Abstract
The present invention is a pyrolysis system including a furnace for batch pyrolysis processing. The pyrolysis system receives scrap tires or other organic waste materials as inputs and performs batch pyrolysis processing to produce pyro-products as outputs. The pyro-products produced include pyro-vapors from which are condensed pyro-oil with a surviving pyro-gas and also include pyro-solids, particularly pyro-carbon (carbon char) and steel. The pyro-oil includes an inhibitor.
Claims
1. A pyrolysis system comprising: one or more furnaces, each furnace including, a chamber for receiving a cart supporting waste material for pyrolysis processing to form pyrolysis products, a door in the furnace for opening to load and unload the cart and for closing to seal the chamber during pyrolysis processing, a furnace port for receiving pyro-vapors from the chamber during pyrolysis processing, one or more heat units, each heat unit for heating the chamber to pyrolysis temperatures, a vapor unit for receiving pyro-vapors from the chamber during pyrolysis processing, a control unit for controlling the pyrolysis processing with a heating cycle up to a temperature greater than 400 C. for greater than one hour.
2. The system of claim 1 wherein a nitrogen port is provided in each of the one or more furnaces for injecting nitrogen into the chamber for purging the chamber through the furnace port.
3. The system of claim 1 further including an unload station in a separate location from the furnace for removing pyro-solids from the cart.
4. The system of claim 3 wherein the unload station includes a magnetic separator for extracting steel from the pyro-solids.
5. The system of claim 1 wherein the vapor unit includes, condenser stages for cooling pyro-vapors to separate out pyro-liquids, a pyro-gas scrubber connected for processing uncondensed pyro-gases from the condenser stages to provide gas products.
6. The system of claim 5 wherein the scrubber removes sulfur and other impurities from the pyro-gas.
7. The system of claim 5 wherein the condenser stages operate over different temperature ranges to fractionally condense pyro-oils of different molecular weights and wherein the system further includes a pyro-oil unit for processing the pyro-oils of different molecular weights to form pyro-oil products including inhibitors.
8. The system of claim 1 including a control unit for controlling the furnaces over pyrolysis cycles, each pyrolysis cycle including a load step, a purge step, a temperature increase step, a temperature steady step, a temperature decrease step and an unload step.
9. The system of claim 8 wherein transportable carts during the load step of one pyrolysis cycle are made ready to be transported to a furnace where another transportable cart has been removed for the unload step of another pyrolysis cycle.
10. The system of claim 8 wherein for the pyrolysis cycles, the temperature increase step, the temperature steady step and the temperature decrease step are each about 3 hours long.
11. The system of claim 8 wherein outside gas is injected into the furnace chamber during the decrease step to accelerate cooling of the furnace chamber.
12. The system of claim 8 wherein the pyrolysis cycles for furnaces are offset in time whereby the pyrolysis system operates in a continuous mode.
13. The system of claim 12 wherein the pyrolysis cycles for eight furnaces operating on 12 hour cycle times are offset in time by approximately 2 hours.
14. The system of claim 8 wherein the temperature steady step is at approximately 1800 F. whereby the pyro-solids produced include pyro-carbon substantially free of pyro-oil.
15. The system of claim 1 wherein the system includes an N.sub.2 source for supplying N.sub.2 gas through a nitrogen port to purge the sealed furnace chamber of oxygen whereby the pyro-solids produced during the pyrolysis cycles include pyro-carbon which is not oxidized and is substantially reduced in ash content.
16. The system of claim 1 wherein a plurality of the furnaces have substantially the same design to facilitate manufacturing, maintenance and repairs in the system.
17. The system of claim 1 wherein a control unit turns off one or more of the furnaces while continuing operations with other furnaces whereby pyrolysis processing for the system continues with one or more of the furnaces off.
18. The system of claim 1 wherein a control unit matches the processing capabilities of furnaces and retorts to the waste material supply.
19. The system of claim 1 wherein a control unit sets pyrolysis operational parameters for a plurality of furnances where the pyrolysis operational parameters for some furnaces are different from the pyrolysis operational parameters for other furnaces.
20. The system of claim 1 wherein the waste material includes large tires having steel bands removed by bagel cutting prior to cutting the tires into pieces.
21. The system of claim 1 further including one or more fans for circulating gases within the furnace chamber for even heat distribution and to accelerate cooling.
