Horizontal rotating drum retort

Abstract

A retort including a drum, an electric induction coil, a motor, and first and second jacks. The drum includes an inlet port at an inlet end, an outlet port at an outlet end, and a cylindrical tube extending between the inlet end and the outlet end. The electric induction coil is proximate the cylindrical tube for heating the cylindrical tube. The motor is operably and rotatably coupled to the cylindrical tube of the drum. The first jack is coupled to the drum proximate the inlet end, and is configured to raise and lower the inlet end of the drum. And the second jack is coupled to the drum proximate the outlet end, and is configured to raise and lower the outlet end of the drum.

Claims

1. A retort comprising: a drum comprising an inlet port at an inlet end, an outlet port at an outlet end, a cylindrical tube extending between the inlet end and the outlet end, an inlet seal and bearings rotatably coupling the inlet end of the drum and the cylindrical tube, and an outlet seal and bearings rotatably coupling the outlet end of the drum and the cylindrical tube, the inlet and outlet ends of the drum configured to remain stationary when the cylindrical tube rotates; an electric induction coil proximate the cylindrical tube for heating the cylindrical tube; an outer cover including a first end and a second end opposite the first end, the outer cover encasing at least a portion of the cylindrical tube of the drum and the electric induction coil; a carriage frame supporting the drum, the electrical induction coil, and the outer cover; a first mount coupled to the carriage frame and the inlet end of the drum, the first mount preventing the inlet end of the drum from rotating relative to the cylindrical tube; a second mount coupled to the carriage frame and the outlet end of the drum, the second mount preventing the outlet end of the drum from rotating relative to the cylindrical tube; a first adjustable support comprising a first base portion and one or more first rollers opposite the first base portion, the first adjustable support coupled to the carriage frame and to the first end of the outer cover, the first adjustable support rotatably supporting the cylindrical tube via the one or more first rollers, the first adjustable support configured to support the cylindrical tube at a first height relative to the first base portion; a second adjustable support comprising a second base portion and one or more second rollers opposite the second base portion, the second adjustable support coupled to the carriage frame and to the second end of the outer cover, the second adjustable support rotatably supporting the cylindrical tube via the one or more second rollers, the second adjustable support configured to support the cylindrical tube at a second height relative to the second base portion, the first height being greater than the second height, wherein the first and second adjustable supports are independently adjustable relative to the first and second base portions, respectively; and a motor mounted to the carriage frame and configured to rotate the cylindrical tube of the drum.

2. The retort of claim 1, wherein the first height is configured to increase or decrease via adjustment of the first adjustable support without increasing or decreasing the second height.

3. The retort of claim 1, wherein the second height is configured to increase or decrease via adjustment of the second adjustable support without increasing or decreasing the first height.

4. The retort of claim 1, wherein the outer cover is not operably and rotatably coupled with the motor such that it remains stationary when the cylindrical tube rotates.

5. The retort of claim 1, wherein the outer cover is fixedly coupled to the first adjustable support and the second adjustable support.

6. The retort of claim 1, wherein the carriage frame is suspended above the first base portion and the second base portion.

7. The retort of claim 1, wherein the cylindrical tube comprises at least one lifter coupled to an inner wall thereof.

8. The retort of claim 1, wherein the electric induction coil encircles the cylindrical tube.

9. The retort of claim 1, wherein the motor is configured to rotate the cylindrical tube with the electric induction coil remaining static.

10. The retort of claim 1, wherein a sprocket is coupled to the cylindrical tube, the sprocket and the motor rotatably coupled together via a chain.

11. The retort of claim 10, wherein the sprocket is positioned between the first mount and the first adjustable support.

12. The retort of claim 1, wherein the first adjustable support further comprises a first structure that both couples to the first end of the outer cover and rotatably supports the cylindrical tube via the one or more first rollers, and wherein the second adjustable support further comprises a second structure that both couples to the second end of the outer cover and rotatably supports the cylindrical tube via the one or more second rollers.

