralell
straight
guides.
According to another preferred embodiment, 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,
39
CA 3019711 2018-10-02

the sliding angle and the number of supporting and/or sliding means by square
meter
of the reactor's wall. Advantageously, the height or width of the supporting
means
ranges from 1 mm to the width of the plate. Preferably, 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 abs
be
rectangular, triangular, hexagonal or octagonal. The shape of the plates of
the charge
is advantageously about perfect. Preferably, all the plates present in the
stationary
reactor have about the same size and shape.
Accordingly, 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.
According to a preferred embodiment of the pyrolysis system, 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 00 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/cm3,
preferably
superior to 2,0 g/cm3 and more preferably the density of a plate is comprised
between
5,5 g/cm3 and 9,0 g/cm3.
CA 3019711 2018-10-02

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
conveyor(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.
In the pyrolysis system, 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.
According to a preferred embodiment of the pyrolysis system, 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:
41
CA 3019711 2018-10-02

- 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
- at least one rotating flail chain in permanent or temporary contact with
at least part of the surface of the reaction's support means wherein
pyrolysis takes place, and/or
- at least one ultrasonic means in permanent or temporary contact with
at least part of the surface of the reaction's support means in contact
with part of the surface of a reaction's supports wherein pyrolysis takes
place, and/or
- at least one directed blow means blowing air, with low content in
oxygen. or an inert gas in permanent or temporary contact with at least
part of the surface of a reaction's support 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:
- of the liquid feed type; and/or
- of the solid feed in form of small particulates type; and/or
- of the feeding stream liquid but containing solid particulates type,
advantageously, said spray nozzle are configured to spray, only the surface of

the reaction's support:
- drops of the liquid feeding oily stream having an average drop's size
of less than 10 mm, preferably of less than 5 mm, and more
advantageously lower than 2 mm, and/or
- 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
- a mixture of liquid and particulates with a ratio particulates/liquid
being in weight percent ranging from 5 to 95 %, preferably from 15 to
75 %,
42
CA 3019711 2018-10-02

preferably, 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; and/or
- gaseous stream resuting from the incomplete pyrolysis reaction of a
mixture of
cellulosic material. 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:
- a) feeding a stationary reactor and its internals as defined in the
present
invention with:
- said mixture, by spraying the mixture on at least part of the plates
surfaces during sliding of the plates on the supporting and/or on guiding
means, and
- optionally, a gaseous stream resuting from the incomplete pyrolysis
reaction of a mixture of cellusic materaial;
- b) heating the plates of said stationary reactor and its internals at a
temperature
corresponding to the thermal processing temperature of part of the mixture;
and
43
CA 3019711 2018-10-02

- c) recovering of the products resulting from the vaporizing and/or thermal
processing and for their elimination from said reactor;
wherein the mixture to be thermal processed is brought in contact with at
least part
of the surface of the plates of the charge and result in a reaction and/or
vaporization
of the feed and products allowing the removal of the mixture in the gas and
solids
phases, and
wherein at least part of the plates of the charge moves during the proces, and
wherein the gaseous stream resuting from the incomplete pyrolysis reaction of
a
mixture of celluosic material processed is brought in contact with at least
part of
the surface of the plates of the charge and result in a reaction and/or
vaporization
of the feed and products allowing the removal of the mixture in the gas and
solids
phases, and
wherein at least part of the plates of the charge moves during the process.
Advantageously, in 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.
Advantageously, the average residence time in the sationary reactor:
- a) is, when no gas stream resulting from incomplete pyrolysis of
hydrocarbons is injected in the reaction's zone of the stationary reactor,
44
CA 3019711 2018-10-02

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
- b) has a value, when a gas stream resulting from incomplete pyrolysis of
hydrocarbons is injected in the reaction's zone of the stationary reactor,
reduced by at least about 10 % when compared with the average residence time
according to a).
During performance of the process, the heating temperatnre 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 from150 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.
Advantageously, the pressure in the vertical stationary reactor ranges from 0
to 5,
preferably from Ito 2, more preferably range from 1,2 to 1,3.
When performing the process of the invention, 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.
According to a preferred embodiment of the invention, the various fractions
generated
by the thermal processing are recovered as follow:
- the liquid fraction is recovered by distillation
- the gaseous fraction is recovered by distillation; and
- 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.
CA 3019711 2018-10-02

The process of the invention is of a particular interest when :
a) the feedstock is solely used lubricating oil, thus:
- the amount of the recovered liquid fraction represents between 75%
and 100% weight of the organic reactor feed; and/or
- the amount of the recovered gaseous fraction represents between 0%
weight and 20% weight of the reactor feed; and/or
- the amount of the recovered solid fraction represents between 0%
weight and 25% weight, and
b) 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 ')/0 of the amount obtained in a).
The process may also be operated in a continuous or in a batch mode.
The process of the invention is of particular interest when used for:
- treating wastes oils such as used lubricating oils, form oils, metal
treating oils,
refinery or transportation oil tank bottoms; and/or
- destroying hazardous and/or toxic products; and/or
- reusing waste products in an environmental acceptable form and/or way;
and/or
- cleaning contaminated soils or beaches; and/or
- cleaning tar pit; and/or
- use in coal-oil co-processing; and/or
- recovering oil from oil spills; and/or
- PCB free transformed oils.
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

- a cetane index enhancer; and/or
- a drilling mud base oil or component; and/or
- a solvent or component of a solvent; and/or
46
CA 3019711 2018-10-02

- 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 component in asphalt blends; and/or
- a component of drilling fluids; and/or
- a component of flotation oils; and/or
- a component of dedusting oils.
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. Advantageously, 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 %.
47
CA 3019711 2018-10-02

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) an optional preliminary step wherein water content of the starting material
is
reduced preferably to a value lower than 55 % and/or wherein particulate size
has been reduced to a size ranging from 0,1 mm to 5 mm;
b) a thermal step wherein at least partial liquefying and at least partial
dewatering
of the starting material, eventually obtained in previous steps a) occurs,
wherein starting material is heated under:
- a pressure that is preferably ranging from 0,05 to I atmosphere and,
more preferably, this pressure is about absolute, and preferably is about
0,5 atmosphere, and
- at a temperature that is preferably lower than 300 degrees Celsius;
c) recovering of the liquid fraction resulting from step b), said liquid
fraction can
contain solid matters in suspension;
d) a pyrolysis step wherein:
- 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;
- preferably, with a reduced amount of oxygen present in the stationary
reactor; and
e) 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;
O a condensation and/or fractionation step to obtain liquid fuel and gas, and
48
CA 3019711 2018-10-02

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:
a) an optional preliminary step wherein water content of the starting material
is
reduced preferably to a value lower than 55 % and/or wherein stone and/or
metallic
content is reduced below 10 weight percent;
b)a thermal step wherein at least partial liquefying and at least partial
dewatering of the
starting material eventually obtained in previous steps a), occurs and wherein
starting
material is heated under:
- 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
- at a temperature that is preferably lower than 250 degrees Celsius;
c) recovering of the liquid fraction resulting from step b);
d) recovering unliquified solid fraction from step b);
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; and
f) a pyrolysis step wherein:
- liquid obtained in 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
- reaction and straight run products are recovered from the vertical
rotating reactor as solids and as a solid-gas mixture; and
g) a post treatment step wherein solid-gas mixture exiting the vertical
stationary
reactor is submitted to a solid-gas separation allowing the recovering
of substantially clean vapours and solids; and
49
CA 3019711 2018-10-02

h) 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 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; and
- 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;
b) 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;
c) 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;
d)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
o reaction and straight run products are recovered from the rotating kiln
as solids and as a solid-gas mixture;
e) 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; and
f) a condensation and/or fractionation step to obtain liquid fuel and gas, and
CA 3019711 2018-10-02