22. A pyrolysis system comprising: a load station for loading waste tire material into a plurality of carts, a plurality of pyrolysis stations, each station including, a pyrolysis furnace including, a furnace chamber for receiving the plurality of carts, one at a time, with waste tire material for pyrolysis processing, a furnace door opening for transporting the one of the carts into the chamber and for removing the one of the carts from the chamber, the furnace door for closing to seal the chamber for pyrolysis processing, an exhaust port for exhausting pyro-vapors from the furnace chamber, a nitrogen port for injecting nitrogen into the furnace chamber when the chamber is sealed to purge oxygen from the chamber through the exhaust port, a heat unit for heating the furnace chamber to pyrolysis temperatures causing pyro-vapors to be generated from the waste tire material, a vapor unit for receiving and processing the pyro-vapors from the exhaust port during pyrolysis processing, an oil unit for receiving pyro-oil from the vapor unit, an unload station for receiving the one of the carts with pyro-solids from the furnace chamber after pyrolysis processing and for unloading the pyro-solids.
23. A pyrolysis system comprising: a load station for loading tire waste material into one or more carts, a plurality of pyrolysis stations, each station including, a pyrolysis furnace including, a furnace wall surrounding a chamber for receiving the one or more carts, one at a time, with waste tire material for pyrolysis processing of the waste tire material, a furnace door opening the furnace wall for transporting the one of the carts into the chamber and for removing the one of the carts from the chamber, the furnace door closing to seal the chamber for pyrolysis processing, a nitrogen port for injecting nitrogen into the furnace chamber when the chamber is sealed to purge the chamber through the exhaust port, an exhaust port for exhausting pyro-vapors from the furnace chamber, a heat unit for heating the furnace chamber to the pyrolysis temperatures, a fan unit including a motor external to the furnace wall, a shaft extending from the motor through the furnace wall and a fan blade connected to the shaft where the motor drives the fan blade to circulate gases within the chamber, a vapor unit for receiving and processing the pyro-vapors from the exhaust port, an oil unit for receiving pyro-oil from the vapor unit, an unload station for receiving the one of the carts with pyro-solids from the furnace chamber, after pyrolysis processing, for unloading pyro-solids.
24. The pyrolysis system of claim 23 wherein, the nitrogen injected by the nitrogen port causes air including oxygen to be exhausted through the exhaust port whereby the chamber is substantially oxygen free.
25. The pyrolysis system of claim 23 where the pyro-oil includes an inhibitor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 depicts a pyrolysis system having a load station, a pyrolysis station and an unload station with transportable carts that move among the stations.
[0038] FIG. 2 depicts a schematic view of an alternate furnace for the pyrolysis system of FIG. 1.
[0039] FIG. 3 depicts a top view of a stack of tires of one size bailed together.
[0040] FIG. 4 depicts a front view of the stack of tires of FIG. 3.
[0041] FIG. 5 depicts a top view of another stack of tires of the FIG. 3 size bailed together.
[0042] FIG. 6 depicts a front view of the stack of tires of FIG. 5.
[0043] FIG. 7 depicts a top view of another stack of tires of the FIG. 3 size bailed together.
[0044] FIG. 8 depicts a front view of the stack of tires of FIG. 7.
[0045] FIG. 9 depicts a top view of another stack of tires of the FIG. 3 size bailed together.
[0046] FIG. 10 depicts a front view of the stack of tires of FIG. 9.
[0047] FIG. 11 depicts a front view of the tires of FIG. 4, FIG. 6, FIG. 8 and FIG. 10 stacked together.
[0048] FIG. 12 depicts a front view of the stacks of tires of FIG. 11 bailed together for insertion into a furnace.
[0049] FIG. 13 depicts a top view of a rectangular stack of tires compressed together for insertion into a furnace.
[0050] FIG. 14 depicts a side view of the rectangular stack of tires of FIG. 13.
[0051] FIG. 15 depicts a side view of the rectangular stack of tires of FIG. 13.
[0052] FIG. 16 depicts a front view of the rectangular stack of tires of FIG. 13 loaded in a cart for insertion into a furnace.
[0053] FIG. 17 depicts a front view of a stack of tire pieces cut from large tires and compressed together in a cart for insertion into a furnace.
[0054] FIG. 18 depicts a top view of the stack of tire pieces in the cart of FIG. 17.
[0055] FIG. 19 depicts a top view of an extra-large tire.
[0056] FIG. 20 depicts a top view of the tire of FIG. 19 cut in quarters.
[0057] FIG. 21 depicts a top view of the one-quarter section of the tire cut as shown in FIG. 20.
[0058] FIG. 22 depicts a front view of the one-quarter section of the tire section of FIG. 21.
[0059] FIG. 23 depicts a front view of a stack of tires of the FIG. 22 type.
[0060] FIG. 24 depicts a top view of tire sections of the FIG. 21 nested together.