13. The retort of claim 12, wherein the first adjustable support further comprises a first telescoping member positioned between the first structure and the first base portion, and the second adjustable support further comprises a second telescoping member positioned between the second structure and the second base portion.

14. The retort of claim 1, wherein the first and second adjustable supports are independently supported by the first and second base portions, respectively.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Example embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting.

(2) FIG. 1 is an isometric view of a first embodiment of a retort.

(3) FIG. 2 is a side view of the retort of FIG. 1.

(4) FIG. 3 is a side view of the retort of FIG. 1, except a portion of the retort is shown cutaway.

(5) FIG. 4 is a side view of a second embodiment of a retort with a portion of the retort shown cutaway.

(6) FIG. 5 is a side view of the retort of FIG. 4.

(7) FIG. 6 is a side view of the retort of FIG. 4.

(8) FIG. 7 is a side view of a cooler or heat exchanger.

(9) FIG. 8 is a side view of the cooler or heat exchanger of FIG. 7, except a portion of it is shown cutaway.

(10) FIG. 9 is an open end view of the retort of FIG. 1.

DETAILED DESCRIPTION

(11) Aspects of the present disclosure involve a clean-energy technology process applicable to process coal, and oil shale, among other biomass products. The following is a description of a retort 100, as seen in FIG. 1. The function of the retort 100 is to heat coal or oil shale, among other products, to varying degrees of heat in an oxygen-free environment and remove the hydrocarbons in vapor form with a vacuum or slight vacuum within the retort 100. The hydrocarbon vapor may be transferred to a distillation tower (not shown in FIG. 1) from the retort 100. In the tower, the vapors are condensed to a liquid. The liquid may then be drained off into storage tanks for the different products that are extracted from the coal or oil shale. The char or the spent shale, from the retort 100, may be discharged with a high percentage of the contaminants removed, which provides a much cleaner fuel for use in a power plant or other application.

(12) The process of using the retort 100 may be as follows. The ore—coal, oil shale, or organic material (e.g., wood, crops, garbage) used in the retort 100—may be crushed to ⅜ inch minus size. In certain instances, the ore may be crushed to a different size. Upon being crushed, the ore may be transferred to a bin (not shown) on top of the feed port 102 of the horizontal retort 100. The feed port 102 is at a feed end 104 of the retort 100. The control of the feed into the feed port 102 may be regulated by an air lock rotary valve with a “time on”/“time off” switch at the bottom of the feed bin. The feed bin may maintain a head of ore at the feed port 102 of the retort 100.

(13) Once the ore is in the feed port 102, the flow of the ore through the retort 100 may be controlled by the slope of a rotating drum 106 of the retort 100 from the feed end or intake end 104 to a discharge end 108. And while the rotating drum 106 as seen in FIG. 2 is shown being level with the horizontal plane HP, it is to be understood that the rotating drum 106 may be angled relative to the horizontal plane with the intake end 104 being higher than the discharge end 108 to facilitate the ore moving through the rotating drum 106 via gravity and the angled nature of the retort 100. In a certain instance, the slope may be about 5 degrees from the horizontal axis. In a certain instance, the slope may be about 10 degrees from the horizontal axis. In a certain instance, the slope may be about 15 degrees from the horizontal axis. In a certain instance, the slope may be about 20 degrees from the horizontal axis. In a certain instance, the slope may be about 25 degrees from the horizontal axis. In a certain instance, the slope may be about 30 degrees from the horizontal axis.

(14) The rotating drum 106 may include a cylindrical tube 110 supporting the ore therein. On an internal side of the cylindrical tube 110, the rotating drum 106 may include lifters, flanges, or flighting 136 (as seen in FIG. 3) such that as the lifters 136 rotate with the drum 106, the ore spills off the lifters 136, and falls in the downward direction through the process and moves towards the lower, discharge end 112. The lifters 136 may be continuous or discontinuous pieces of metal that are welded or otherwise coupled to the internal wall of the cylindrical tube 110. The lifters 136 may wrap around the internal wall in a helical fashion, or may be linear strips of metal.

