Note: Descriptions are shown in the official language in which they were submitted.
1
RENEWABLE PROCESSING OF WASTE PRODUCTS
TECHNICAL FIELD
[0001] The present disclosure generally relates to extracting waste products,
such
as mature fine tailings (MFT) from tailings ponds (such as those created in
oil sands
areas) and converting the entrained hydrocarbon and biomass into electricity
or liquid
fuels and inorganic solids suitable for disposal to landfill
BACKGROUND
[0002] Oil sand deposits naturally contain significant amounts of fines,
ranging from
10-30% depending on the deposit geology. Fines are defined as solid particles
with
diameters less than 44 microns and are comprised mostly of clay and silt
material. As
tailings are poured into the pond, coarse sand sinks to the bottom, trapping
up to 30%
of the fines. These fines are trapped within the voids of the coarse tailings
stream,
which is mostly silica sand. This mixture of coarse silica sand and fines
settles easily
and has good shear strength, making the material ideal for the construction of
beaches
and dykes. The remaining fines are suspended in the tailings pond water and
tend to
form a sludge-like substance termed fine fluid tailings (FFT). If left
unprocessed, this
layer of fines eventually degrades into mature fine tailings (MFT) with up to
30% water
by volume which is very difficult to dewater. It is estimated that MFT left
undisturbed
can take up to 150 years to fully dewater and settle out.
[0003] Generally, MFT reclaimed from the tailings pond is up to 99% water with
up
to 1-2% bitumen. The solids are generally composed of very fine clays that do
not
settle easily in the tailings pond. Additionally energy-rich hydrocarbons may
also be
found in the MFT in concentrations of up to 1-2%.
SUMMARY
[0004] The disclosed examples are described in detail below with reference to
the
accompanying drawing figures listed below. The following summary is provided
to
illustrate some examples disclosed herein. These examples are supplied for
illustrative purposes, and it is not meant to limit the scope of the invention
to any
particular configuration or sequence of operations disclosed herein.
[0005] According to a first aspect there is provided a system for processing
mature
fine tailings (MFT) located in a pool, the system comprising: a barge coupled
to a
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2
submersible pump configured to pump the MFT from the pool, wherein the barge
further comprises a trapping mechanism for capturing MFT masses floating at or
near
a surface of the pool; and an MFT processing facility configured to use the
MFT
pumped by the submersible to generate a methane-rich gas mixture for use in
generating electricity or liquid fuel, wherein the MFT processing facility
comprises: a
grinder for breaking down the MFT pumped by the submersible pump or the MFT
masses captured by the trapping mechanism into an MFT feed; a vaporizer for
vaporizing the MFT feed to separate inorganic material from organic material
of the
MFT feed; and a reactor to convert the organic material of the MFT feed into
methane
gas.
[0006] In some embodiments, the system includes a dewatering stage in which
one
or more screens or centrifuges are used to remove excess water from the MFT
feed.
[0007] Some aspects disclosed herein generally relate to a system for
processing
MFT located in a pool (sometimes referred to as a pond). The system includes a
barge
coupled to a submersible pump configured to pump the MFT from the pool and an
MFT
processing facility. The MFT processing facility is configured to use the MFT
pumped
by the submersible to generate a methane-rich gas mixture for use in
generating
electricity or for conversion to a liquid fuel.
[0008] In some aspects, the submersible pump includes at least one wall
defining a
chamber for enclosing the submersible pump; and at least one opening in the at
least
one wall permitting passage of material in the pool to be pumped.
[0009] In some aspects, the methane-rich gas mixture is made up of 10-20%
hydrogen and the rest methane.
[0010] In some aspects, the barge includes a trapping mechanism for capturing
MFT
masses floating at or near a surface of the pool.
[0011] In some aspects, the trapping mechanism is at least one of a net, a
fence, or
a grate positioned, at least partially, along a bottom side of barge.
[0012] In some aspects, the barge includes one or more shredders, pulverizers,
or
macerators for breaking up the MFT masses.
[0013] In some aspects, the MFT processing facility includes a grinder for
breaking
down the MFT masses captured by the trapping mechanism of the barge.
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[0014] In some aspects, the MFT processing facility includes: a grinder for
breaking
down the MFT pumped by the submersible pump or the MFT masses captured by the
trapping mechanism into an MFT feed; a vaporizer for vaporizing the MFT feed
to
separate inorganic material from organic material of the MFT feed; and a
reactor to
convert the organic material of the MFT feed into methane gas.
[0015] In some aspects, the MFT processing facility includes: a grinder for
breaking
down the MFT pumped by the submersible pump or the MFT masses captured by the
trapping mechanism into an MFT feed; a vaporizer for vaporizing the MFT feed
to
separate inorganic material from organic material of the MFT feed; a reactor
to convert
the organic material of the MFT feed into methane gas; a primary scrubber
configured
to cool the methane gas heated out of the MFT feed; a secondary scrubber
configured
to remove residual acid and water from the cooled methane gas from the primary
scrubber; a compressor to compress the methane gas from the secondary scrubber
into a compressed gas mixture; and a hydrogen separator to separate the
compressed
gas mixture into a hydrogen stream and a methane-rich gas mixture stream,
wherein
the separated methane-rich gas mixture is supplied to an electric generator or
a fuel
cell to generate the electricity.
[0016] In some aspects, the electric generator includes a gas turbine.
[0017] In some aspects, the MFT processing facility includes: a grinder for
breaking
down the MFT pumped by the submersible pump or the MFT masses captured by the
trapping mechanism into an MFT feed; a vaporizer for vaporizing the MFT feed
to
separate inorganic material from organic material of the MFT feed; a reactor
to convert
the organic material of the MFT feed into methane gas; a primary scrubber
configured
to cool the methane gas heated out of the MFT feed; a secondary scrubber
configured
to remove residual acid and water from the cooled methane gas from the primary
scrubber; a compressor to compress the methane gas from the secondary scrubber
into a compressed gas mixture; and a hydrogen separator to separate the
methane-
rich gas mixture from the compressed gas mixture, wherein the separated
methane-
rich gas mixture is supplied to a liquid fuel plant to generate the liquid
fuel.
[0018] In some aspects, a pipe delivers the MFT from the barge to the MFT
processing facility.
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[0019] In some aspects, the liquid fuel includes at least one of diesel fuel,
ethanol, or
methanol.
[0020] Some aspects are directed to methods for generating electricity or
liquid fuel
from MFT. The methods involve: receiving MFT extracted from a pool containing
a
suspension of MFT in water; processing the MFT at an MFT processing facility
to
generate a methane gas from the MFT; and supplying the methane gas from the
MFT
processing facility to an electric generator or fuel cell for generating the
electricity or to
a liquid fuel plant for generating the liquid fuel.
[0021] Some aspects extract the MFT from the pool containing the suspension of
MFT using a submersible pump.