[0061] FIG. 25 depicts a schematic perspective view of a cart used for transporting material among the load station, the pyrolysis station and the unload station.
[0062] FIG. 26 depicts a schematic cutaway view of a furnace with a stack of tires in a cart ready for pyrolysis processing.
[0063] FIG. 27 depicts a sequence of processing through a pyrolysis process.
[0064] FIG. 28 depicts a schematic view of a detailed vapor unit for use in the FIG. 1 system.
[0065] FIG. 29 depicts a typical graph of one example of the temperature of a furnace 2 during pyrolysis processing.
[0066] FIG. 30 depicts a pyrolysis system having a plurality of pyrolysis furnaces for receiving the transportable carts.
[0067] FIG. 31 depicts a schematic view of a pyrolysis system having groups of pyrolysis furnaces sharing vapor units.
[0068] FIG. 32 depicts a graph of one example of a typical temperature of a furnace cycled twice over a 24 hour period.
[0069] FIG. 33 depicts a graph of one example of typical temperatures of six furnaces cycled sequentially.
[0070] FIG. 34 depicts a graph of one example of typical temperatures often furnaces cycled sequentially.
[0071] FIG. 35 depicts a production well for pumping crude oil from the ground together with inhibitor apparatus for injecting an inhibitor into the production well.
[0072] FIG. 36 depicts a block representation of an inhibitor including polar and non-polar components.
DETAILED DESCRIPTION
[0073] In FIG. 1, a pyrolysis apparatus 70 is shown. The pyrolysis system receives scrap tires 74 or other organic waste materials as inputs and performs pyrolysis processing to produce pyro-products as outputs. The pyro-products produced include pyro-vapors that are separated into pyro-oil and pyro-gas and include pyro-solids, particularly pyro-carbon (carbon char) and steel. One of the pyro-products is an inhibitor 10. The pyrolytic system 70 has a load station 71, a pyrolysis station 72, an unload station 73 and a control unit 83. The pyrolysis apparatus 70 includes a transportable cart 75 for moving along a transport track 84 or along other transport paths. The transport track 84 extends to each of the load station 71, the pyrolysis station 72 and the unload station 73. In the load station 71 scrap tires 74 or other materials for pyrolysis are loaded onto transportable cart 75 for transport along the track 84 to the pyrolysis station 72.
[0074] The pyrolysis station 72 has a pyrolysis furnace 90 for receiving the transportable cart 75 and the scrap tires 74. The furnace 90 includes a heat unit 78 for heating the furnace 90 to pyrolysis temperatures. The heat unit 78 connects via heat line 91 to heaters 76-1 and 76-2 within the furnace 90 where they operate to heat the pyrolysis chamber 92 to the pyrolysis temperatures. The heat unit 78 is supplied with fuel by different means. For example, the heat unit 78 receives fuel from a natural gas source (not shown), receives co-generated fuel from the vapor unit 79 on line 85, or receives co-generated fuel from the oil unit 80 on line 86. The choice of what fuel source is used for the heat unit 78 is a function of the cost, cleanliness and sufficiency of the fuel. Gas, oil or both may be used.
[0075] Before the pyrolysis operation, the scrap tires 74 or other materials are on the transportable cart 75. After pyrolysis, the pyro-solids 77 remain on the transportable cart 75 and are transported to the unload station 73. The entry and exit of the transportable cart 75 into and from the chamber 92 of furnace 90 is through a door 93 in the wall of the furnace 93. The door 93 is opened to receive the transportable cart 75 from the load station 71, is closed during the pyrolysis operation and thereafter is opened to allow transport of the cart 75 and pyro-solids 77 to the unload station 73.
[0076] The pyrolysis station 72 includes a vapor unit 79 that connects via the piping 82 to the furnace 90 to receive the vapors resulting from the pyrolysis operation. The vapor unit 79 connects by piping 83 to the oil unit 80. The oil unit 80 connects by piping 82 to the inhibitor storage 81 which stores the inhibitor 10 produced by the pyrolysis operation.
[0077] In FIG. 2, a schematic view of an alternate furnace 90 is shown for the pyrolysis system of FIG. 1. In FIG. 2, the heaters 76-1, 76-2 and 76-3 are positioned on the sides and top of the furnace 90. The cart 75 with the scrap tires 74, before pyrolysis, is positioned so as to be surrounded by the heaters 76-1, 76-2 and 76-3. After pyrolysis, the pyro-solids 77 remain in a pile on the cart 75 ready to be moved to an unload station.
[0078] In FIG. 3, a top view is shown of a stack of tires 41-1s of one size, including a top tire 41-1-1, bailed together by bailing wires 42-1.