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.
Advantageously, starting material that are used in the process are waste
hydrocarbons
and/or organics material or a mixture of the two, wherein:
- solids present in starting material are broken into small pieces below
20 mm; and/or
- agglomerates are made of at least 75% by weight of organics or
hydrocarbons mixed with water; and/or
- metals and rocks have been sorted out from the agglomerate,
preferably by gravity and/or by magnetic separation; and/or
-the water content in the starting material is less than 87% as during the
(agglomeration) pelletizing part the water was taken out; and/or
- 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
- dewatering is done with drum dryers or belt dryers or settler to get to
a lower water content.
Advantageously, in 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; and
- liquefy more than 50 % of the heavier hydrocarbons and/or organics
present in
the starting material,
while managing cracking of the feedstock under treatment.
Advantageously, in step c): 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
51
CA 3019711 2018-10-02

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.
According to a preferred embodiment, in step c), 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.
Advantageously, in 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.
In step c): the water and lighter materials and lighter portion, only present
if some
material cracks, are advantageously separated from the heavier portion
allowing to
eliminate water and to recover lighter products which can be further separated
and
used as fuel. According to another preferred embodiment, in step d): the
liquefied and
entrained solids (resulting of step c) are directed to the vertical stationary
reactor,
preferably with added sweep gas, and/or preferably with an inert gas,
preferably
directly in the piping or conduit to treat them in a, preferably indirectly
fired, stationary
reactor operating preferably under positive pressure and/or preferably with a
pressure
control system; said indirectly fired stationary kiln having:
a. a heating system;
b. at least one plate moving inside the stationary reactor;
c. a charge of plates of consistent shapes;
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;
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,
52
CA 3019711 2018-10-02

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.
The transformation condition in the vertical stationary reactor are
advantageously at
least one of the followings:
- temperature range from 200 to 750 degrees Celsius;
- pressure lower than 5 atmospheres, preferably below 2 atmospheres, more
preferably about 1,1 atmospheres;
- residence times ranges from 1 second to 2 hours, preferably 5 seconds to
10
minutes, preferably about 3 minutes; and
- 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).
In step e), 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; and/or
- 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;
-
finally, the vapours are condensed and separated either in a distillation
column
or multiple condensers and/or in a flash drum.
The 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 ).
- viscosity below 80, advantageaously 40 cSt g 40 C, more preferably below
20 cSt @ 40 C, more preferably below 10 cSt @
40 C, more preferably
below 5 cSt @ 40 C, more preferably below 3 cSt @ 40 C;
53
CA 3019711 2018-10-02

- flash point as per ASTM D92 or D93 over 40 C (preferably after
fractionation);
- over 55 C for medium fraction (preferably after fractionation); and
- water content, as measured by ASTM D1533 below 25%, more preferably
below 15%, more preferably below 5% after fractionation.
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
% by weight or 10 to 20 % by weight of the feed mass flow rate entering the
stationary reactor.
15 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,
20 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.
Advantageously, 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.
54
CA 3019711 2018-10-02

Advantgaeously, at least one of the following components is used to reduce
solid
content in the feed stream: gaseous or liquid fraction recovered at the exit
of the
stationary vertical reactor in operation
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. Advantageously, thermal processing being performed on at least
part of
the surface of said plates in movement. Thermal prcoessing 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. Preferably, 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.
CA 3019711 2018-10-02

According to apreferred embodiment of the processes of the invention, 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, micro-
waves 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 external 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.
In the stationary reactor, 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.
Preferably,
each plate has a density that is superior to 2.0 g/cm3, preferably superior to
7.5 g/cm3
and more preferably comprised between 5.5 g/cm3 and 9.0 g/cm3.
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. According to a preferred embodiment, spray nozzles spray the
56
CA 3019711 2018-10-02

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 gray' ity 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.
Advantageously, 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 from100 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
57
CA 3019711 2018-10-02

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
L/W 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.
According to a preferred embodiment of the invention, 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.
58
CA 3019711 2018-10-02

According to another prefered embodiment of the processes of the invention,
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. Parameters of the process
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:
- a transit line connecting the two heated enclosures constituting of the
central
module and of the post-treatment module; and/or
- 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
- an extension of the combustion chamber surrounding the pyrolysis reactor
being connected with the post-treatment module, preferably by means of heat
transfer line(s).
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.
Advantageously, 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
59
CA 3019711 2018-10-02

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 representspreferably between 30%
and
90% weight of the reactor feed; and/or
CA 3019711 2018-10-02

- 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, and
when applied to plastic:
- the amount of the recovered liquid fraction, preferably, of the recovered
diesel
represents between 50 % and 90 % weight of the reactor feed; and/or
- 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; and/or
- the amount of the recovered solid fraction i.e of recovered coke
represents
between 2 and 40 % weight.
Advantageously, when used in the processes of the invention, the vertical
stationary
reactor 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. Preferably, 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.
When the feedstock is organic waste material The 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
61
CA 3019711 2018-10-02

- 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 additive to animal feed; and/or an insulator; and/or a humidity
regulator;
and/or
- an air decontaminator; and/or a protective element against
electromagnetic
radiation; 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 detoxification agent; and/or a carrier for active pharmaceutical
ingredients;
and/or
- an exhaust filter; and/or a semiconductor; and/or a therapeutic bath
additive;
and/or
- a skin cream additive; and/or a soap additive; and/or a substitute for
lignite;
and/or
- a filling for mattresses and/or pillows; and/or an ingredient in food;
and/or a
bio-oil for combustion; and/or chemicals such as acids, alcohols, aromatics,
aldehydes, esters, ketones, sugars, phenols, guaiacols, syringols, furans,
alkenes; and/or
emulsification agent for fuels; and/or
- refining secondary feeds et dedusting oils; and/or
a feed for steam reforming.
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
62
CA 3019711 2018-10-02

stationary reactor. In the managing systemof the invention, 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.
The following table I describe constituting elements of the stationary reactor
and of
corresponding pyrolysis system. Function, positionning and interactions with
other
components as well as the type of interactions are also reported with
references to
corresponding element numbers as apparent on various Figures. It is to be
considered
that the fonction associated with a constituent element of astyaionary reactor
and with
apyrolysis system of the envent applies to any corresponding feature previosly
defined
in its broadness in the previous general definition.
63
CA 3019711 2018-10-02

ID Name Function Position
Interacts Type of interaction
with
VR Vertical Location in which Seen in Figure
reactor thermal reactions take 2
place on heated plates
sliding on trays, in
which plates are fed to
and from the elevator.
Elevator Receives plates from the Seen in Figure
bottom of the vertical 2
reactor, heats them and
feeds them into the top
of the vertical reactor.
OPR One-piece Location in which Seen in Figure
reactor thermal reactions take 76
place on heated plates
sliding on trays, in
which trays are
conveyed from the
bottom-most tray to the
top-most tray and heated
on a conveyor system
which is located in the
same enclosure as the
trays and feed spray.
TC Top Prevents vapours within Before the
pressurise the reactor from entrance of
d chamber entering the elevator by plates into the
introducing a sweep gas reactor. Placed
into the chamber, while between the
allowing the flow of reactor and the
plates from the elevator elevator and
into the vertical reactor. above the
bottom
pressurised
chamber.
Seen in Figure
2
BC Bottom Prevents vapours within After the exit
pressurise the reactor from of plates out of
d chamber entering the elevator by the reactor.
introducing a sweep gas Between the
into the chamber, while reactor and the
allowing the flow of elevator and
plates from the vertical below the top
reactor into the elevator. pressurised
chamber.
64
CA 3019711 2018-10-02