[0022] Some aspects extract the MFT from the pool containing the suspension of
MFT using a trapping mechanism coupled to a barge.
[0023] In some aspects, generating the methane gas from the MFT includes:
grinding
the MFT into an MFT feed; vaporizing the MFT feed to separate organic gas from
inorganic material of the MFT; mixing the organic gas of the vaporized MFT
feed with
hydrogen gas to create a vaporized hydrogen-methane gas mixture that includes
the
organic gas of the vaporized MFT feed; removing acid, water and particulate
matter
from the hydrogen-methane gas mixture using one or more scrubbers; compressing
the hydrogen-methane gas mixture after the one or more scrubbers; separating
hydrogen from the hydrogen-methane gas mixture to create a methane-rich gas
mixture; and supplying the methane-rich gas mixture to either an electric
generator for
generating the electricity, a fuel cell for generating the electricity, or a
liquid fuel plan
for generating the liquid fuel.
[0024] Some aspects are directed to a system for generating electricity or
liquid fuel
from MFT. Specifically, the system includes one or more barges configured with
either
a submersible pump or a trapping mechanism for capturing the MFT and an MFT
processing facility. The MFT processing facility includes: a grinder for
grinding the
MFT captured by the one or more barges into an MFT feed, a vaporizer for
vaporizing
the MFT feed to separate organic gas from inorganic material of the MFT and
mixing
the organic gas of the vaporized MFT feed with hydrogen gas to create a
vaporized
hydrogen-methane gas mixture that includes the organic gas of the vaporized
MFT
feed, one or more scrubbers for removing acid and water from the hydrogen-
methane
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gas mixture, a separator for separating hydrogen from the hydrogen-methane gas
mixture to create a methane-rich gas mixture; and a tank for storing methane-
rich gas
mixture for use in generating the electricity or the liquid fuel.
[0025] In some aspects, the electricity is generated by an electric generator
being
supplied with the methane-rich gas mixture.
[0026] In some aspects, the electricity is generated by a fuel cell being
supplied with
the methane-rich gas mixture.
[0027] In some aspects, the liquid fuel is generated by a liquid power plant
from the
methane-rich gas mixture.
[0028] In some aspects, the methane-rich gas mixture includes 10-20% hydrogen.
[0029] In some aspects, a system for generating electricity or liquid fuel
from MFT
may include multiple feed sources. For example, the feed sources may feed
material
into a reactor for converting the organic material of the feed sources into
methane gas.
One feed source may be MFT. Another feed source may comprise petroleum coke.
Yet another feed source may comprise used rubber tires from vehicles.
[0030] Each of the multiple feed sources may be coupled to a distributor that
blends
the feed sources and feeds them as a single feed. The single feed may be fed
into the
reactor or into another component of the system.
[0031] A pulverizer may be used to receive petroleum coke and to reduce it to
powder
form prior to feeding the powder to the distributor or the reactor. Similarly,
a pulverizer,
or a milling machine, may be used to receive rubber tires and to reduce them
to powder
form prior to feeding the powder to the distributor or the reactor.
[0032] Two or more of the multiple feed sources may be combined in defined
proportions to create a desired capability for energy release or capture.
[0033] According to a second aspect there is provided a method for generating
electricity or liquid fuel from mature fine tailings (MFT), the method
comprising: using
a submersible pump and a trapping mechanism coupled to a barge to extract MFT
from a pool containing a suspension of MFT in water; receiving the extracted
MFT;
processing the MFT at an MFT processing facility to generate a methane gas
from the
MFT; and supplying the methane gas from the MFT processing facility to an
electric
generator or fuel cell for generating the electricity or to a liquid fuel
plant for generating
Date recue / Date received 2021-12-14
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the liquid fuel, wherein the processing step further comprises: grinding the
MFT into
an MFT feed; and vaporizing the MFT feed to separate organic gas from
inorganic
material of the MFT.
[0034] According to a third aspect there is provided a system for generating
electricity
or liquid fuel from mature fine tailings (MFT), the system comprising: one or
more
barges configured with either a submersible pump or a trapping mechanism for
capturing the MFT; and an MFT processing facility comprising: a grinder for
grinding
the MFT captured by the one or more barges into an MFT feed, a vaporizer for
vaporizing the MFT feed to separate organic gas from inorganic material of the
MFT
and mixing the organic gas of the vaporized MFT feed with hydrogen gas to
create a
vaporized hydrogen-methane gas mixture comprising the organic gas of the
vaporized
MFT feed, one or more scrubbers for removing acid and water from the hydrogen-
methane gas mixture, a separator for separating hydrogen from the hydrogen-
methane
gas mixture to create a methane-rich gas mixture; and a tank for storing
methane-rich
gas mixture for use in generating the electricity or the liquid fuel.
[0035] According to a fourth aspect there is provided a system for
decarbonizing air,
the system comprising: (i) a feed source comprising waste material, (ii) an
energy
extraction system for receiving (a) the waste material, (b) hydrogen and (c)
steam, and
producing inorganic waste and generating electricity or liquid fuel, and (iii)
an air carbon
capture system powered by the generated electricity or liquid fuel to capture
carbon
from the ambient air.
[0036] The waste material may comprise one or more of: petroleum coke, rubber
tires, or mature fine tailings.
[0037] The energy extraction system may comprise a vaporizer to mix a gas
produced from the feed source with the hydrogen gas to create a vaporized
hydrogen-
hydrocarbon gas mixture.
[0038] The energy extraction system may comprise one or more scrubbers for
removing acid and water from the hydrogen- hydrocarbon gas mixture.
[0039] The energy extraction system may produce hydrocarbon rich vapor as an
intermediate product that is then converted to electricity or liquid fuel.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The disclosed examples are described in detail below with reference to
the
accompanying drawing figures listed below:
[0041] Figure 1 is a side view of a barge with a submersible pump for removing
MFT
from a pool.
[0042] Figure 2A is a perspective view of a barge with a submersible pump for
removing MFT from a pool.
[0043] Figure 2B is a perspective view of a pump enclosure for a submersible
pump
usable in removing MFT from a pool.
[0044] Figures 3-6A are perspective views of alternative barges with
submersible
pumps for use in extracting MFT from a pool.
[0045] Figure 6B is a cross-sectional view of a pump enclosure of a
submersible
pump usable for removing MFT from a pool.
[0046] Figure 7 is a side view of a barge with a trapping mechanism for
capturing
MFT masses in a pool.
[0047] Figure 8 is a perspective view of a barge with a trapping mechanism for
capturing MFT masses in a pool.
[0048] Figure 9 is a side view of a barge with a trapping mechanism and a
submersible pump for extracting MFT in a pool.
[0049] Figure 10 is a block diagram of a processing facility for generating
electricity
or liquid fuel from MFT extracted from a pool by one or more barges.
[0050] Figures 11-12 are flow charts of workflows for processing MFT into
electricity
or liquid fuel.