[0079] In FIG. 4, a front view is shown of the stack of tires 41-1s of FIG. 3. The stack 41-1s includes the four tires 41-1-1, 41-1-2, 41-1-3 and 41-1-4 bailed together by bailing wires 42-1.
[0080] In FIG. 5, a top view is shown of a stack of tires 41-2s of one size, including a top tire 41-2-1, bailed together by bailing wires 42-2 for insertion into a furnace.
[0081] In FIG. 6, a front view is shown of the stack of tires 41-2s of FIG. 5. The stack 41-2s includes the four tires 41-2-1, 41-2-2, 41-2-3 and 41-2-4 bailed together by bailing wires 42-2.
[0082] In FIG. 7, a top view is shown of a stack of tires 41-3s of one size, including a top tire 41-3-1, bailed together by bailing wires 42-3 for insertion into a furnace. The bailing wires are steel with magnetic properties that are easily removed magnetically from the char after processing.
[0083] In FIG. 8, a front view is shown of the stack of tires 41-3s of FIG. 7. The stack 41-3s includes the four tires 41-3-1, 41-3-2, 41-3-3 and 41-3-4 bailed together by bailing wires 42-3.
[0084] In FIG. 9, a top view is shown of a stack of tires 41-4s of one size, including a top tire 41-4-1, bailed together by bailing wires 42-4 for insertion into a furnace.
[0085] In FIG. 10, a front view is shown of the stack of tires 41-4s of FIG. 9. The stack 41-4s includes the four tires 41-4-1, 41-4-2, 41-4-3 and 41-4-4 bailed together by bailing wires 42-4.
[0086] In FIG. 11, a front view is shown of the bailed tire stacks 41-1s, 41-2s, 41-3s and 41-4s of FIG. 4, FIG. 6, FIG. 8 and FIG. 10 which are stacked together for insertion into a furnace.
[0087] In FIG. 12, a front view is shown of the bailed tire stacks 41-1s, 41-2s, 41-3s and 41-4s of FIG. 11 bailed together as a stack 74.
[0088] In FIG. 13, a top view of a rectangular stack 140 of tires is shown. The stack 140 includes tires 141-1, 141-2, 143-3 and so on.
[0089] In FIG. 14, the side view of the rectangular stack 140 of tires of FIG. 13 is shown. The stack 140 includes tires 141-4, 141-5, 143-6 and so on.
[0090] In FIG. 15, a side view of the rectangular stack 140 of tires of FIG. 13 is shown. The stack 140 includes tires 141-7, 141-8, 143-9 and so on.
[0091] In FIG. 16, a front view of the rectangular stack 140 of tires of FIG. 15 is shown loaded in a cart 75 for insertion into a furnace. The stack 140 includes tires 141-7, 141-8, 143-9 and so on.
[0092] In FIG. 17, a front view of a stack 142 of tire pieces cut from large tires and compressed together in a cart 75 is shown ready for insertion into a furnace. The stack 142 includes tires 143-1, 143-2, 143-3 and so on.
[0093] In FIG. 18, a top view of the stack 142 of tire pieces in the cart 75 of FIG. 17 is shown. The stack 142 includes tires 143-4, 143-5, 143-6 and so on.
[0094] Tires can be of many different sizes. In the case of some large tires, for example large mining truck tires, the tires have thick steel bands that are difficult to cut. Such tires, in one embodiment, are bagel cut to remove the steel bands before cutting the tires into smaller pieces. In addition to the steel bands, the large tires have additional steel pieces in the tread and sidewalls that are readily cut along with the tire to fit the tire pieces into the cart for pyrolysis processing.
[0095] In FIG. 19, a top view of an extra-large tire 150 is shown. By way of example, tire 150 is thirteen feet in diameter with a center hole of three feet. Typically, such large tires have steel bands 151 removed by bagel cutting prior to cutting the tires into pieces
[0096] In FIG. 20, a top view of the tire 150 of FIG. 19, with steel bands removed, cut in quarters 150-1, 150-2, 150-3 and 150-4.
[0097] In FIG. 21, a top view of the quarter 150-1 of the tire 150 of FIG. 20 is shown.
[0098] In FIG. 22, a front view of the quarter 150-1 of FIG. 21 is shown.
[0099] In FIG. 23, a front view of the four quarters 150-1, 150-2, 150-3 and 150-4 stacked for loading into a cart of the FIG. 25 type.
[0100] In FIG. 24, a top view of tire quarters 150-1 and 150-2 nested together for loading into a cart of the FIG. 25 type.