(15) The retort 100 may also include another air-lock rotary valve 112 at the discharge end 108 that insures an oxygen-free environment inside the retort 100. The operator of the retort 100 may monitor the temperature of the ore via thermostats positioned throughout the retort 100, for example, and may adjust the slope of the rotating drum 106 to maintain the temperature necessary for the ore type, size, intended result, etc. The discharge rotary valve 112 may be controlled with a “time on”/“time off” switch to balance the discharge with the flow of the ore into the retort 100.

(16) As the ore is heated up to around 930 degrees Fahrenheit within the rotating drum 106, it releases the hydrocarbon gasses as it flows through the process. A slight vacuum or full vacuum may be maintained inside the retort 100 by the air-lock valves 112, which may be variable-speed vacuum fans at the ends of the retort 100. As described previously, the vapors may be transferred to a distillation tower where they are condensed into various petroleum products with market value. In some instances, vapor outlets may be positioned along the tube such that different vapors are emitted and extracted at different processing stages.

(17) The processed ore can be routed through a dryer (not shown) to use the heat for the drying process or it can be transferred to a char storage bin through the heat ex-changer with a cold-water jacket without going through the dryer. The ore may be discharged from the heat ex-changer into a bucket or belt conveyor that takes the ore to the top of the char storage bin.

(18) The hot ash or processed ore may also be routed through the dryer if solid fuel is used for the heat source in the retort 100, as may be the case with the retort of FIGS. 4-6. The ore may be heated to a temperature of about 230 degrees to evaporate the surface moisture. In certain instances, this may increase the efficiency of the retort 100.

(19) If a fire source of heat is used (as opposed to an electric heating source), as may be the case with the retort of FIGS. 4-6, the flue gasses may be sucked through a pipe and filtered through an aeration system in an algae pond where the toxins will be consumed by the algae. Oxygen is produced by the algae making a clean process.

(20) Support equipment such as a crusher, serener, surge bins, dryer, bucket elevator, condensing tower, augers and conveyors are not shown in every instance, but a person having ordinary skill in the art would understand these components can be utilized in the retort 100 and overall system for generating clean energy/fuel.

(21) The retort 100 will be discussed in further detail with respect to FIGS. 1-3. FIGS. 1-3 depict, respectively, an isometric view of a first embodiment of a retort 100, a side view of the retort 100, and a cutaway side view of the retort 100. As seen in the figures, the retort 100 includes an outer cover 114 in the form of a cylindrical tube 116. The outer cover 114 may be supported by leveling jacks 118 (e.g., trailer jacks) which can be raised or lowered so as to raise or lower the portion of the outer cover 114 that is supported on the particular leveling jack 118. In this way, the leveling jacks 118 may adjust a slope or angle of the retort 100 (relative to a horizontal axis) from an intake end 104 to a discharge end 108 such that the ore moves via gravity from the intake end 104 to the discharge end 108. A flow rate of the ore through the retort 100 may be adjusted by increasing or decreasing the slope or angle of the retort 100 (or, more particularly, the rotating drum 6). The leveling jacks 118 as described herein may include hydraulic, pneumatic or mechanical (e.g., screw-driven scissor jack) lifting devices. The leveling jacks 118 may be considered adjustable supports. And as seen in FIG. 9, there may be a pair of leveling jacks 118 coupled together via cross-braced tubing 160 where the pair of leveling jacks 118 are adjusted up or down in concert with each other.

(22) In place of the leveling jacks 118, a frame or support may be utilized in the retort 100. The support may be height adjustable or non-adjustable. The adjustable support may be capable of manually adjusting the height of the cross-braced tubing 160. For example, the adjustable support may include a series of spaced-apart through-holes for extending a shaft of the cross-braced tubing 160 through. The adjustable support may have its heights set along a length of the retort 100 to accomplish the desired slope from the intake end 104 to the discharge end 108.