[0051] Figure 13 is a block diagram of a processing facility for generating
electricity
or liquid fuel from one or more of a plurality of feed sources.
DETAILED DESCRIPTION
[0052] The various embodiments will be described in detail with reference to
the
accompanying drawings. Wherever possible, the same reference numbers will be
used
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throughout the drawings to refer to the same or like parts. References made
throughout this disclosure relating to specific examples and implementations
are
provided solely for illustrative purposes but, unless indicated to the
contrary, are not
meant to limit all examples.
[0053] Disclosed herein are embodiments and examples that remove MFT from
water bodies (e.g., tailings ponds) and then convert the hydrocarbon and
biomass
entrained in the MFT into usable electricity or liquid fuels (e.g., diesel,
ethanol,
methanol). Using the disclosed embodiments, environmentally hazardous MFT are
both removed from tailings ponds (or other water bodies) and converted into
electricity
or fuel, which may then be (at least partially) used to power the entire
process. Thus,
the disclosed embodiments demonstrate a greener way to extract MFT and
generate
electricity or fuel therefrom. Additional feed sources, such as petroleum
coke, rubber
tires, or the like, can also be processed (e.g. reduced in size to a powder
form) and
combined with the MFT feed to provide a mixture having a desired energy
release
profile.
[0054] Several embodiments are disclosed for removing MFT from water bodies,
such as tailing ponds. As discussed below, this may be done using submersible
pumps, some of which include various screens to filter out entrained
vegetation and
debris (e.g., branches) that could damage pumping or processing equipment. A
further
embodiment of this disclosure includes a maceration function which homogenizes
the
debris further increasing the biomass component of the MFT media. Solidified
masses
of MFT, with higher bitumen concentrations, typically float at or near the
surface of the
water body, and thus, some embodiments use barges or other sea vessels to skim
these denser masses of MFT from or near the water's surface, and the so-
retrieved
masses may be pulverized before being processed into reusable electricity,
fuel
liquids, or other renewables. These solidified masses of MFT consist of higher
concentrations of hydrocarbons than aqueous MFT, and therefore yield higher
levels
of electricity/fuel production. Aqueous MFT may be dewatered using one or more
screens and then one or more centrifuges. After MFT extraction, the removed
MFT is
sent to a processing facility to be converted into electricity or fuel. The
removed MFT
may be combined with other energy containing substances, such as petroleum
coke
or rubber tires.
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[0055] Before proceedings, some key definitions are provided below to aid the
reader
in understanding the disclosed embodiments.
[0056] The term "mixing" and "sufficiently mixed" refers to the homogenous
mixing of
the vaporized organic material with an excess of hydrogen and superheated
steam so
that the organic material is completely dehalogenated and reduced by the
hydrogen
gas. Thorough mixing allows hydrogen gas to bombard the organic compounds in
the
MFT from all directions and helps the dehalogenation, desulfurization and
reduction
reactions to near completion. If the vaporized MFT is not sufficiently mixed
with the
excess amount of hydrogen gas and superheated steam, the compounds in the
organic
material will not be completely dehalogenated and reduced, resulting in the
formation
and condensation of a tarry material. Mixing is accomplished using any known
means,
for example, a static mixer (standalone or incorporated into the vaporizer) or
ensuring
conditions that produce turbulent flow.
[0057] The term "tarry material" as used herein refers to condensed
polyaromatic
hydrocarbons that results from insufficient mixing of the MFT with an excess
amount
of hydrogen gas and superheated steam. In some embodiments, when the MFT is
not
sufficiently mixed with an excess amount of hydrogen gas and superheated
steam, the
MFT is incompletely dehalogenated and/or desulfurized and are subsequently
incompletely reduced. As a result, aromatic compounds in the MFT condense and
form tarry material that accumulates in the process reactor causing the
process to be
shut down.
[0058] The term "superheated steam" as used herein refers to water that has
been
heated to a temperature of about 600 C to 900 C at a pressure greater than 0-
2ATM.
[0059] The term "vaporized" as used herein refers to a liquid that has been
converted
to its vapor form by the application of heat.
[0060] FIG. 1 illustrates a pump system 100 for use in a body of fluid 104.
The body
of fluid 104 can contain any one of, or any combination of, used or unused
process
water, treated wastewater effluent, mature fine tailings (MFT), slurry and the
like,
resulting from mining operations and related activities. In some embodiments,
the
body of fluid 104 contains a bed of MFT 108 adjacent to a bottom 112 of the
body of
fluid 104. In addition, the MFT 108 or any other portion of the body of fluid
104 can
contain debris 116, such as vegetation (e.g. tree branches). In operation, the
pump
Date recue / Date received 2021-12-14
10
system 100 reclaims the MFT 108 from the body of fluid 104 and delivers the
reclaimed
MFT to other equipment (not shown) for processing into reusable energy (e.g.,
electricity, diesel fuel, ethanol, methanol, or the like).
[0061] In some embodiments, the pump system 100 includes a barge 120, with a
pump support, configured to float at a surface 124 of the body of fluid 104.
The barge
120 supports a pump 128, such as a submersible centrifugal pump, from a line
132.
The line 132 may include a fluid discharge hose from the pump 128, as well as
one or
more conduits for supplying power and control to the pump 128. In other
embodiments,
the fluid discharge hose can be separated from the line 132.
[0062] Additionally or alternatively, the pump system 100 may include a pump
enclosure 136. The pump enclosure 136 includes one or more walls defining a
chamber 138 for enclosing the pump 128. At least one of the walls defining the
chamber 138 includes at least one opening therein for permitting the entry of
material
(such as MFT) into the chamber 138, to be collected by the pump 128 and
delivered
to the barge 120 or other equipment for processing. The opening may also be
configured to reduce or eliminate the entry of debris 116 or other material
into the pump
enclosure 136 that may damage the pump 128 or interrupt the operation of the
pump
128. Furthermore, when the pump enclosure 136 is installed around the pump
128,
the distance between at least a portion of the walls of the pump enclosure 136
and an
inlet of the pump 128 is greater than a predefined threshold.
[0063] In operation, the pump 128, exerts suction pressure on material
surrounding
the inlet. The suction pressure exerted by the pump 128 causes the material to
move
towards the inlet at an increasing radial velocity. In some embodiments, this
fluid
velocity is proportional to the distance from the pump suction and decreases
radially
from the pump inlet. The filtering action of the walls of the pump enclosure
136, in the
relatively low velocity field, located at some radial distance from the pump
suction,
effectively increases the filtration efficiency of the present invention over
that of a
simple pump strainer for two reasons. First, the lower transit velocity of the
media
through the screen of the pump enclosure reduces the pressure drop across the
screen. Second, the larger surface area of the pump enclosure screen, as
compared
to the pump suction strainer, provides a larger surface area than the pump
strainer,
thereby reducing the possibility of total flow blockage.