[0101] In FIG. 25, a schematic perspective view of a cart 75 is shown. The cart 75 is used for transporting material among the load station 71, the pyrolysis station 72 and the unload station 73 of FIG. 1. The cart 75 typically includes one side 75-1 shown open, in a hinged down position for example, for loading tires or other organic material for pyrolysis processing and for unloading pyro-solids after pyrolysis processing.
[0102] In FIG. 26, a schematic cutaway view of a furnace 90 is shown. The furnace 90 includes heaters 76 which are heated by heat unit 78 of FIG. 1 to pyrolysis temperatures. A stack of tires 74 are on cart 75 ready for pyrolysis processing in the furnace chamber 92. A vent 82-1 (vapor transfer line) is in the furnace wall 95 leading to the vent pipe 82 is shown for exhausting pyro-vapor from the chamber 92. A vent 94-1 and a vent 94-2 are provided for injecting nitrogen gas into the chamber 92 for purging oxygen (or air containing oxygen) through the port 82-1 and the pipe 82. The furnace 90 includes one or more fans 96 for circulating gases in the chamber 92. One or more fan shafts 97 extend from outside the furnace 90 from one or more motors 98 through the furnace wall to the fans 96. The motors 98 rotate the fans 96 which are positioned over baffles 99 that help direct the gases in the chamber 92. The fans are controlled in speed and have circulating gases directed to keep the gases from stirring up carbon or directing carbon into the vapor transfer line.
[0103] In FIG. 27, a sequence of pyrolysis processing is shown for a furnace 90 in four stages 90-1, 90-2, 90-3 and 90-4. In the first stage 90-1, the door 93 is open ready to receive the cart 75 and stack of tires 74. The cart 75 is ready to be transported along track 84 into the chamber 92. In the second stage 90-2, the door 93 is closed with the cart 75 and stack of tires 74 in the chamber 92. In the second stage 90-2, the pyrolysis processing occurs with an increase in temperature to pyrolysis levels. In the third stage 90-3, the pyrolysis processing continues with a decrease in temperature to leave a solid residue 77, the gas and oil pyro-products having been excavated from chamber 92. In the fourth stage 90-4, the pyrolysis processing is completed, the door 93 is opened and the cart 75 and the residue 77 is removed from the chamber 92.
[0104] In FIG. 28, a schematic view of a detailed vapor unit 79 and distillation unit 179 are shown for use in the FIG. 1 system and with the furnace 90 of FIG. 26. The pyro-vapors produced during the pyrolysis processing are vented through the vapor transfer line including port 82-1 and pipe 82 of the FIG. 26 furnace to the vapor unit 79 and/or to the distillation unit 179. The vapor unit 79 includes, for example, condensing stages 79-1, 79-2 and 79-3 for processing the pyro-vapors to extract pyro-products including pyro-gases and pyro-oils. The first stage 79-1 is connected through valves 12-1, 12-4 and 112-1 which are opened or closed, under control of control unit 5, to extract pyro-oil or pyro-gas of a first property as pyro-oil or pyro-gas output products. The first stage 79-1 is connected through valves 12-1 and 112-1 which are opened or closed, under control of control unit 5, to extract pyro-gases for further processing in a fractional distillation unit (1.sup.st DU) 183-1. The unit 183-1 connects through valve 113-1 to a 1.sup.st storage unit 184-1 (1.sup.st STORE).
[0105] The second stage 79-2 receives the output from the first stage 79-1 and is connected through valves 12-2, 12-4 and 112-2 which are opened or closed, under control of control unit 5, to extract pyro-oil or pyro-gas of a second property as pyro-oil or pyro-gas output products. The second stage 79-2 is connected through valves 12-2 and 112-2 which are opened or closed, under control of control unit 5, to extract pyro-gases for further processing in a fractional distillation unit (2.sup.nd DU) 183-2. The unit 183-2 connects through valve 113-2 to a 2.sup.nd storage unit 184-2 (2.sup.nd STORE).
[0106] The third stage 79-3 receives the output from the second stage 79-2 and is connected through valves 12-3, 12-4 and 112-3 which are opened or closed, under control of control unit 5, to extract pyro-oil or pyro-gas of a first property as pyro-oil or pyro-gas output products. The third stage 79-3 is connected through valves 12-3 and 112-3 which are opened or closed, under control of control unit 5, to extract pyro-gases for further processing in a fractional distillation unit (3.sup.rd DU) 183-3. The unit 183-3 connects through valve 113-3 to a 3.sup.rd storage unit 184-3 (3.sup.rd STORE).