Seen in Figure
2
Cl Cyclone 1 Removes solid material Within the B Removes solids
from
from the vapour-solid reactor exit the reactor
vapour
mixture (reactor vapour tube, before exit stream
(B)
exit stream) exiting the cyclone 2.
vertical reactor.
Seen in Figure
3
C2 Cyclone 2 Remove solid material Within the B Removes solids
from
from the vapour-solid reactor exit the reactor
vapour
mixture (reactor vapour tube, after exit stream (B)
exit stream) exiting cyclone I.
cyclone I.
Seen in Figure
3
Reactor Stream of feed material Seen in Figure
feed which may be 2
stream comprised of solids,
liquids, gasses or a
combination of at least
two of these, which is at
least partially
transformed during
thermal processing
inside the vertical
reactor
Reactor Stream of feed material
liquid feed comprised mainly of a
stream liquid, but may also
have entrained solids
and/or gasses, which is
sprayed onto hot plates
inside the vertical
reactor and/or the one-
piece reactor and is at
least partially
transformed during
thermal processing
Reactor Comprises of sweep Seen in Figure
vapour gas, vapours produced 2
exit stream from thermal reactions,
material fed into the
reactor that remains
untransformed, solid
material removed from
plates or any
combination of at least
two of these.
Reactor Vapours exiting the Seen in Figure
product cyclone(s) which have 3
stream at least slightly less
CA 3019711 2018-10-02

solid material than the
reactor vapour exit
stream
Screw Stream of solid material Seen in Figure
conveyor exiting the reactor solid 2
solid exit exit tube
stream
Cyclone Stream of solid material Seen in Figure
solid exit exiting the cyclone(s) 3
stream
Sweep gas Stream of sweep gas Seen in Figure
feed which enters at least one 2
stream of the sweep gas
entrance tubes to
provide a pressure
which prevents vapours
from exiting the vertical
reactor and/or the one-
piece reactor
X Exhaust Stream of gasses Seen in Figure
stream produced in and/or fed 2
into the elevator which
exit the exhaust tube.
May have entrained
solid material.
Horizontal Used for descriptive Seen in Figure
axis purposes 2
V Vertical Used for descriptive Seen in Figure
axis purposes 2
ES Empty Used for descriptive Seen in Figure
space purposes 5
a Angle of Used for descriptive Seen in Figure
the top purposes 37
pressurise
d chamber
13 Angle of Used for descriptive Seen in Figure
the bottom purposes 41
pressurise
d chamber
Angle of a Used for descriptive Seen in Figure
plate purposes 39
Low angle Used for descriptive Seen in Figure
of the purposes 2
reactor
floor
Steep Used for descriptive Seen in Figure
angle of purposes 69
reactor
floor
(1) Angle of a Used for descriptive Seen in Figure
tray purposes 14
66
CA 3019711 2018-10-02

A Reactor Used for descriptive Seen in Figure
height purposes 2
excluding
the section
below the
bottom-
most tray
Reactor Used for descriptive Seen in Figure
length purposes 2
Reactor Used for descriptive Seen in Figure
width purposes 5
Height of a Used for descriptive Seen in Figure
tray wall purposes 49
Height of a Used for descriptive Seen in Figure
tray guide purposes 49
Length of Used for descriptive Seen in Figure
a tray purposes 49
Width of a Used for descriptive Seen in Figure
tray purposes 49
Width of a Used for descriptive Seen in Figure
tray wall purposes 49
Width of a Used for descriptive Seen in Figure
tray guide purposes 49
o Thickness Used for descriptive Seen in Figure
of a purposes 52
scraper bar
Length of Used for descriptive Seen in Figure
a scraper purposes 52
bar
2 Reactor Allows the flow of the On the ceiling
exit tube reactor vapour stream of the reactor.
and/or reactor product
stream out of the Seen in Figure
vertical reactor and/or 2
one-piece reactor to be
processed further
downstream
3 Reactor Angled floor which Seen in Figure 16, 4 Directs
solid material
floor allows solid material 2 (16) to the
reactor
which falls on said floor solid exit
tube (4)
to be directed towards
the reactor solid exit
tube and fall into said
tube, in which said
material is pushed out of
the vertical reactor
and/or one-piece reactor
via a screw conveyor
4 Reactor Allows the flow of solid Attached to
solid exit material out of the and centered
tube vertical reactor and/or along the
one-piece reactor. reactor floor
67
CA 3019711 2018-10-02

Location in which the
reactor screw conveyor Seen in Figure
housed. 2
Reactor Allows flow of sweep Within the
sweep gas gas into the vertical reactor solid
entrance reactor and/or one-piece exit tube.
tube reactor through the
reactor solid exit tube so Seen in Figure
that vapours within said 2
reactor do not exit said
reactor through the
reactor solid exit tube
6 Reactor Location on
which Seen in Figure 11, 10 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
7 Reactor Location on
which Seen in Figure 11, 10 Trays (11) may be
right wall plates can bounce off of 2
attached. Plates (10)
when transitioning
may bounce off when
between trays. Trays transition ing
may be attached between trays
8 Reactor Seen in Figure
ceiling 2
9 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)
Plate Location on which Seen
in Figure 10, 11, Plates (10) slide on
thermal processing 4
6, 7, 22, trays (11) and bounce
occurs. Plates are heated
23, 91, off the left and right
in the elevator by
97, 98, reactor walls (6, 7)
burner(s) and/or
92, 93, while transitioning
inductive heater(s) 94,
9, between trays. They
and/or are heated in the
12, 52, may be flipped by
conveyor system by
64, 40, flipper(s) (22) and/or
inductive heater(s).
49, 16, flipping tray(s) (23)
54, 53, while transitioning
When falling off the 42, 30, between trays.
conveyor system, the 33
plates land on tray(s)
Guides (91), center
and descend the one-
guide(s) (97), guide
68
CA 3019711 2018-10-02

______________________________________________________________________________
-
piece reactor by sliding plate(s) (98),
scraper
on said tray(s). bar(s) (92),
scraper
mesh(es) (93) and/or
When falling off the punctured
scraper(s)
elevator system, they (94) scrape
the
land on the top bottom surface
of the
pressurised chamber plates as they
slide on
floor and slide into the the trays. The
plates
top pressurised chamber slide through
the
by passing through the reactor
entrance door
top pressurised chamber (9), the
reactor exit
entrance door, which door (12), the
bottom ,
may remove at least part pressurised
chamber
of the solid material exit door (52)
and the
located on the top top
pressurised
surface of said plates. chamber
entrance
They continue to slide door (64),
which
on said floor within the scrape the top
surface
top pressurised chamber of the plates.
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.
Within the vertical When scraped,
at
reactor and/or one-piece least part of
the solid
reactor, 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.
located on the bottom
surfaces of said plates Within the
elevator,
removed by guides, they are
lifted by
center guide(s), guide lifters
(54) and
plate(s), scraper bar(s), supports (53)
and
scraper mesh(es) and/or scrape along
the left
punctured scraper(s). elevator wall
(42)
During the plates' while they
ascend
decent, reactor feed said elevator.
Within
material and/or feed the one-piece
reactor,
spray contacts said they land on
the
plates, causing said feed conveyor belt
(30)
to thermally react to and are pushed
form pyrolysis vapours upwards by
conveyor
and char, plate supports
(33).
69
CA 3019711 2018-10-02

When transitioning Plates are
heated by
between trays, the plates burner(s) (63)
and/or
hit the left or right inductive
heater(s)
reactor wall or flip via (66)
the means of flippers or
flipping plates.
As plates slide off the
bottom-most tray of the
one-piece reactor, they
land on a conveyor
system which heats said
plates and bring them to
the top-most tray of said
reactor.
As plates slide off the
bottom-most tray of the
vertical reactor, they
pass through the bottom
pressurised chamber
entrance door, which
may remove at least part
of the solid material
located on the top
surface of said plates,
and slide on the bottom
pressurised chamber
floor into the bottom
pressurised chamber.
They continue to slide
on said floor within the
bottom pressurised
chamber and enter the
elevator by passing
through the bottom
pressurised chamber
exit door, which may
remove at least part of
the solid material
located on the top
surface of said plates.
11 Tray Allows plates to be Within
the 10, 12, Allows plates (10) to
directed downwards reactor, placed 36 slide
downwards
towards the reactor exit in sequence towards
inside the
door and/or conveyor and spaced vertical
reactor (VR)
system. 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
CA 3019711 2018-10-02