Date recue / Date received 2021-12-14
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[0064] The threshold distance is selected such that beyond the threshold
distance,
the velocity of material that is pulled towards the inlet of the pump 128 is
reduced
sufficiently to reduce or eliminate the likelihood of material (e.g., debris
116) clogging
the above-mentioned opening in the walls of the pump enclosure 136. Various
embodiments of the pump enclosure 136 are described in greater detail below.
[0065] Referring now to Figure 2A, the barge 120 is illustrated with two pumps
128
suspended therefrom into the body of fluid 104 by respective lines 132. In
other
embodiments, more than two pumps 128 can be suspended from the barge 120. In
further embodiments, a single pump 128 can be suspended from the barge 120.
[0066] One of the pumps 128 suspended from the barge 120 is enclosed in pump
enclosure 136. In other embodiments, both pumps 128 suspended from the barge
120
can be enclosed in respective pump enclosures.
More generally, in some
embodiments every pump 128 suspended from the barge 120 can be enclosed in a
pump enclosure 136.
[0067] The chamber 138 of the pump enclosure 136 is defined by a side wall
200, a
lower wall 204 and an upper wall 208. The side wall 200 is a substantially
cylindrical
side wall in the present example. In other embodiments, the side wall 200 can
have
the shape of a rectangular prism. The side wall 200 is connected at a lower
end to the
lower wall 204, and at an opposite, upper end to the upper wall 208.
[0068] As mentioned earlier, the pump enclosure 136 includes at least one
opening
to allow entry of material from the body of fluid 104 into the pump enclosure
136 for
collection by the pump 128. In the present example, the side wall 200 includes
a
plurality of spaced apart rods 212 (see Figure 2B) extending between the upper
wall
208 and the lower wall 204. The at least one opening thus includes a plurality
of
openings, each opening being defined by the space between two adjacent rods
212.
In other embodiments, the side wall 200 can include a mesh instead of the set
of rods
212 shown in Figures 2A and 2B.
[0069] The pump enclosure 136 can include further openings in addition to
those
defined in the side wall 200. For example, the lower wall 204 of the pump
enclosure
136 can also include additional openings. In the example illustrated in
Figures 2A and
2B, the lower wall 204 includes a ring 216 and a plurality of rods 220
extending along
chords of the ring 216 (that is, from one point on an inner side of the ring
216 to another
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point on the inner side). The spaces between adjacent ones of the rods 220 are
openings in the lower wall 204.
[0070] In some embodiments, the upper wall 208 can also include an opening
therein. For example, as seen in Figure 2A, the upper wall 208 includes an
opening
224 therethrough to allow passage of the line 132. In some embodiments, the
opening
224 can also be large enough to allow passage of the pump 128 therethrough. In
such
embodiments, the enclosure 136 can be installed in the body of fluid 104, for
example
by anchoring the enclosure (e.g. via the lower wall 204 and/or upper wall 208)
to the
bottom 112 of the body of fluid 104. One or both of the lower wall 204 and the
upper
wall 208 can be buoyant, to maintain the orientation of the enclosure 136
relative to
the bottom 112. Once the enclosure 136 is installed, the pump 128 can be
lowered
from the barge 120 into the enclosure 136 via the opening 224. The position of
the
pump 128 can also be adjusted within the chamber 138 during operation by
spooling
or unspooling the line 132 from the barge 120.
[0071] The pump enclosure 136 can also include further openings defined in the
side
wall 200. In particular, as seen in Figures 2A and 2B, a plurality of openings
in the side
wall 200 can each accommodate a macerator 228. In the present embodiment, the
pump enclosure 136 includes four macerators 228. In other embodiments, more
than
four macerators 228 can be included. In further embodiments, as few as zero
macerators 228 can be included in the pump enclosure 136 (that is, the
macerators
228 can be omitted entirely). Further, the position of the macerators 228 can
be varied.
In the present embodiment, the macerators 228 protrude through the side wall
200
adjacent to the lower wall 204. In other embodiments, the macerators 228 can
be
placed in the side wall 200 at any suitable location intermediate to the lower
wall 204
and the upper wall 208. In further embodiments, each macerator 228 can be
placed
at a different height in the side wall 200 from the other macerators 228.
[0072] Each of the macerators 228 includes an inlet for receiving material
from the
body of fluid 104, one or more grinding or cutting mechanisms for reducing
breaking
the material received at the inlet into pieces, and an outlet for discharging
the pieces
into the chamber 138. Power supply and control signals for the macerators 228
can
travel along the line 132 or be supplied from a separate floating companion
barge. As
also mentioned earlier, the distance between at least a portion of the walls
200, 204
Date recue / Date received 2021-12-14
13
and 208 and an inlet 232 of the pump 128 is greater than a predetermined
threshold.
In the present example, the predetermined threshold distance is a fraction or
multiple
of the diameter "D" of an inlet 232 of the pump 128. In some embodiments, the
threshold is equivalent to at least one inlet diameter. Thus, for a pump inlet
diameter
of about eight inches, the threshold distance is about eight inches from the
pump inlet.
In further embodiments, the threshold is equivalent to at least two inlet
diameters.
Thus, for a pump inlet diameter of about eight inches, the threshold distance
is about
sixteen inches from the pump inlet. In other embodiments, the threshold is
equivalent
to a greater multiple of the inlet diameter than two. In further embodiments,
the
threshold is equivalent to a multiple of the inlet diameter that is between
one and two.
[0073] Thus, at least a portion of at least one of the side wall 200, the
lower wall 204
and the upper wall 208 is farther from the inlet 232 than the threshold
distance as
defined above. In the present embodiment, the entirety of each of the walls
200, 204
and 208 are further from the inlet 232 than the threshold distance as defined
above.
Maintaining at least the threshold distance between the inlet 232 and at least
a portion
of the walls of the enclosure 136 reduces the velocity of material (imparted
by the pump
128) at the openings in the walls of the enclosure 136, and therefore can
reduce the
likelihood of the openings becoming clogged with debris. In addition, the
outlets of
each the macerators 228 are preferably further from the inlet 232 than the
threshold
distance as defined above. This allows the macerated flow stream to blend and
normalize prior to passage through the pump suction strainer reducing the
possibility
of pump suction blockage.
[0074] Figure 3 illustrates an example of a pump enclosure 336. The pump
enclosure 336 defines a chamber 338 within a side wall 300 connected between a
lower wall 304 and an upper wall 308. The side wall 300 is substantially
cylindrical in
the present embodiment. In other embodiments, the side wall 300 can have other
configurations, including the shape of a rectangular prism. The side wall 300
includes
a plurality of spaced apart rods 312, and thus defines openings between
adjacent rods
312. The lower wall 304 includes a ring 316 and a plurality of rods 320
extending along
chords of the inner side of the ring 316, thus forming additional openings
between the
chamber 338 and the exterior of the chamber 338.