[0107] The unit 183-1 receives an input from the vapor transfer line (pipe 82) under control of control unit 5. The unit 183-1, unit 183-2 and the unit 183-3 are connected in series through valves under control of control unit 5. The third unit 183-3 connects through a valve, under control of control unit 5, to the oil unit 59.
[0108] In vapor unit 79, the first stage 79-1, second stage 79-2 and third stage 79-3 are condenser units that operate over different temperature ranges to condense pyro-vapors from vapor transfer line pipe 82 of different molecular weights. The pyro-vapors of different molecular weights produce pyro-oils of different molecular weights, including inhibitors, through the valves 12-1, 12-2 and 12-3. The non-condensed pyro-gases not transferred to the fractional distillation unit 182 pass from the third stage 79-3 to the pyro-gas scrubber 79-4. The outputs from the valves 12-1, 12-2 and 12-3 on line 65 connect through valve 12-4 to the oil unit 59. The outputs from the oil unit 59 are stored in oil storage unit 64. The storage 64 typically includes different tanks for the different types of pyro-oil extracted by the different stages 79-1, 79-2 and 79-3 and includes the inhibitor storage 81 for storing inhibitor 10.
[0109] In distillation unit 179, the first stage 183-1, second stage 183-2 and third stage 183-3 are typically fractional distillation units that operate over different temperature ranges and augment the operation of the vapor unit 79 to condense pyro-vapors from vapor transfer line pipe 82 of different molecular weights. The pyro-vapors of different molecular weights produce pyro-oils and pyro-gases of different molecular weights that are stored in stores 184-1, 184-2 and 184-3. The non-condensed pyro-gases not stored are transferred to the oil unit 59. The pyro-gas output from the third stage 79-3 of the vapor unit 79 is input to the pyro-gas scrubber 79-4 which scrubs sulfur and other impurities from the pyro-gas to provide outputs on pipe 67 to provide pyro-gas products. One of the pyro-gas products from scrubber 79-4 on line 67 connects in FIG. 1 to line 86 to provide fuel to the heat unit 78. The pyro-gas scrubber 79-4 transports the pyro-gas via gas line 66 for storage in gas storage 63. The gas storage 63, the oil storage 64 and the inhibitor 81 comprise the product storage 60. The output from the pyro-gas scrubber 79-4 that is not a pyro-gas product is used as a fuel available on line 67 or is disposed of, by burning or other means. Line 67 connects to valve 112-4 that the fuel on line 67 to storage unit 185 and electrical generator 186. The storage unit 185 has an output line 85 that feeds the heat unit 78 of FIG. 1. Any sulfur is collected as a sulfur product.
[0110] In FIG. 29, a graph is shown of the temperature of a furnace 90 of FIG. 1 during pyrolysis processing. The control unit 83 of FIG. 1 allows for tires to be bailed and ready to be loaded into a furnace 90 during a LOAD period. The cart is then loaded into the furnace 90 and is ready for pyrolysis processing. The furnace door is closed thereby forming the furnace chamber into a retort. Next, nitrogen gas is injected into the furnace to purge the chamber and force oxygen out. The control 83 causes the heat unit 78 to provide heat to the chamber 92 and the temperature begins to rise during the INCREASE period as indicated in FIG. 29 at the t2 hour. Initially, the temperature is at Tmin, for example, standard room temperature. The control unit 83 typically applies maximum heating over the INCREASE period causing the temperature to rise until the temperature approaches Tmax, for example 1800 F., at time t5 hour. The control unit 83 maintains the temperature at about Tmax during the STEADY period for about 3 hours until about t8 hour. Thereafter the heat is turned off. A DECREASE period of approximately 3 hours allows cooling to occur from about t8 hour until about t11 hour. The cooling can be accelerated by introducing cooling nitrogen into the furnace chamber 92 until the furnace chamber 92 approaches Tmin. After t11 hour, the control unit 83 of FIG. 1 allows for the pyro-solids to be unloaded during the UNLOAD period from t11 to t12 or longer if needed. Air is not introduced into the furnace 90 or chamber 92 while the temperature of any of the carbon residue 77 is over approximately 300 degrees F., otherwise the carbon can catch fire/oxidize when contact with oxygen is made. To avoid introducing oxygen into the chamber 92, a nitrogen gas, in one example, is used as a cooling substance. Also, a fan with a slow revolution setting is used to circulate the nitrogen and is operated so as not to stir up carbon dust. An alternative for cooling uses cool gas from the gas storage 63 where the pyro-gas is injected back into the furnace chamber 92.
[0111] Using the batch processing techniques as described and in one embodiment, the cooling is accelerated by introducing cooling gas (free of oxygen) into the furnace chamber 92 to reduce the temperature to less than 300 degrees F.