object from falling to another
towards the conveyor
through the tray. At least during their system (36).
one of these guide walls descent in the
may be a wall of the vertical reactor
reactor. May have and/or one-
empty space to allow the piece reactor.
feed stream and/or Attached to at
liquid feed stream to least one
contact the bottom reactor wall.
surface of the plates Angled
sliding on said tray. Said downwards
empty space may also from the
allow the flow of vapors horizontal axis
and/or solid material towards the
through the reactor. central
symmetrical
axis such that
plates can
slide via
gravitational
forces.
Seen in Figure
4
12 Reactor Allows plates to pass Near
the 10, BC, Allows plates (10) to
exit door through the door from bottom of the VR, 16, enter the
bottom
the reactor into the reactor, 25
pressurised chamber
bottom pressurised directly
next to (BC) and exit the
chamber. Also scrapes the bottom-
vertical reactor (VR).
the top surface of the most section
Scrapes the surface
plates which pass of the bottom-
of said plates which
through it which may most tray.
may remove at least
remove at least part of
part of the solid
the solid material on Seen in Figure
material (16) on said
said surface. 4 surface.
Rotates
along the reactor exit
door axis of rotation
(25)
13 Reactor Turns within the reactor Within
the S, 4 Pushes the screw
screw solid exit tube to push reactor solid
conveyor solid exit
conveyor solids out of the reactor. exit tube.
stream (S) out of the
reactor solid exit tube
Seen in Figure (4).
4
14 Reactor Location on which the Seen in Figure 11
Trays (1 1 ) may be
back wall tray(s) may be attached 5 attached
15 Reactor Location on which the Seen in Figure II
Trays (11) may be
front wall tray(s) may be attached 5 attached
16 Solid Solid material which is Seen in Figure 10, 91, Solid
material (16)
material entrained into
the 65 97, 98, fed into the vertical
reactor with the reactor
92, 93, reactor and/or one
feed stream and/or
94, 40, piece reactor and/or
71
CA 3019711 2018-10-02

liquid feed stream 49, 3, 4, formed on
the
and/or is formed during VR,
surfaces of the plates
thermal reactions. Is OPR, B, (10), which
is
removed from the
13, E, scraped off by
surfaces of the plates X, 65
guide(s) (91), center
and fed out of the
guide(s) (97), plate
vertical reactor, elevator
guide(s) (98), scraper
and/or one piece reactor
bar(s) (92), scraper
by being pushed by a mesh(es)
(93),
screw conveyor or by
punctured scraper(s)
being entrained with a
(94), the bottom
stream exiting the
pressurised chamber
vertical reactor, elevator
floor (40) and/or the
and/or one piece reactor. top
pressurised
chamber floor (49).
Solid material removed
that falls on the reactor
Solid material which
floor is directed into the
lands on the reactor
solid exit tube due to the
floor (3) is directed
angle of said floor,
into the reactor solid
exit tube (4)
Entrained out of the
vertical reactor (VR)
and/or one piece
reactor (OPR) by
being entrained by
the reactor vapor exit
stream (B) and/or by
being pushed the
reactor
screw
conveyor (13).
Entrained out of the
elevator (E) by being
entrained by the
exhaust stream (X)
and/or by being
pushed by the
elevator
screw
conveyor (65)
17 Reactor Used for descriptive Seen in Figure
central purposes 4
symme-
trical axis
18 Vertical Used for descriptive Seen in Figure
center of purposes 69
the reactor
left wall
19 Feed spray Spray of liquid feed Seen in Figure 27, 10
Sprayed from
material produced by 65 nozzles
(27).
nozzles which contact
Contacts plates (10)
72
CA 3019711 2018-10-02

the plates and undergo and
undergoes
thermal reactions thermal
reactions.
20 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).
Attached to
another tray.
Seen in Figure
6
21 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.
rotation, the plate can
pass through said door. Seen in Figure
11
22 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)
Seen in
Figure 12
23 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.

directly below the
flipping tray.
_
24 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
downwards towards the reactor wall.
73
CA 3019711 2018-10-02

subsequent flat tray,
despite the verticality of Seen in Figure
the plates which fall on 13
them.
25 Reactor Allows the reactor exit Located at the 12 Allows
the rotation
exit door door to rotate when a top of the of the reactor
exit
axis of plate pushes on said
reactor exit door (12)
rotation door. Through this door.
rotation, the plate can
pass through said door. Seen in Figure
20
26 Flipper Allows the flipper to Located in the 22 Allows the
rotation
axis of rotate. Through this
center of a of a flipper (22)
rotation rotation, the flipper flipper, which
picks up plates from a is the point of
tray and flips them. intersection of
each of said
flipper's arms.
Seen in Figure
12
27 Nozzles Sprays liquid feed Located -- on 10
-- Sprays liquid on the
towards the plates in either wall of plates (10).
order for said liquid feed the vertical
to make contact with the reactor and/or
surface of the plates. one piece
Thermal reactions occur reactor and
due to said contact of directed
liquid feed onto the towards the
surface of the plates. plates which
slide on trays.
Seen in Figure
Not
represented as
being present
on every wall
of the reactors
28 Bottom of Scrapes the top surface Not shown 10 Scrapes the
top
the reactor of the plates surface of the
plates
entrance (10)
door
29 Bottom- Used for descriptive Shown in
most purposes Figure 5
extremity
of a tray
30 Conveyor Object which moves due Near the right 10 Transports
plates
belt to the conveyor drivers wall of the (10) by
allowing said
and is equipped with reactor, placed plates to rest
on the
conveyor support plates. below the
74
CA 3019711 2018-10-02

Allows plates to rest bottom-most belt while
in
against it and move the tray and above movement
plates from the bottom- the top-most
most tray to the top- tray.
most tray
Seen in Figure
79
31 Conveyor Equipped with a motor, Between the 30 Enables
the
driver it drives the movement conveyor belt, movement of the
of the conveyor belt located at the conveyor belt
(30)
extremities of
the conveyor
and in areas
where the
conveyor
angle is
changing
Seen in Figure
79
32 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
wall vapours and/or solid inductive
material. heater
Seen in Figure
79
33 Conveyor Supports plates as they Perpendicular 10, 30
Supports the plates
plate ascent the conveyor to the (10) on the
conveyor
support conveyor belt, belt (30),
preventing
spaced out them from
falling.
from one Attached to the
another along conveyor belt
said conveyor
belt.
Seen in Figure
79
34 Internal Location on which Seen in
Figure 10, 11 Plates (10) hit the
left wall plates can bounce off of 79 wall and fall
onto a
when sliding off the tray (11) below
trays
35 Internal Wall on which inductive 66 Wall on
which
right wall heater is attached inductive
heater (66)
is attached
36 Conveyor Allows plates to be On the right 10, 11 Transports
plates
system brought from the side of the (10) from the
bottom-most tray to the one-piece bottom-most
tray
top-most tray, while reactor, (11) to the top-
most
allowing for the plates positioned tray and heats
them
to be heated such that during their
ascent.
CA 3019711 2018-10-02

plates which
fall off the
bottom-most
tray land on
said system
and are carried
to the top-most
tray.
Seen in Figure
79
40 Bottom
Allows plates and other Floor of the 10, VR, Allows plates (10) to
pressurise solids to slide on it and bottom BC, E, slide from
the
d chamber pass through the bottom pressurised 16, 73
vertical reactor (VR)
floor pressurised chamber chamber, into
bottom
into the elevator. May leading to the
pressurised chamber
scrape the bottom elevator
(BC) and into the
surface of the plates and system
elevator (E). May
remove at least part of
scrape the bottom
the solid material from Seen in Figure
surface of the plates
said surface. Allows 3
and remove at least
plates to fall off said
part of the solid
floor and onto the
material (16) from
elevator system
said surface. Allows
plates to fall onto the
______________________________________________________________ elevator
system (73)
41 Bottom Allows the flow of Located within G, BC
Allows the passage
pressurise sweep gas into the the bottom
of sweep gas (G) into
d chamber bottom pressurised pressurised the
bottom
sweep gas chamber so that the chamber.
pressurised chamber
entrance pressure within said (BC)
tube chamber can increase Seen in Figure
and become larger than 3
the pressure within the
vertical reactor, thus
preventing the flow of
vapours from said
reactor into said
chamber.
42 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
without falling off the
lifters and supports.
76
CA 3019711 2018-10-02