Date recue / Date received 2021-12-14
14
[0075] In addition, the upper wall 308 defines an opening 324 therein. While
the
pump enclosure 136 illustrated in Figures 2A and 2B enclosed a single pump
128, the
pump enclosure 336 encloses a plurality of pumps 128. In particular, the
opening 324
in the upper wall 308 is sufficiently large to surround the entirety of the
barge 120. The
chamber 338 defined by the upper wall 308, the side wall 300 and the lower
wall 304
is sufficiently large to enclose the plurality of pumps 128 suspended from the
barge
120.
[0076] In the installed position, the pump enclosure 336 can be anchored to
the
bottom 112 of the body of fluid 104, for example by anchor lines connected to
the lower
wall 304 and/or the upper wall 308. The upper wall 308, the lower wall 304, or
both,
can be buoyant to assist in maintaining the orientation of the pump enclosure
336. The
upper wall 308 can lie below the surface 124 in the installed position in some
embodiments. In other embodiments, a portion of the upper wall 308 can rise
above
the surface 124 of the body of fluid 104. In such embodiments, the portion of
the upper
wall 308 that rises above the surface 124 may provide protection for the barge
120
from waves and debris floating on the surface 124.
[0077] As seen in Figure 3, the distance from the inlet of each pump 128
enclosed
within the pump enclosure 336 exceeds the above-mentioned threshold distance
of
the inlet diameter "D" of the pump 128,
[0078] Referring now to Figure 4, a further embodiment is illustrated in the
form of a
pump enclosure 436. Certain components of the pump enclosure 436 are as
described
above in connection with the pump enclosure 336. Those components bear similar
reference characters to the components of the pump enclosure 336, but with a
leading
'4' rather than a leading '3'. Thus, the chamber 438, the side wall 400, the
lower wall
404, the upper wall 408, are as described above in connection with the chamber
338,
the side wall 300, the lower wall 304, the upper wall 308, respectively. The
same
principle applies to the ring 416, the rods 412 and 420, and the opening 424.
[0079] In addition, the pump enclosure 436 includes a plurality of macerators
428
mounted in the side wall 400. As described in connection with the macerators
228
shown in Figure 2, the macerators 428 collect material from outside the
chamber 438,
grind or cut the material, and discharge the ground or cut material into the
chamber
438. In the present embodiment, the pump enclosure 436 includes ten macerators
428
Date recue / Date received 2021-12-14
15
(eight macerators 428 are visible in Figure 4). In other embodiments, fewer
than ten
macerators 428 can be provided, including zero macerators, as seen in the
embodiment of Figure 3. In further embodiments, a number of macerators 428
greater
than ten may be provided. The positions of the macerators 428 can also be
varied
within the side wall 400.
[0080] Referring to Figure 5, another pump enclosure 536 is illustrated. The
pump
enclosure 536 includes a chamber 538 defined by a side wall 500, a lower wall
504
and an upper wall 508. As in the embodiments of Figures 3 and 4, the pump
enclosure
536 surrounds the barge 120 and thus the chamber 538 encloses all the pumps
128
suspended from the barge 120. However, the walls 500, 504 and 508 of the pump
enclosure 536 are solid and impermeable, rather than made of rods or mesh as
in the
embodiments described above. The upper wall 508 preferably extends above the
surface 124 of the body of fluid 104.
[0081] The pump enclosure 536 includes at least one opening in the side wall
500,
in the form of a plurality of macerators in the side wall 500. In the present
embodiment,
in which the upper wall 508 extends above the surface 124 of the body of fluid
104, the
macerators 528 provide the only openings from within the body of fluid 104
into the
chamber 538.
[0082] In the embodiments of Figures 3, 4 and 5, the installation of the pump
enclosures 336, 436 and 536 can be performed by, for example, floating the
pump
enclosure to the planned location of operation of the barge 120 in the body of
fluid, and
then sinking the pump enclosures into the body of fluid to the desired depth
and
anchoring the pump enclosures. The barge 120 can then be floated over the pump
enclosures. In other embodiments, the pump enclosures and the barge 120 can be
floated out to the desired position within the body of fluid 104 together
(with the barge
120 already surrounded by the pump enclosure). The pump enclosure can then be
sunk and anchored. Following placement of the pump enclosure and the barge
120,
the pumps 128 can be deployed from the barge 120 into the chamber 338, 438 or
538.
[0083] Referring now to Figures 6A and 6B, a further pump enclosure 636 is
illustrated. The pump enclosure 636 defines a chamber 638 that encloses at
least a
portion of a pump 128. At least the portion of the pump 128 that bears the
inlet 232 is
enclosed within the chamber 638. The chamber 638 can be defined by a side wall
600
Date recue / Date received 2021-12-14
16
connected between a lower wall 604 and an upper wall 608. At least one of the
walls
600, 604 and 608 includes at least one opening. For example, the side wall 600
can
be made of a mesh or grating, and can therefore include a plurality of
openings therein
for material to enter the chamber 638 from the body of fluid 104. The side
wall 600 is
illustrated as being substantially cylindrical in shape in Figure 6A. In
other
embodiments, the side wall 600 can have other shapes, including the shape of a
rectangular prism.
[0084] The lower wall 604 and the upper wall 608 can be substantially disc-
shaped
walls, with the exception of a slot cut into each of the walls 604 and 608 to
allow for
the passage of a discharge hose 650 from the pump 128. The side wall 600 can
also
protrude inwardly to form a channel allowing the passage of the discharge hose
650.
In other embodiments, the discharge hose 650 can rest on the upper wall 608
and
travel along the outermost extent of the side wall 600 before returning to the
barge 120.
In such embodiments, the walls 600, 604 and 608 can omit the above-mentioned
slots
and channels.
[0085] In some embodiments, the upper wall 608 may be sufficiently buoyant to
support the pump enclosure 636, without the pump 128, at or near the surface
124 of
the body of fluid 104. Thus, to install the pump 128 within the enclosure 636,
the
enclosure 636 may be floated adjacent to the barge 120, and the pump 128 may
be
lowered into the upper wall 608. In some embodiments, the upper wall 608 may
include a coupling mechanism for securing the pump 128 to the upper wall 608.
Upon
insertion of the pump 128, the pump 128 and the enclosure 636 together may be
lowered from the barge 120 via the line 132 to the desired depth within the
body of
fluid. The additional weight of the pump 128 may be greater than the buoyancy
provided by the upper wall 608, thus allowing the assembled pump enclosure 636
and
pump 128 to descend into the body of fluid 104.
[0086] In some embodiments (not shown), the pump enclosure 636 may also
include
one or more macerators mounted in the side wall 600. For example, in some
embodiments four macerators may be mounted in the side wall 600 adjacent to
the
lower wall 604.
[0087] Variations to the above embodiments are contemplated. For example, the
pump 128 can include a cage or strainer at the inlet 232 in any of the above
Date recue / Date received 2021-12-14
17
embodiments, to prevent any debris that reaches the interior of the pump
enclosures
from entering the inlet 232 and damaging or interrupting the operation of the
pump 128.