(23) In the case of non-adjustable supports, there may be a number (e.g., four non-adjustable supports in the use with the retort 100 of FIG. 1) of non-adjustable supports of different heights positioned at various lengths along between the intake end 104 and discharge end 108 to accomplish the desired slope of the retort 100.

(24) As seen in FIGS. 1-3, the rotating drum 106 is positioned within an inner cavity of the outer cover 114. Ore is fed into the rotating drum 106 via an ore feed or intake opening 102. Because of the slope of the retort 100 from left-to-right (as seen in FIG. 2, and assuming an angle relative to the horizontal plane HP where the intake end 104 is higher than the discharge end 108), the ore will travel from the ore feed 102 into the rotating drum 106. To the left of the ore feed 102 is a vapor fan 112 which draws vapor from within the rotating drum 106 and out a vapor tube to a distilling tower (not shown). At an opposite end of the retort 100 (at the discharge end 108), another vapor fan 112 and vapor tube 120 exhaust air and vapor from within the rotating drum 106 and to the distilling tower.

(25) Back at the intake end 104, between the ore feed 102 and the rotating drum 106 is a seal and bearing 122 permitting the rotating drum 106 to rotate while the ore feed 7 remains stationary and fixed to a mount 124. A gear motor 126 is coupled to the rotating drum 106 via a belt or chain (or similar component) 128 (as seen in FIG. 2) that engages a sprocket 162 that is coupled to the rotating drum 106. In this way, as the motor 126 rotates, the chain 128 is caused to rotate, which cause the sprocket 162 and the rotating drum 106 to rotate within the outer cover 114. With the retort 100 of FIGS. 1-3, the outer cover 114 remains stationary or static (i.e., it does not rotate with the drum 106).

(26) At the discharge end 108, the retort 100 includes an ore discharge or discharge opening 128 that is linked with the rotating drum 106. Between the ore discharge 128 and the rotating drum 106 is a seal and bearing 122 for permitting the rotating drum 106 to rotate while the ore discharge 128 and vapor fan 112 remain stationary and supported by a mount 124. The retort 100 may be supported by a carriage frame 130 extending generally the length of the retort 100. The mounts 124 on either end of the retort may be supported on the carriage frame 130.

(27) Referring to FIGS. 1-3, it can be seen that above that there are four leveling jacks 118 used to support the retort 100 above the ground. The two inner leveling jacks 118 may include a connection flange 132 including a concave, semi-cylindrical surface for supporting the outer cover 114. The flange 132 may be at the interconnection or seal of the cylindrical tubes 116 of the outer cover 114. In this way, the retort 100 may include three sections of cylindrical tubes 116 making up the outer cover 114. The three sections of cylindrical tubes 116 may be coupled together at or near the connection flanges 132 of the two inner leveling jacks 118.

(28) As seen in FIG. 9, the outer tubes 116 of the outer cover 114 are supported on the flange 132. Referring back to FIGS. 1-3, the two outer leveling jacks 118 are coupled to drum rollers 164 positioned against and supporting the rotating drum 106. Thus, as the rotating drum 106 rotates, the drum rollers 164 passively rotate. The two outer leveling jacks 118 may also include connection flanges 132 that couple to the outer cover 114. As seen in FIG. 1, the connection flange 132 coupled with the leveling jack 118 nearest the discharge end 108 includes a ring or annular disk that is coupled to the end of the outer cover 114. The rotating drum 106 extends through the central opening of the annular disk.

(29) As seen in the cutaway portion in FIG. 3, in between an inner wall of the outer cover 114 and an outer wall of the rotating drum 106 are heat induction coils 134 that may be coupled to the outer cover 114. The coils 134 may wrap around or encircle the rotating drum 106 and permit the rotating drum 106 to rotate within an inner volume formed by the coils 134. The coils 134 may be connected to a power source (not shown) in order to generate heat on the rotating drum 106.