If the elevator has an
inductive heater, wall
acts simply as an
enclosure and the plates
lean on the inner coil
wall instead.
43 Elevator Location on which Seen in Figure
right wall burners may be placed 3
44 Elevator Seen in Figure
ceiling 3
45 Elevator Allows the solids within Location on
floor the elevator to fall on the which at least
elevator floor and be part of the
pushed out of said elevator screw
elevator by the elevator conveyor is. Is
screw conveyor, attached to
the
Location in which the elevator solid
elevator screw conveyor exit tube
is.
Seen in Figure
3
46 Elevator Allows flow of solids Located at the
solid exit out of the elevator, bottom of the
tube Location in which at elevator,
least part of the elevator attached to the
screw conveyor is elevator floor.
located. Location in
which at least
part of the
elevator screw
conveyor is.
Seen in Figure
3
47 Bottom Allows plates to be Located 10 Does not
interfere
slanted carried upwards through directly above with the
plates (10)
elevator the elevator without the bottom- movement
wall getting suck between the most end of
corner of the wall the bottom
directly above the pressurised
bottom pressurised chamber
floor.
chamber floor and the
support and/or lifter Seen in Figure
directly below the plate 3
which is being carried
upwards.
48 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
pressurised chamber pressurised
floor. This is prevents chamber floor.
77
CA 3019711 2018-10-02

the plates from getting
stuck in between the Seen in Figure
corner of the wall 3
directly above the top
pressurised chamber
floor and the support
and/or lifter directly
below the plate which is
sliding on to the top
pressurised chamber
floor.
49 Top Allows plates and
Seen in Figure 10, 73, Allows plates (10) to
pressurise possibly other solid 3
TC, 11, slide off the elevator
d chamber material to slide on it VR
system (73) onto the
floor and pass from the top
pressurised
elevator, through the top
chamber floor, into
pressurised chamber
the top pressurised
and into the reactor. chamber (TC) and
onto the first tray
(11) of the vertical
reactor (VR).
50 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
tube increase and become Seen in Figure
larger than the pressure 3
within the vertical
reactor, thus preventing
the flow of vapours
from said reactor into
said chamber.
- 51 Exhaust Allows the gasses
Located within X Allows the passage
tube within the elevator to the elevator,
of the exhaust stream
exit said elevator. (X)
Seen in Figure
3
52 Bottom Allows
plates to pass Located along 10, BC, Allows plates (10) to
pressurise through the door from the bottom 69 exit
the bottom
d chamber the bottom pressurised pressurised
pressurised chamber
exit door chamber into the chamber floor,
(BC) and scrapes the
elevator. Also scrapes after the
surface of said plates.
the surface of the plates reactor exit
Rotates along the
which pass through it. door and also
bottom pressurised
after the
chamber exit door
bottom axis of
rotation (69)
pressurised
chamber
sweep gas
entrance tube.
78
CA 3019711 2018-10-02

Seen in Figure
9
53 Support Part of the elevator Located along 10, 53, Plates (10)
rest on the
which move upwards the inner and 56, 55 supports (53)
while
and give a place for outer support ascending
the
plates to rest on while chains within elevator,
thus
they are carried through the elevator, carrying them.
The
the elevator. They move support is
carried by
at a speed slower than Seen in Figure the support
inner
the movement of the 9 chain (56) and
the
lifters, thus allowing the support outer
chain
angle of the plates to (55).
change as the ascent the
elevator.
54 Lifter Part of the elevator Located along 10, 58, Plates (10)
rest on the
which move upwards the inner and 57 lifters (54)
while
and catch the plates as outer lifter ascending
the
the slide off the bottom chains within elevator,
thus
pressurised chamber the elevator, carrying them.
The
floor. The length of the lifter is
carried by the
bottom part of the lifters Seen in Figure lifter inner
chain (58)
is such that the plates 9 and the lifter
outer
have a tendency of chain (57).
falling off the lifter and
onto the support beside
said lifter. They also
provide a surface on
which plates can rest on
while they are carried
through the elevator.
They move at a speed
faster than the
movement of the
supports, thus allowing
the angle of the plates to
change as the ascent the
elevator.
55 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
pulleys.
Placed further
from the
center of said
pulleys
relative to the
support inner
chain and
positioned
such that the
79
CA 3019711 2018-10-02

supports
attached to
these inner and
outer support
chains can
move along
the elevator
system
without having
their
movement
hindered
Seen in Figure
9
56 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).
support
pulleys.
Placed closer
to the center of
said pulleys
relative to the
support outer
chain and
positioned
such that the
supports
attached to
these inner and
outer support
chains can
move along
the elevator
system
without having
their
movement
hindered
Seen in Figure
9
57 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).
bottom parts are pulleys. Placed
attached to this chain. further from
the center of
said pulleys
CA 3019711 2018-10-02

relative to the
lifter inner
chain and
positioned such
that the lifters
attached to
these inner and
outer lifter
chains can
move along the
elevator system
without having
their
movement
hindered
Seen in Figure
9
58 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).
back parts are attached pulleys. Placed
to this chain. closer to the
center of said
pulleys relative
to the lifter
outer chain and
positioned such
that the lifters
attached to
these inner and
outer lifter
chains can
move along the
elevator system
without having
their
movement
hindered
Seen in Figure
9
59 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).
through the elevator bottom
system. pressurised
chamber floor.
81
CA 3019711 2018-10-02

Seen in Figure
9
60 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).
lifters through the part of the
elevator system. bottom
pressurised
chamber floor.
Seen in Figure
9
61 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 top- chain (56)
and
chains, thus moving the most part of support outer
chain
supports through the the top (55).
elevator system. pressurised
chamber floor.
Seen in Figure
9
62 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).
lifters through the the top
elevator system. pressurised
chamber floor.
Seen in Figure
9
63 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)
64 Top Allows plates to pass Located along 10, TC, Allows
plates (10) to
pressurise through the door from the top 70 enter the
top
d chamber the elevator into the top pressurised pressurised
chamber
entrance pressurised chamber. chamber floor,
(TC) and scrapes the
door Also scrapes the surface before the top surface of
said
of the plates which pass reactor plates. Rotates
along
through it. entrance door the top
pressurised
and also chamber exit
door
before the top axis of rotation (70)
82
CA 3019711 2018-10-02

pressurised
chamber
sweep gas
entrance tube.
Seen in Figure
9
65 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).
elevator solid
exit tube.
Seen in Figure
9
66 Inductive Inductive heater in Located 10
Heats plates (10).
heater which current is passed between the
in order to produce a inner coil wall
magnetic field which and the outer
ultimately heats the coil wall
plates which are carried within the
upwards through the elevator.
elevator.
Located
The inductive heater is between the
represented as a long inductive
cylindrical coil, but may heater
also be in the form a protective wall
series of flat induction and the
coils. internal right
wall within the
one piece
reactor.
Seen in Figure

67 Inner coil Allows plates to lean Located within 10, 42, Plates
(10) scrape
wall against the wall while the elevator, E,
16, along the elevator
ascending the elevator, below the top 66 left wall (42)
when
thus allowing the angle pressurised ascending
the
of the plates to change chamber floor elevator and
said
during said ascent and above the
wall prevents pates
without falling off the bottom slanted from falling
off the
lifters and supports. elevator wall. elevator (E)
Also protects the
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)
83
CA 3019711 2018-10-02

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.
68 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
inductive
heater.
Seen in Figure