[0088] In additional embodiments, the alternative configurations are
contemplated
for the macerators 228 and 428, as well as the macerators mentioned in
connection
with the embodiment illustrated in Figures 6A and 6B. As discussed above, each
macerator has a flow path (from inlet, to grinding or cutting elements, to
outlet) that
travels from the exterior of the pump enclosures to the interior of the pump
enclosures
(the chambers 238, 438, 638). In other embodiments, each macerator can instead
have a flow path that is substantially parallel to the side wall of the pump
enclosure.
That is, the macerator can be mounted outside the side wall of the pump
enclosure,
and both ingest debris and discharge cut or ground debris outside the side
wall. Such
macerators can also be movably connected to the exterior of the pump
enclosures. For
example, referring to Figure 4, one or more of the macerators 428 can be
mounted on
a track on the ring 416 and can travel on the track around the exterior of the
side wall
400 to clear accumulated debris.
[0089] In further embodiments, the pump enclosures can include additional
pumping
devices adjacent to the inlets of the macerators. For example, an eductor, or
water
dredge, may be placed near the inlet of each macerator to increase the flow of
material
(e.g. MFT) into the macerator.
[0090] Various advantages to the embodiments described herein will now be
apparent. For example, by reducing or preventing the entry of debris to within
at least
a threshold distance of the pump inlet, the enclosures described above not
only reduce
the likelihood of suction blockage and/or damage to the pump, but also
restrain any
debris in the body of fluid at a sufficient distance from the pump inlet that
the likelihood
of the debris impinging against the outside of the enclosure and clogging one
or more
openings in the enclosure is reduced. In addition, in embodiments that include
macerators, debris that may otherwise impede the operation of pumps is not
only
prevented from impeding the operation of the pumps, but can also be reduced in
size
sufficiently to be removed from the body of fluid 104 by the pumps.
[0091] The barge 120 may also be connected to one or more pipes that transport
pumped MFT back to shore for processing. For example, these pipes may be used
to
transport MFT from the barges 120 to the MFT processing facility 1000
discussed
Date recue / Date received 2021-12-14
18
below in FIG. 10. In large pools (or ponds) 124, such piping may stretch
several
kilometers long across the surface 124 of the pool and be attached to barges
supporting the pump system 120. This allows for the barges to pump up MFT
using
the disclosed submersible pumps and pipe the extracted MFT back to land for
transport
to the processing facilities disclosed below that, in turn, process such MFT
into
electricity and/or fuel liquids (e.g., diesel, ethanol, methanol, or the
like).
[0092] The disclosed embodiments may retrieve MFT using other sea vessels,
some
of which do not use a submersible pump. As previously mentioned, some of the
most
hydrocarbon-rich MFT has a high bitumen concentration and floats as masses at
or
near the surface 124 of the body 104. Some embodiments use a barge with a net
or
other trapping mechanism for collecting these masses of MFT. An example of
such a
barge is shown in Figures 7 and 8.
[0093] Figure 7 illustrates a side view 700 of an MFT-collecting barge 720
with a
trapping mechanism 730 underneath for capturing MFT masses 710 that are
floating
at or near (e.g., within 10 meters) the surface 124 of the pool 104. The
trapping
mechanism 730 may be a net, fence, grate, or other compartment that allows
water to
pass through while catching and holding the MFT masses 710 as the barge 720
moves
through the pool 740 (as shown by arrow 740). Though not shown, the barge 720
may
also include one or more shredders, pulverizers, or macerators that operate to
break
up the MFT masses 710 for easier transport to the processing facilities
described in
more detail below.
[0094] Figure 8 illustrates a perspective view of the barge 720 with the
trapping
mechanism 730. As the barge 720 moves across the surface 124 of the pool 104
in
direction 740, MFT masses 710 are collected in the trapping mechanism 730
between
barge arms 810 and 820. Arms 810 and 820 form an inlet spanning distance 830
for
the MFT masses 710 to be captured. Captured MFT masses 710 may be carried by
the barge 720 back to shore for transport to the processing facilities
mentioned below.
For instance, the trapping mechanism 730 may be unloaded into a truck or
carried by
a crane to a bed of a processing facility that uses the disclosed techniques
to process
the MFT masses 710 into electricity or fuel liquids.
[0095] While the barge 720 in Figures 7-8 is shown without a submersible pump,
embodiments may include both the submersible pumps described in Figures 1-6B
in
Date recue / Date received 2021-12-14
19
addition to the trapping mechanism 730 shown in Figures 7-8. Figure 9 shows a
side
view 900 of a barge 920 that includes both the trapping mechanism 730 (not
identified
in Fig. 9) (e.g., an underside net) for capturing larger MFT masses 710
floating at or
near the surface 124 and the submersible pump 128 for pumping up smaller or
liquified
MFT from the pool 104. Barge 902 provides the ability to both pump MFT from
depths
of the pool 104 (while separating out some debris) and also skim MFT masses
710
that are at or just under the surface 124 of the pool 104. In some
embodiments, the
MFT masses 710 may be crushed on the barge 920 and piped back with the MFT
collected by the submersible pump 128 back to shore for processing into
electricity/liquid fuel. Alternatively, in some embodiments, the MFT masses
710 are
collected and transported back to shore by the barge 702 without crushing.
[0096] Figure 10 illustrates an MFT processing facility 1000 used to process
the MFT
and/or the MFT masses 710 into electricity and/or liquid fuel (e.g., diesel,
ethanol,
methanol, or the like). To do so, the MFT processing facility 1000 includes a
grinder
1002, a vaporizer 1004, a reactor 1008, a primary scrubber 1010, a secondary
scrubber 1012, a compressor 1014, a hydrogen separator 1016, a gas tank 1018,
an
electric generator or fuel cell 1020, and a liquid fuel power plant 1022. The
depicted
embodiment is but one example of a processing facility for generating
electricity or
liquid fuel from the MFT and MFT masses 710 that are extracted from the pools
100.
Also, some of the depicted components may reside outside of the MFT processing
facility 1000. For example, the electric generator or fuel cell 1020 or the
liquid power
plant 1022 may be located at a different plant than the MFT processing
facility 1000.
Moreover, for the sake of clarity, no distinction is made in the following
discussion of
the MFT processing facility between "MFT" and "MFT masses." Both are referred
to
below simply as "MFT."
[0097] As shown, the MFT extracted by any of the previously discussed barges
120,
720, 01 920 are supplied to the MFT processing facility 1000¨ either directly
from the
barges themselves (e.g., through a pipeline), via truck, or some other
conveyance.
[0098] The extracted MFT may be dewatered before entrance into, or as it
enters,
the MFT processing facility 1000. This may be implemented using one or more
dewatering screens and one or more centrifuges.