(30) As seen in FIG. 3, within the rotating drum 106 are lifters 136 coupled to an internal wall of the drum 106 that are designed to agitate or mix the ore positioned within the drum 106. In FIG. 3, the lifters 136 are shown as linear strips of metal or steel angles. Thus, as the drum 106 rotates, the ore contacts the lifters 136 and is moved throughout the drum 106 and downward along the slope of the drum 106 towards the discharge end. The lifters 136 may be steel welded or coupled to an inner wall of the drum 106, and may be linear or curved. Additionally or alternatively, the lifters 134 may be continuous along the entire length of the rotating drum 106 or may be discontinuous along the length.

(31) Continuing on, reference is made to FIGS. 4-6, which depict a second embodiment of a retort 100. FIGS. 4-6 depict, respectively, a cutaway side view of the retort 100, a side view of the second embodiment of the retort 100, and another cutaway side view of the second embodiment of the retort 100. The retort 100 in these figures may include many of the same or similar components to the retort 100 in FIGS. 1-3, except the retort 100 in FIGS. 4-6 utilizes a burning ore as a heat source to heat the rotating drum 106. As seen in FIG. 4, the stationary outer cover (of the previous embodiment) is replaced by an outer rotating drum 138 that rotates along with the inner rotating drum 106. As such, both the inner and outer drums 106, 138 rotate in this embodiment of the retort 100.

(32) The outer rotating drum 138 includes a hot ore or hot ash feed 140 for in taking ore to be heated/burned within the outer rotating drum 138. Since the inner rotating drum 106 is positioned within the cavity of the outer rotating drum 138, the hot ore heats up the inner rotating drum 106 so as to cause the ore feed within the inner rotating drum 106 to release gaseous vapors through the vapor port 142 and to the distillation tower.

(33) Opposite the hot ore feed 140 is a vapor port 144 for exhausting vapors from within the cavity between the inner wall of the outer rotating drum 138 and the outer wall of the inner rotating drum 106. The outer rotating drum 138 also includes a hot ore or hot ash discharge 146 for discharging the hot ore or hot ash after it has moved longitudinally through the outer rotating drum 138.

(34) The retort of FIG. 4 may include a gear motor 126 (positioned near the middle of the retort 100) for rotating the outer rotating drum 138, and the inner rotating drum 106. More particularly, the gear motor 126 may be rotatably coupled to a sprocket 154 that is coupled to the outer and inner rotating drums 138, 106 via a chain (not shown in FIG. 4). A thrust roller 148 may be positioned adjacent the sprocket 154, and may roll against the sprocket 154, passively, as the sprocket 154 is driven by the gear motor 126 and chain. In this way, the thrust roller 148 may function as an idler, and may also function to support the retort 100 as it is angled downward. As seen in the figure, the thrust roller 148 is on a downward or discharge side of the sprocket 154.

(35) The outer rotating drum 138 may be supported by carriage or drum rollers 150 at both the intake end 104 and discharge end 108. The rollers 150 may be coupled to leveling jacks 118 for raising and lowering the portion of the retort 100 to which it is coupled. Thus, the leveling jacks 118 may be used to angle the rotating drums 138, 106 at an angle such that the ore fed into the ore feed 102 and hot ore fed into the hot ore feed 140 are caused to move or tumble via gravity from the intake end 104 to the discharge end 108.

(36) As seen in FIG. 4, the portion of the rotating drums 138, 106 intermediate of the intake ports 102, 140 and the discharge ports 144, 142 may rotate while the outer portions remain stationary. The retort 100 may include seals and bearings 152 to facilitate the inner portion of the rotating drums 138, 106 to rotate relative to the outer portions. And as seen in FIG. 4, the retort 100 may include lifters 136 coupled to an inner wall of the outer rotating drum 138, and lifters 136 coupled to an inner wall of the inner rotating drum 106. In FIGS. 5-6, the fuel feed 140 includes an air input port 156 for air to enter and aid in the combustion with the hot ore.