69 Bottom Allows the bottom Located at the 52 Allows the
rotation
pressurise pressurised chamber top of the
of the bottom
d chamber exit door to rotate when bottom pressurised
chamber
exit door a plate pushes on said pressurised exit door (52)
axis of door. Through this
chamber exit
rotation rotation, the plate can door.
pass through said door.
Seen in Figure
36
70 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.
rotation rotation, the plate can
pass through said door. Seen in Figure
40
71 Bottom Seen in Figure
pressurise 9
d chamber
ceiling
72 Top Seen in Figure
pressurise 9
d chamber
ceiling
73 Elevator Conveys plates which Seen in Figure 10, 40, Conveys
plates (10)
system fall off the bottom 45 49 which fall off
the
pressurised chamber bottom
pressurised
floor up to the top chamber floor
(40)
pressurised chamber up to the top
floor via the use of pressurised
chamber
lifters and supports floor (49)
74 Right- Used for descriptive Seen in Figure
most purposes 9
extremity
of the top
pressurise
84
CA 3019711 2018-10-02

d chamber
floor
75 Right- Used for descriptive Seen in Figure
most purposes 9
extremity
of the
bottom
pressurise
d chamber
floor
76 Center of Used for descriptive Seen in Figure
the purposes 45
elevator
system
77 Flames Heats plates Seen in Figure 63, 10 Exits from
burners
9 (63) and heats
plates
(10)
80 Flipper Arm of a flipper which Attached to 10, 22
Provides a surface
arm rotates along the the center
of for plates (10) to rest
flipper's axis of rotation of a on while
being
rotation. As the flipper flipper, flipped by a
flipper
arm rotates, plates can (22).
be carried, and thus Seen in Figure
flipped. The flipper arm 46A
preferably has a gap in
its center to allow the
passage of solids and
vapours to enter contact
with the plates being
flipped.
81 Tip of a Extrusion at the Located at the 10 22 Provides
a surface
flipper arm extremity of a flipper extremity of a for plates (10)
to rest
arm on which plates can flipper arm. on while
being
rest while being flipped, flipped by a
flipper
This extrusion allows Seen in Figure (22).
for more surface area of 46A
the plates to be available
while said plates are
being flipped and to
allow for vapors, and
possibly entrained
material, to pass through
the arm during its
rotation while a plate is
being flipped on said
arm.
82 Front of a Used for descriptive Seen in Figure
flipper tip purposes 46B
83 Top of a Used for descriptive Seen in Figure
flipper tip purposes 46B
84 Back of a Used for descriptive Seen in Figure
flipper arm purposes 46B
CA 3019711 2018-10-02

85 Left side Used for descriptive Seen in Figure
of a flipper purposes 47
arm
86 Left side Used for descriptive Seen in Figure
of the front purposes 46B
of a flipper
arm
87 Right side Used for descriptive Seen in Figure
of the front purposes 46B
of a flipper
arm
90 Wall of a Wall which prevents the Located at the 10, 11
Prevents the plates
tray plates sliding on the back and front
(10) sliding on the
trays to deviate from of a tray.
trays (11) to deviate
their path. from their
path
Seen in Figure
48
91 Guide of a Part of the tray on which Located
in 10, 11, Allows plates (10) to
tray plates can slide, between
the 16 slide on the trays ( 1 1)
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
48
material (16) from
said plate.
92 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.
to leave room
for fluids
and/or solids
to pass
through the
tray. Also, if
flippers are
present, they
are not placed
in the way of
the flipper
arms attached
to said tray
and/or the
flipper arms
attached to the
86
CA 3019711 2018-10-02

_
_____________________________________________________________________________
tray directly
above said
tray.
Seen in Figure
48
_
_____________________________________________________________________________
93 Scraper Mesh which scrapes the Located
in 10, 93, Scrapes the surface
mesh bottom surface of the between the 16
of the plates (10)
plates while said plates guides of the sliding over the
slide on the tray to tray. Also, if scraper mesh (93) to
which the scraper bar is flippers are
remove at least part
attached. present, they
of the solid material
are not placed (16) from said
in the way of surface.
the flipper
arms attached
to said tray
and/or the
flipper arms
attached to the
tray directly
above said
tray.
Seen in Figure
50
94 Punctured Surface comprising Located
in 10, 94, Scrapes the surface
scraper holes which scrapes the between
the 16 of the plates (10)
bottom surface of the guides of the sliding over the
plates while said plates tray. Also, if punctured scraper
slide on the tray to flippers are
(94) to remove at
which the scraper bar is present, they least part of the solid
attached. are not placed
material (16) from
in the way of said surface.
the flipper
arms attached
to said tray
and/or the
flipper arms
attached to the
tray directly
above said
tray.
Seen in Figure
51
95 Start of Used for descriptive
Located on the
guides purposes left or right
wall on which
the curved tray
is attached.
87
CA 3019711 2018-10-02

Seen in Figure
55
96 End of Used for descriptive Located
curve purposes between the
curved trays
and the flat
trays which
are attached
together.
Seen in Figure
55
97 Center Additional guide placed Placed along 10, 16 Provides
a surface on
guide between both guides of the length of a which plates
(10) can
a tray which provides an tray, at the slide. May
scrape the
additional surface on same height of bottom surface
of the
which the plates can the guides of plates and
remove at
slide, which reduces the said tray. least part of
the solid
stress on the guides of a material (16)
from
tray which are attached Seen in Figure said surface
to the walls of a tray. 5
May also scrape the
bottom surface of the
plates and remove at
least part of the solid
material from said
surface.
98 Guide Provides a larger surface Placed along 10, 16
Provides a surface on
plate on which plates can the bottom of a which plates
(10) can
slide and replaces the tray. slide. May
scrape the
use of guides of a tray. bottom surface
of the
Does not allow the Seen in Figure plates and
remove at
passage of fluids. 5 least part of
the solid
material (16) from
said surface
100 Bottom Bottom part of the lifter Bottom part of 10, E
Carries the plates
end of a on which the plate being the lifter, (10) upwards
through
lifter lifted can rest on. It is angled and the elevator
(E).
angled such that plates pointing
have a crevice to rest in. towards the
supports,
attached to the
outer lifter
chain.
Seen in Figure
59
101 Back end Back part of the lifter Back part of 10, 45, Prevents
the plates
of a lifter which prevents the plate the lifter, E
(10) from falling
being lifted from falling which is onto the
elevator
off. Also prevents plates directed along floor (45).
Also
which fall off the carries the
plates
88
CA 3019711 2018-10-02

bottom pressurised the inner
lifter upwards through the
chamber floor from chain. elevator (E).
passing the lifters and
falling onto the elevator Seen in Figure
floor. 59
102 Top of Used for descriptive
Seen in Figure
bottom purposes 59
end of a
lifter
103 Front of a Used for descriptive Seen in Figure
bottom purposes 60
end of a
lifter
104 Bottom of Used for descriptive Seen in Figure
a bottom purposes 60
end of a
lifter
105 Side of a Used for descriptive Seen in Figure
bottom purposes 59
end of a
lifter
106 Front of Used for descriptive
Seen in Figure
the back purposes 60
end of a
lifter
107 Back of Used for descriptive
Seen in Figure
the back purposes 59
end of a
lifter
108 Side of the Used for descriptive Seen in Figure
back end purposes 59
of a lifter
109 Top of the Used for descriptive Seen in Figure
back end purposes 59
of a lifter
110 Body of a Main part of the support Main part of 10, E Carries
the plates
support on which plates can rest the support (10) upwards
through
on while being carried located along the elevator
(E).
upwards through the the inner and
elevator, outer support
chains.
Seen in Figure
61
111 Arm of a Part of a lifter which Attached to 10, E Carries
the plates
support allows extra space for the body of a (10) upwards
through
the plate to rest on while support, the elevator
(E).
said plate rests on the angled and
lifter carrying said plate. pointing in the
direction of
the lifters.
89
CA 3019711 2018-10-02

Seen in Figure
36
112 Top of the Used for descriptive Seen in Figure
body of a purposes 61
support
113 Side of the Used for descriptive Seen in Figure
body of a purposes 61
support
114 Top of the Used for descriptive Seen in Figure
arm of a purposes 61
support
115 Side of the Used for descriptive Seen in Figure
arm of a purposes 61
support
116 Front of Used for descriptive
Seen in Figure
the arm of purposes 61
a support
117 Angle of Used for descriptive Seen in Figure
the arm of purposes 61
a support
120 Peg of a Peg which hooks on to Attached 55, 56, Pulls the
lifter and
pulley the inner and outer along the inner 57, 58 support
outer and
support chains and inner and outer rings inner chains
(55, 56,
and outer lifter chains, of the top and 57 and 58).
Moves with the bottom lifter
movement of the pulley and support
to which it is attached. pulleys.
Seen in Figure
63A
121 Outer ring Outer ring of pegs Ring of pegs 55, 57 Pulls the
lifter and
of a pulley which pull on the outer located close support outer
chains
support/lifter chains, to the edge of a (55 and 57).
pulley.
Seen in Figure
63B
122 Inner ring Inner ring of pegs which Ring of pegs 56,58 Pulls
the lifter and
of a pulley pull on the outer located closer
support inner chains
support/lifter chains, to the center of (56 and 58).
pulley relative
to the outer
ring of said
pulley.
Seen in Figure
63B
130 Top Used for descriptive Seen in Figure
surface of purposes 73
a plate
CA 3019711 2018-10-02