Date recue / Date received 2021-12-14
20
[0099] In some embodiments, the MFT is ground in the grinder 1002 into a
uniform
and easily conveyable MFT feed. Put another way, the grinder 1002 breaks down
the
masses formed from the higher bitumen concentrations of MFT. In operation, the
grinder 1002 grinds the material to a uniform size and allows for transferring
the
material through the MFT processing facility 1000. Alternative embodiments do
not
use the grinder 1002, and instead directly supply the MFT to the vaporizer
1004,
because the MFT is uniform enough, or liquefied, that grinding is not
necessary. Thus,
the MFT feed mentioned below may be a ground version of the MFT captured by
the
barges 120, 720, 920 (in some embodiments) or a just the MFT without being
ground
(in other embodiments).
[00100] The vaporizer 1004 receives and vaporizes the MFT feed into its
constituent
gasses. In some embodiments, the vaporizer 1004 is a rotatable reaction,
mixing
and/or milling apparatus that is heated and therefore vaporizes the MFT feed.
The
MFT feed, in addition to organic compounds that can be vaporized, may also
contain
inorganic material that does not vaporize. In an embodiment, the inorganic
material
that does not vaporize in the vaporizer 1004 may be collected from the
vaporizer 1004
as solid inorganic waste (illustrated as output 1005). Examples of inorganic
waste
include any type of material which will not vaporize in the heat of the
vaporizer 1004,
including, without limitation, metals, minerals, stones, sand or silica. Such
inorganic
waste, being free of organic material, may be suitable for recycling or
disposal in a
landfill.
[00101] The vaporized organic material of the MFT is thoroughly mixed with an
excess amount of hydrogen gas and superheated steam (illustrated as entering
via
input 1006). Thorough mixing of the vaporized organic material from the MFT
with the
excess amount of hydrogen gas and superheated steam allows for the components
of
the mixture to be sufficiently mixed and reduce the formation of tarry
material. Mixing
may also be accomplished using any other known means.
[00102] The mixed and heated vaporized organic material, hydrogen gas, and
superheated steam are conveyed on vapor outlet 1007 to the reactor 1008. In
some
embodiments, the reactor 1008 is a tubular gas phase reduction (GPR) (or other
arcuately shaped) reactor that is substantially free of oxygen. In operation,
the
Date recue / Date received 2021-12-14
21
vaporized organic material, hydrogen gas, and superheated steam are further
heated
in the reactor 1008 to produce methane gas.
[00103] This methane gas is directed from the reactor 1008 to the primary
scrubber 1010, where the methane gas mixture is cooled, and acid, water, and
any
particulate matter are removed. In a further embodiment, the gas mixture
enters a
secondary scrubber 1012 to remove residual acid and water. Additional
scrubbers
may be used to continue removing water and acid. Water is a by-product of the
reactions occurring in the process reactors, and exits the process as stream
from the
primary scrubber 1010 and the secondary scrubber 1012. These steam byproducts
may be combined and then treated, in some embodiments, before exiting the
process
as effluent.
[00104] After the scrubbers, the gas mixture predominantly comprises hydrogen
gas
and methane. This hydrogen-methane gas mixture is directed to the compressor
1014,
which compresses and cools the hydrogen-methane gas mixture. Any suitable type
of
compressor may be used, e.g., a centrifugal, diagonal, axial-flow,
reciprocating, rotary
screw, or other type of compressor.
[00105] The compressed gas mixture is directed from the compressor 1014 to the
hydrogen separator 1016. In some embodiments, the hydrogen separator 1016 may
be a membrane type separator that separates the hydrogen gas from the
compressed
gas mixture with about 85% efficiency to form two separate gas streams 1016a
and
1016b. Stream 1016b is substantially hydrogen gas recovered from the
compressed
gas mixture that is recycled to be used again in the process. In some
embodiments,
the hydrogen gas of stream 1016b is directed back to the vaporizer 1004 as an
energy
or heat source. Recycling this hydrogen gas in such a manner makes the MFT
processing facility 1000 operate in a greener and more efficient manner.
[00106] Stream 1016a is a methane-rich gas stream that contains 10-20%
hydrogen,
which can subsequently be used, for example, as a clean burning fuel, for the
generation of heat or electricity or for any other known use for methane. In a
further
embodiment the methane-rich gas stream 1016a stored in gas tank 1018 and may
be
directed to the electric generator or fuel cell 1020 or to the liquid fuel
power plant 1022.
Along these lines, it is one benefit of present disclosure that the gases
produced in the
MFT processing facility 1000 are used as clean-burning fuels. For example, the
Date recue / Date received 2021-12-14
22
methane-rich gas mixture may be used as a fuel source in any known energy-
generating system, for example, but not limited to gas-fired turbines, steam-
fired
turbines, and other engines. The methane can also be converted to hydrogen
using
known carbon dioxide reforming and water gas shift processes and the hydrogen
subsequently used as a fuel in known hydrogen power generation systems, for
example, fuel cells. The methane and/or hydrogen are either collected and
transported
to the energy generating system or can be fed directly into such systems, that
in one
embodiment of the disclosure, are in close proximity to or in combination with
the
process apparatus.
[00107] Figure 11 illustrates a flowchart diagram depicting an example
workflow
1100 for generating electricity or liquid fuel from MFT extracted from a pool.
As shown
at 1102, the MFT is extracted from the pool, e.g., using a barge with
submersible
pumps to pump the MFT from the pool, or using barges with trapping mechanisms
that
capture MFT masses on or near (e.g., within 10 meters) of a surface of the
pool. The
captured MFT (including the MFT masses) are transported to an MFT processing
facility, such as the one illustrated in Figure 10, as referenced at 1104. The
MFT
processing facility performs generates a hydrogen-methane gas mixture (e.g.,
methane and 10-20% hydrogen) from the MFT through various grinding, heating,
compressing, and separating components, as shown at 1106. An example workflow
1200 detailing one example of processing the MFT into the methane gas is shown
in
Figure 12 and described in more detail below.
[00108] The methane gas generated from the MFT may then be supplied to an
electric generator, fuel cell, or liquid fuel plant, as shown at 1108, 1110,
and 1112,
respectively. As
shown at 1114, the electric generator ¨ which, in some
embodiments, include a gas-powered turbine ¨ and the fuel cell generate
electricity
using the methane gas. As shown at 1116, the liquid fuel plan generates a
liquid fuel
(e.g., diesel, ethanol, methanol, or the like) from the methane gas.
[00109] Figures 12A and 12B illustrate flowchart diagrams depicting an example
workflow 1200 of an MFT processing facility processing extracted MFT into
electricity
or liquid fuel. Looking initially at Figure 12A, MFT is received at the
processing facility,
e.g., through piping from the barges mentioned herein or from a truck, tanker,
pipeline,
or other transport, as shown at 1202. The received MFT is shredded, ground, or
Date recue / Date received 2021-12-14
23
pulverized by a grinder into a uniform MFT feed that may easily be supplied to
other
components in the MFT processing facility, as shown at 1204. Some MFT masses
of
higher bitumen concentration captured in the pool (e.g., using barges 720 or
920) may
be larger masses that must be ground down to a certain consistency in order to
be
processes.