[0112] Using the processing techniques as described, the 1800 F. Tmax temperature is effective in driving off volatile substances such as contained in pyro-gases and pyro-oils so that the remaining pyro-carbon after pyrolysis processing has a very low surface volatile content.
[0113] Using the processing techniques as described, the sealed configuration of the furnace chamber 92 with oxygen purged from the furnace chamber 92 reduces or eliminates the burning/oxidation of the pyro-carbon product and eliminates creation of unnecessary ash content.
[0114] In FIG. 30, a unitary pyrolysis system 1 is shown having a plurality of pyrolysis furnaces 6, like the furnace 90 of FIG. 1, for receiving the transportable carts 75. Each of the furnaces 6 includes, in one embodiment, a heat unit 3, like heat unit 78 in FIG. 1, for heating the corresponding furnace 6. The pyrolysis stations 8, like the pyrolysis station 72 of FIG. 1, include a vapor unit 4, like the vapor unit 79 of FIG. 1, which connects on pipes 82 to each of the furnaces 6 and is shared by the furnaces 6. In addition, the unitary pyrolytic system 1 includes a load station 7 and an unload station 9 like the load station 71 and the unload station 73 of FIG. 1. The unitary pyrolytic system 1 receives scrap tires 41 as inputs and performs batch pyrolysis processing to produce pyro-products as outputs. The pyro-products produced include pyro-vapors 11 that are condensed into pyro-oil leaving some pyro-gas and pyro-solids 58, particularly pyro-carbon.
[0115] In the unitary pyrolysis system 1, the furnaces 6 are serviced by transportable carts 75. The carts 75 load scrap tires 41 in stacks 74 into the furnaces 6 for pyrolysis processing. The pyrolysis processing of the furnaces 6 engages the vapor unit 4 for injecting and exhausting vapors into and out from furnaces 6 in connection with pyrolysis processing. The carts 75 are then transported to the unload station 9. Pyro-vapors out from the furnaces 6 are condensed in vapor unit 4 to form pyro-gas and pyro-oil products that are further processed by pyro-oil unit 59 and stored in oil storage 64 and inhibitor storage 10. Vapors remaining from the furnace 6 after condensing are processed and stored as gas products and are processed, in some embodiments, to provide fuel for the heat units 3 of FIG. 1 or for cogeneration of electricity. Typically 70% to 80% is used for electrical generation. In the pyrolysis system 1, a solid unload station 9 is for removing pyro-solids 58 from the furnace 6 after gas and oil processing has occurred.
[0116] In FIG. 31, a schematic view of a pyrolysis system 1 is shown having groups of pyrolysis furnaces 6 sharing vapor units 4. Each furnace 6 performs a batch pyrolysis process. The plurality of furnaces 6 are configured as a unitary pyrolytic system 1 wherein the batch pyrolysis operating cycles of the different furnaces 6 are offset in time. With cycles offset in time and by way of example, at any particular time, operations for one or more furnaces 6 is in a loading period, one or more other furnaces 6 are in the pyrolysis period and still one or more furnaces 6 are in unloading periods. While each of the particular furnaces 6 operates with steps in discrete periods and hence each furnace 6 is not continuous, the plurality of furnaces 6 collectively taken together form a unitary pyrolytic system 1 that accepts input of scrap tires 41 that is a continuous input supply and provides an output of pyro-products, including pyro-vapor 11 and pyro-solids 58, that is a continuous output.
[0117] In FIG. 31, the unitary pyrolytic system 1 includes a first group of furnaces 6.sub.1, 6.sub.2, and 6.sub.3 and a second group of furnaces 6.sub.4, 6.sub.5, and 6.sub.6. The first group of furnaces 6.sub.1, 6.sub.2, and 6.sub.3 connect to the vapor unit 4.sub.1 and the second group of furnaces 6.sub.4, 6.sub.5, and 6.sub.6 connect to the vapor unit 4.sub.2. The first group of furnaces 6.sub.1, 6.sub.2, and 6.sub.3 have heat units 3.sub.1, 3.sub.2, and 3.sub.3, for heating the chambers 14.sub.1, 14.sub.2, and 14.sub.3 through lines 69.sub.1, 69.sub.2, and 69.sub.3. The second group of furnaces 6.sub.4, 6.sub.5, and 6.sub.6 have heat units 3.sub.4, 3.sub.5, and 3.sub.6, respectively, for heating the chambers the chambers 14.sub.4, 14.sub.5, and 14.sub.6 through lines 69.sub.4, 69.sub.5, and 69.sub.6.