131 Bottom Used for descriptive Seen in Figure
surface of purposes 74
a plate
132 Front Used for descriptive Seen in Figure
surface of purposes 73
a plate
133 Back Used for descriptive Seen in Figure
surface of purposes 74
a plate
134 Right Used for descriptive Seen in Figure
surface of purposes 73
a plate
135 Left Used for descriptive Seen in Figure
surface of purposes 74
a plate
136 Top right Used for descriptive Seen in Figure
edge of a purposes 73
plate
91
CA 3019711 2018-10-02

EXAMPLES
The following example is given as a matter of exemplification only and may not
be
interpreted as bringing any restriction to the definition of the invention in
its broadest
scope.
Example 1: treatment of a used oil
Set-up - The vertical reactor (VR), according to the embodiment illustrated
in Figure
65, is used to thermally treat 16 L/h of used oil comprised of used
lubricating oils as
well as other oily streams such as metal working oils, transmission fluids,
greases,
form oils, and any number of unknown waste oil streams. About 5 wt% steam was
injected into this feed stream prior to being sprayed onto the plates.
In the case of the present example, as seen in Figure 2, the reactor has a
height of 252.3
cm, a length of 104 cm and a width of 11 cm. Its walls (6, 7 14, 15), floor
(3) and
ceiling (8) are made of 304L stainless steel. Said reactor is connected to an
elevator
(E) according to the embodiment illustrated in Figure 9. The walls (42, 43),
floor (45)
and ceiling (44) of said elevator (E) are made of 304L stainless steel. All
the piping is
also made of 304L stainless steel.
The reactor is designed to hold about 21 plates (10) at a time. Said plates
are made of
304L stainless steel and have a length (not shown) of 20 cm, a width (not
shown) of
10 cm and a height (not shown) of 0.4 cm. They are pos;tioned lengthwise along
the
length (f) of the trays (11). The reactor had an operating at atmospheric
pressure and
an operating temperature of 490 C.
The products obtained from the thermal treatment of the used oil is summarised
in
Table 2 below. All product yields are calculated on a dry oil basis. As seen
in Figure
4, the floor (3) of the reactor is angled (r) at 10 downwards towards the
center
symmetrical axis (17) of the reactor (VR), which leads to the reactor solid
exit tube (4)
located in the center of said floor.
92
CA 3019711 2018-10-02

Test Method Units Fee Gas Naphth Gaso Heav Coke
a il y Oil &
Oil Solid
Weight % on Dry Oil 100 5.3 8.0 56.5 20.6 9.6
Feed
Density ASTM g/m1 0.89 0.758 0.866 0.933 1.4
* 15C D4052
Molecula g/mole 36.7
r Weight
Water ASTM Volum 5.7 0.7
D1533 e%
Metals Digestion ppm 216 3 240 2555
& ICP-IS Weigh 0 0
Sulphur LECO Weigh 0.63 0.003 0.05 0.26 0.91 2.63
S32 t 7
Halogens Oxygen ppm 470 192 84.3 5 219
bomb Weigh
Combusti t
on
Viscosity ASTM cSt 33.6 2.11 77.1
@ 40C D445
Copper ASTM 1 a
Strip D120
Corrosio
Sediment ASTM mg/ml 128 0.5 0.05
D2276
Flash ASTM C 3.34 48 <100
Point D92
CCR ASTM Weigh 0.4 1.01
D189 t%
Ash ASTM I Weigh 0.01 0.05 7.43
D4422 & t%
ASTM D
482
pH
Distillatio ASTM Weigh
D2887 t %
IBP C 162 30 110 338
10% C 246 47 156 374
50% C 414 98 255 436
90% C 528 133 355 525
EP C 592 157 419 589
The solid exit tube has a circular entrance having a diameter of 5 cm. The
diameter of
the tube in which the reactor screw conveyor (13) is located is also 5 cm. The
screw
conveyor has a diameter of about 4 cm and is positioned on the bottom of the
reactor
solid exit tube to push solid material (16) out of the reactor, while leaving
space above
93
CA 3019711 2018-10-02

the screw conveyor for the sweep gas (G) to enter said reactor through said
solid exit
tube, which can be seen in Figure 2. The reactor sweep gas entrance tube (5)
also has
a diameter of 5 cm. he sweep gas (G) which is fed into the reactor sweep gas
entrance
tube (5), the bottom pressurised chamber sweep gas entrance tube (41) and the
top
pressurised chamber sweep gas entrance tube (50) is steam. The feed rate of
steam for
each of these tubes is dependant on the pressure inside reactor (VR), bottom
pressurised chamber (BC) and top pressurised chamber (TC), respectively.
As seen in Figure 2, the reactor (VR) and elevator (E) are connected by the
top and
bottom pressurised chambers (TC, BC) which are made of 304L stainless steel.
These
pressurised chambers operate at 10 kPa above the pressure inside the vertical
reactor
(VR). As seen in Figures 37 and 41, said chambers have floors (40, 49) and
ceilings
(71, 72) which are angled (a, 13) at 30 downwards from the horizontal axis
(H), in
order to allow plates (10) to slide on said floors and overcome any frictional
forces
acting on said plates. The top pressurised chamber is angled downwards towards
the
vertical reactor (VR) and the bottom pressurised chamber is angled downwards
towards the elevator (E). As seen in Figures 38 and 42, the length (ac, ae),
width (not
shown) and height (ad, af) of said chambers are 40 cm, 10.5 cm and 3 cm
respectively.
The doors (9, 12, 52, 64) within said chambers are made of 304L stainless
steel and
have a thickness (not shown), width (not shown) and height (not shown) of 0.1
cm,
10.5 cm and 3 cm respectively. These doors are also equipped with means of
rotating
along their rotational axis (21, 25, 69, 70). The floor of the bottom
pressurised chamber
(40) and the floor of the top pressurised chamber (49) are 70 cm long.
As seen in Figure 65, the vertical reactor (VR) contains four trays (11). The
first and
second trays are designed according to the trays visible on Figure 49 and do
not have
any scraper bars (92). The third and fourth trays are designed according to
the trays
visible on Figure 52. Said third tray is equipped with 9 scraper bars (92) and
said fourth
tray is equipped with 12 scraper bars. Said scraper bars are designed to
scrape the
entire width of the bottom surface (131) of the plates, thus removing at least
part of
the solid material off said surfaces as said plates slides on said trays
equipped with
said scraper bars.
According to the dimensions seen in Figure 49, the length (f) and width (g) of
each
tray (11) is 100 cm and 11 cm respectively, except for the last tray which has
a length
of about 134.6 cm. The width of a tray wall (h) and the width of a tray guide
(m) are
0.25 cm and 0.6 cm respectively. The height of a tray wall (d) and the height
of a tray
guide (e) are 1.5 cm and 0.5 cm respectively.
94
CA 3019711 2018-10-02