[00110] In some embodiments, the ground MFT feed is supplied to a vaporizer
that
vaporizes the MFT into it constituent gasses, separating constituent organic
gas(ses)
from inorganic material, as shown at 1206. The inorganic material may then be
collected and safely discarded. The organic gas(ses) are mixed with hydrogen
gas
and steam, as shown at 1208. The mixed organic material, hydrogen gas, and
steam
are conveyed to a reactor that heats this mixture again to release methane
gas, as
shown at 1210.
[00111] This methane gas is directed from the reactor to the primary scrubber,
where
the methane gas mixture is cooled, and acid, water, and any particulate matter
are
removed, as shown at 1212. In a further embodiment, the gas mixture enters a
secondary scrubber to remove residual acid and water, as shown at 1214,
leaving a
cooled hydrogen-methane gas mixture.
[00112] Turning attention to Figure 12B, the hydrogen-methane gas mixture is
compressed by a compressor and cooled, as shown at 1216. As shown at 1218, a
hydrogen separator separates hydrogen from the hydrogen-methane gas mixture
(e.g.,
methane and 10-20% hydrogen), producing two streams: one of hydrogen and one
of
the hydrogen-methane gas mixture. The hydrogen is recycled back into the MFT
processing facility for use in heating the vaporizer, as show at 1220. And the
methane-
rich gas mixture is collected in a tank, or other receptacle, for use in
generating
electricity or liquid fuel, as shown at 1222. In some embodiments, the methane-
rich
gas mixture is 10-20% hydrogen and the rest methane.
[00113] As previously mentioned, the methane-rich gas mixture generated from
the
MFT may then be supplied to an electric generator, fuel cell, or liquid fuel
plant, as
shown at 1224, 1226, and 1228, respectively. As shown at 1230, the electric
generator
and the fuel cell generate electricity using the methane-rich gas mixture. As
shown at
1232, the liquid fuel plan generates a liquid fuel (e.g., diesel, ethanol,
methanol, or the
like) from the methane gas.
Date recue / Date received 2021-12-14
24
[00114] Reference is now made to Figure 13, which is a block diagram of an
alternative processing system 1300 for generating electricity or liquid fuel
from one or
more of a plurality of feed sources.
[00115] In Figure 13, the processing system 1300 comprises a processing
facility
1302 that is similar to MFT processing facility 1000, but in addition to the
MFT sources
120, 720, or 920, processing system 1300 includes two additional input
sources,
namely a petroleum coke source 1304 and a waste rubber tire source 1306. A
pulverizer 1314 is provided to crush the petroleum coke to a suitable size for
processing. Similarly, a milling machine 1316 is provided to shred the waste
rubber
tires 1306 to a fine powder. In a similar way to the MFT processing facility
1000, the
MFT sources 120, 720, or 920 are fed into the grinder 1002 (although the
grinder 1002
is located outside the processing facility 1302 rather than inside the MFT
processing
facility 1000). In some embodiments, the coke and the tire particles or powder
may be
provided as a suspension.
[00116] The outputs of the grinder 1002, the pulverizer 1314, and the milling
machine
1316 are fed into a distributor 1320 that blends the feed sources 120, 1304,
1306 and
feeds them as a single feed. The distributor 1320 determines which of the
three
sources 120, 1304, 1306 should be fed into the vaporizer 1004, and the
proportions of
each source 120, 1304, 1306 to be used. The decision on which sources to use
may
be based on availability of the source, the desired capability for energy
release or
capture, or any other suitable criterion. The distributor 1320 may operate a
valve in
the feed line from each of the grinder 1002, the pulverizer 1314, and the
milling
machine 1316 to control the amount of feed that it receives.
[00117] The distributor 1320 then feeds the output to the vaporizer 1004,
which is
processed in a similar manner to how the MFT processing facility 1000
operates.
[00118] In the processing system 1300, the liquid fuel and electricity that
are output
from the processing facility 1302 may be used (in part or entirely) to power
an air
carbon capture system 1330. This has the advantage of using the generated fuel
to
obtain carbon credits. The air carbon capture system 1330 may be similar to
those
provided by Carbon Engineering Ltd of Vancouver, Canada. However, any
convenient
air carbon capture system may be used.
Date recue / Date received 2021-12-14
25
[00119] In other embodiments, different input sources (for example, other
waste
sources) may be input to the processing system 1300 than those described
above.
[00120] It
is to be understood that the above description is intended to be illustrative,
and not restrictive. For example, the above-described embodiments (and/or
aspects
thereof) may be used in combination with each other. Furthermore, invention(s)
have
been described in connection with what are presently considered to be the most
practical and preferred embodiments, it is to be understood that the invention
is not to
be limited to the disclosed embodiments, but on the contrary, is intended to
cover
various modifications and equivalent arrangements included within the spirit
and scope
of the invention(s). Further, each independent feature or component of any
given
assembly may constitute an additional embodiment. In addition, many
modifications
may be made to adapt a particular situation or material to the teachings of
the
disclosure without departing from its scope. Dimensions, types of materials,
orientations of the various components, and the number and positions of the
various
components described herein are intended to define parameters of certain
embodiments, and are by no means limiting and are merely exemplary
embodiments. Many other embodiments and modifications within the spirit and
scope
of the claims will be apparent to those of skill in the art upon reviewing the
above
description. The scope of the disclosure should, therefore, be determined with
reference to the appended claims, along with the full scope of equivalents to
which
such claims are entitled.
[00121] While the aspects of the disclosure have been described in terms of
various
examples with their associated operations, a person skilled in the art would
appreciate
that a combination of operations from any number of different examples is also
within
scope of the aspects of the disclosure.
[00122] When introducing elements of aspects of the disclosure or the examples
thereof, the articles "a," "an," "the," and "said" are intended to mean that
there are one
or more of the elements. The terms "comprising," "including," and "having" are
intended to be inclusive and mean that there may be additional elements other
than
the listed elements. The term "exemplary" is intended to mean "an example of."
The
phrase "one or more of the following: A, B, and C" means "at least one of A
and/or at
least one of B and/or at least one of C."
Date recue / Date received 2021-12-14
26
[00123] Having described aspects of the disclosure in detail, it will be
apparent that
modifications and variations are possible without departing from the scope of
aspects
of the disclosure as defined in the appended claims. As various changes could
be
made in the above constructions, products, and methods without departing from
the
scope of aspects of the disclosure, it is intended that all matter contained
in the above
description and shown in the accompanying drawings shall be interpreted as
illustrative
and not in a limiting sense.
Date recue / Date received 2021-12-14