(37) As described previously, the thrust roller 148 passively roll against the drum sprocket 154 such that as the gear motor 126 operates to rotate the drum sprocket 154 via a chain, the thrust roller 148 passively rotates with the drum sprocket 154 on the discharge side of the drum sprocket 154. The drum sprocket 154 may be a sprocket that is welded to the outer drum 138 such that as the drum sprocket 154 is driven via the motor 126, the outer drum 138 rotates as well. In certain instances, the outer drum 138 is rigidly coupled to the inner drum 106 such that they rotate together. And in certain instances, the outer drum 138 is rotatably coupled to the inner drum 106 such that they may rotate independent of each other.

(38) In certain instances, the heat sources for the retort 100 that is fed into the hot ore port 140 may be solid fuel (coal or shale or spent shale), natural gas, propane, crude oil or used recycled oil, land fill garbage, and/or a combination of any of the above heat sources.

(39) FIG. 7 illustrates a side view of a char cooler 200, and FIG. 8 illustrates a cutaway side view of the char cooler 200. As seen in the figures, the char cooler 200 may include an ore feed chute 202 that intakes processed ore from the ore discharge port (reference 128 on FIG. 6). The char cooler 200 may also include an outer tube 204, an inner tube 206 positioned within the outer tube 204, and an auger flighting 208 (seen in FIG. 8) positioned within the inner tube 206. Opposite the ore feed chute 202 is an ore discharge port 210. The outside tube 204 includes fluid input ports 212 and fluid discharge ports 214. Since the ore is hot as it enters the feed chute 202, the fluid (e.g., cold water) enters the input ports 212, contacts and cools the outer wall of the inside tube 206, and then exits through the discharge ports 214. The ore is moved through the inside tube 206 via rotation of the auger flighting 208. The auger flighting 208 is rotated via a gear motor 216 to which it is rotatably coupled.

(40) FIG. 9 illustrates a cross-sectional view of the retort 100 of FIGS. 1-3 with induction coils 134 providing heat to the rotating drum 106. As seen in the figure, the outer cover 114 is supported on a flange support 132, which is further supported on cross-braced tubing 160. The tubing 160 is supported by the leveling jacks 118. The induction coils 134 encircle the rotating drum 106 and reside in close proximity thereto. The internal side of the rotating drum includes six lifters therein for agitating the ore.

(41) In certain instances, a method of operating the retort 100 may be as follows. The method may include setting a slope of the drum 106 of the retort 100 relative to a horizontal plane such that an inlet or intake end 104 of the drum 106 is higher than an outlet or discharge end 108 of the drum 108. The drum 106 may include a cylindrical tube 110 extending between the inlet end 104 and the outlet end 108. The retort 100 further may include an electric induction coil 134 proximate the cylindrical tube 110 for heating the cylindrical tube 110. The retort may also include a motor 126 operably and rotatably coupled to the cylindrical tube 110 of the drum 106. The retort 100 may also include first and second supports 118 (e.g., jacks). The first support 118 may be coupled to the drum 106 proximate the inlet end 104, where the first support 118 raises and lowers the inlet end 104 of the drum 106. The second support 118 may be coupled to the drum 106 proximate the outlet end 108, where the second support 118 raises and lowers the outlet end 108 of the drum 106. The retort 100 may include any of the features or elements described in the application without limitation.

(42) The method may also include feeding ore into the inlet port of the drum 106. And the method may also include heating the drum via the electric induction coil so as to remove volatiles from the ore. The method may also include removing oxygen from the drum 106, rotating the drum 106.

(43) While the present disclosure has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the present disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, embodiments in accordance with the present disclosure have been described in the context of particular implementations. Functionality may be separated or combined in blocks differently in various embodiments of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.

(44) In general, while the embodiments described herein have been described with reference to particular embodiments, modifications can be made thereto without departing from the spirit and scope of the disclosure. Note also that the term “including” as used herein is intended to be inclusive, i.e. “including but not limited to.”

(45) The construction and arrangement of the retort and its systems as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, the position of elements may be reversed or otherwise varied and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present disclosure.