As seen in Figure 52, the scraper bars (92) on the trays (11) are made of 304L
stainless
steel and have a length (p), width (r) and thickness (o) of 10.5 cm, 0.5 cm
and 0.3 cm
respectively. There is one scraper bar placed 2 cm from each extremity of the
tray's
length, while the rest of the scraper bars are spread out evenly along the
length (1) of
the trays. Each scraper bar is integrated into the guides (91) of the trays
such that the
top surface of said scraper bar is along the same plane as the top surface of
the guides
to which it is attached.
As seen in Figure 5, each tray is attached to both the from: and back reactor
walls (15,
14), while also being attached to either the left or right reactor walls (6,
7). As seen in
Figure 65, the first tray (11) begins directly next to the bottom edge of the
top
pressurised chamber floor (28) on the reactor right wall (7). This location is
3 cm below
the top-most edge of the reactor entrance door, which is 2 cm below the
reactor ceiling.
The top-most extremity of each subsequent tray is located 10 cm vertically
beneath the
bottom-most extremity (29) of the tray (11) directly above, attached to the
reactor wall
opposite of the wall to which the tray located directly above is attached. The
trays are
angled (4)) at 30 downwards from the horizontal axis (H), towards the reactor
central
symmetrical axis (17).
As seen in Figure 65, the vertical reactor (VR) also contains three nozzles
(27) which
are of type IS 2 Rectangular Pattern Nozzle manufactured by BETE. The first
nozzle
extends into the reactor from the reactor back wall, is positioned 1.1 cm
downwards
from the reactor ceiling and 64.4 cm to the left of the reactor right wall and
is angled
to be perpendicular to the top surface of the plates sliding on the top-most
tray. The
second nozzle extends into the reactor from the reactor back wall, is
positioned 118.9
cm downwards from the reactor ceiling and 64.4 cm to the right of the reactor
left wall
and is angled to be perpendicular to the bottom surface of the plates sliding
on the
second top-most tray. The third nozzle extends into the reactor from the
reactor back
wall, is positioned 121.1 cm downwards from the reactor ceiling and 64.4 cm to
the
left of the reactor right wall and is angled to be perpendicular to the top
surface of the
plates sliding on the third top-most tray. Each nozzle is centered along an
axis parallel
to the vertical center of the reactor left wall, which can be seen in Figure
69.
As seen in Figure 65, the nozzles (27) have a rectangular spray pattern which
substantially avoids the sprayed feedstock to reach the ceiling (8), the floor
(3) and the
walls (7, 14, 15) of the vertical reactor (VR) and the walls (90) and guides
(91) of the
trays (11). The spray is directed on the plates and hits at least the central
9 cm of the
CA 3019711 2018-10-02

width of the plates, while spanning the at least the bottom-most 80 cm of the
plates'
length along the length of the trays. The surface area affected by the three
nozzles
(active area) is about 2160 cm2. The volume of the reactor, defined by the
reactor
height, width and length described above, is 288631.2 cm3. The ratio of active
area to
volume is therefore 0.0075 cm2/cm3.
The nozzles are automated to spray a constant rate of liquid feed material
onto the
plates as described above. They are also programmed to stop spraying feed
material
after a certain amount of time if the reactor entrance door is closed for more
than 1
second, as this indicates that there are no plates entering the reactor and
therefore no
plates to spray on. The shutting off and turning on of the spray nozzles is
different for
each spray nozzle. The timing for each spray nozzle shutting off and turning
on is
calculated knowing the duration that the reactor entrance door is closed and
time is
takes for plates to slide down the trays.
The elevator system is designed to carry plates from the right-most extremity
of the
bottom pressurised chamber floor (75) to the right-most extremity of the top
pressurised chamber floor (74) at a rate of about 1 plate every 8.7 seconds,
while
heating said plates to 490 C through the use of burners.
ADVANTAGES OF THE STATIONARY REACTOR AND OF THE
PROCESSES OF THE INVENTION
This is a simple process that can treat a wide variety of waste such as
cellulosic
material, MSWT, plastic and make useful and environmentally friendly products.
This
process is in energy equilibrium. The produced gas and naphtha may be consumed
on
site, and there is little or no need to purchase fuel, or to use the more
valuable wide
range diesel or heavy oil products from the unit. There is also no naphtha to
dispose
of. The coke is removed from the vapour oil stream as it leaves the reactor.
Therefore,
the sulphur and metals are not present when the oil is condensed into liquid
fuels. One
of the safety features of this process is that there is no vessel containing
large amounts
of oil in this process. Residence times are low.
In summary some of the advantages of the new thermal processing apparatus
include
at least one of the followings:
- a steady and controllable reaction temperature;
96
CA 3019711 2018-10-02

- a product slate of consistent quality;
- preventing coke and other material from depositing and sticking on the
reaction's surfaces;
- longer run times, shorter shut-downs, less maintenance cost;
- safer operation;
- less by-products to dispose of in industrial landfills;
- less need for the purchase of chemicals and disposal of spent chemicals;
- a steady and controllable reaction pressure, and
- possibility to treat very diverse waste material, even without shut-down of
the
stationary reactor or of the pyrolysis system.
Advantages of the reactor operating:
- better control of pressure in the reactor;
- no air ingress into the reactor, combusting the flammable vapours within the
reactor;
- less risk of an explosion;
- steadier flow of products out the reactor; and
- better control of cyclone operation.
Advantages of the use of a sweep gas, over the use of the new thermal
apparatus alone:
- sweep gas injection stabilizes reactor operations, both pressure and
97
CA 3019711 2018-10-02

temperature are selected and kept in the range appropriate to a particular
feedstock;
The presence of sweep gas inside the reactor reduces the partial pressure of
the organic
reactor feed and/or the organic vapours, helping the vaporization of the
lighter bio-oil
and/or organic vapour components. This reduces the incidence of over-cracking,

resulting in a more stable organic product slate.
Sweep gas helps in keeping the velocity of the vapours exiting the reactor,
improving
the separation of the solids from the reactor products. Sweep gas injection
effectively
reduces organic vapours' residence time, thereby reducing the incidence of
secondary
reactions, and destabilization of the product gasoil and/or bio-oil; and sweep
gas
injection rates can compensate for variations in feedstock quantities.
Similarly, sweep gas injection allows the use of the same reactor to treat
very different
feedstocks from municipal waste to used lubricating oils to bunker. This, in
turn,
permits the treating of a wide variety of waste. The injection of the sweep
gas makes
for safer reactor operations. In the event of a leak in the reactor or
downstream
equipment, the steam present acts as snuffing steam, reducing the risk of a
fire from
oil and/or bio-oil and/or combustible vapours above its auto-ignition
temperature
coming in contact with air. Nitrogen can also reduce the risk of a fire. In
the event of
steam as sweep gas, injection of steam into the reactor can reduce or replace
stripping
steam injection in the product separation stage.
Sweep gas injected into the reactor feed line can change the flow patterns and
prevent
coking in the piping and plugging of either the feed line or feed nozzle. It
reduces the
viscosity of the organic liquid reactor feed, and contributes to the
atomization of the
organic liquid reactor feed droplets through the spray nozzles. If introduced
into the
feed line at temperatures above that of the organic liquid feed into the
reactor, it
reduces the amount of heat that must be generated by the kiln.
Advantages of the process: organic material thermal cracking process has many
advantages over other organic material cracking or reuse processes:
98
CA 3019711 2018-10-02

- it is flexible and permits the treating of a wide variety of organic
material;
- the sulphur and metals do not enter into the finished oil and/or bio-oil
products;
- each liquid droplet entering the kiln take the energy necessary to crack,
but
do not reach a temperature at which they will crack again;
- there is no liquid phase present in the reaction 's zone at any time during
its
operation, so the vapours produced are not wet, and thus do not readily pick
up
contaminants; and
- the vapours produced from pyrolysis do not travel through a thick film of
solid and/or liquid, and thus do not readily pick up contaminants before
exiting
the kiln;
- there are no open vessels causing a bad odour; and
- the process is relatively quick and there are no long residence times.
In the cases wherein composition of the feeding material is about constant,
the
composition of the mixture exiting the rotating kiln may be about constant
and/or
easily managed.
Some embodiments of the invention may have only one of these advantages; some
embodiments may several advantages and may have all of simultaneously.
Although the present invention has been described with the aid of specific
embodiments, it should be understood that several variations and modifications
may
be grafted onto the embodiments and that the present invention encompasses
such
modifications, usages or adaptations of the present invention that will become
known
or conventional within the field of activity to which the present invention
pertains, and
which may be applied to the essential elements mentioned above.
99
CA 3019711 2018-10-02

Representative Drawing