[0118] In FIG. 32, a graph of the temperatures of a furnace 6 cycled twice over a 24 hour period is shown. The control unit 5 of FIG. 30 allows for tires to be bailed and ready to be loaded into a furnace 6 during LOAD periods, t0-t2 and t11-t13. The control unit 5 causes the heat units 3 to provide heat to the chambers and the temperatures begin to rise during the INCREASE periods t2-t5 and t13-t16. Initially, the temperature is at Tmin, for example, standard room temperature. The control unit 5 typically applies maximum heating over the INCREASE period causing the temperature to rise until the temperature approaches Tmax, for example 1800 F., at time t5 and t16 hours. The control unit 5 maintains the temperature at about Tmax during the STEADY period for about 3 hours until about t8 and t19 hours. Thereafter the heat is turned off. A DECEASE period of approximately 3 hours allows cooling to occur from about t8-t11 and t19-t22 hours. The cooling can be accelerated by introducing cooling air into the furnace chamber until the furnace chamber approaches Tmin. After t11 and t22 hours, the control unit 5 allows for the pyro-solids to be unloaded during the UNLOAD period from t11-t13 and t22-t24.
[0119] In FIG. 33, a graph is shown of the temperatures of six furnaces cycled sequentially. The graphs of the temperatures of six furnaces 6 of FIG. 33 are shown over approximately a one day 24 hour period. The six furnaces are 6.sub.1, 6.sub.6, 6.sub.3, 6.sub.4, 6.sub.5, and 6.sub.6. These six furnaces are connected to the vapor unit 4-1 of FIG. 31. The LOAD, INCREASE, STEADY, DECREASE and UNLOAD periods for the six furnaces 6.sub.1, 6.sub.6, 6.sub.3, 6.sub.4, 6.sub.5, and 6.sub.6 are listed in the TABLE 1.
TABLE-US-00001 TABLE 1 LOAD INCREASE STEADY DECREASE UNLOAD 6.sub.1 t0-t2 t2-t5 t5-t8 t8-t11 t11-t13 6.sub.2 t2-t4 t4-t7 t7-t10 t10-t13 t13-t15 6.sub.3 t4-t6 t6-t9 t9-t12 t12-t15 t15-t17 6.sub.4 t6-t8 t8-t11 t11-t14 t14-t17 t17-t19 6.sub.5 t8-t10 t10-t13 t13-t16 t16-t19 t19-t21 6.sub.6 t10-t12 t12-t15 t15-t18 t18-t21 t21-t23
[0120] As is evident from TABLE 1, the offset of the processing steps for each of the furnaces 6.sub.1, 6.sub.2, 6.sub.3, 6.sub.4, 6.sub.5, and 6.sub.6 distributes the use of the system facilities so that no facility presents a bottleneck for processing. For example, each of the furnaces 6 is allocated a different time for the LOAD step so that loading is evenly distributed at the load station 7. Similarly, each of the furnaces 6 is allocated a different time for the UNLOAD step so that unloading is evenly distributed at the unload station 9. The pyrolysis processing during the INCREASE, STEADY and DECREASE steps balances the load on the vapor unit 4-1.
[0121] Similar to the example described in connection with FIG. 33 and TALE 1, the four furnaces 6.sub.7, 6.sub.8, 6.sub.9, and 6.sub.10 are operated as a separate unit with, in one example, the furnaces 6.sub.1, 6.sub.2, 6.sub.3, 6.sub.4, 6.sub.5, and 6.sub.6 idle. These four furnaces 6.sub.7, 6.sub.8, 6.sub.9, and 6.sub.10 are connected to the vapor unit 4-2 of FIG. 31. The LOAD, INCREASE, STEADY, DECREASE and UNLOAD steps for the four furnaces 6.sub.7, 6.sub.8, 6.sub.9, and 6.sub.10 are analogous to those periods in TABLE 1 using two fewer furnaces.
[0122] In FIG. 34, another example of the operation of the system of FIG. 34 is represented where all ten of the furnaces 6.sub.1, 6.sub.2, 6.sub.3, 6.sub.4, 6.sub.5, 6.sub.6, 6.sub.7, 6.sub.8, 6.sub.9 and 6.sub.10 are operating. In FIG. 35, graphs of the temperatures of ten furnaces 6 of FIG. 33 are shown. The furnaces are connected to the vapor unit 4-1 and 4-2 of FIG. 33. The LOAD, INCREASE, STEADY, DECREASE and UNLOAD steps for the ten furnaces 6.sub.1, 6.sub.2, 6.sub.3, 6.sub.4, 6.sub.5, 6.sub.6, 6.sub.7, 6.sub.8, 6.sub.9 and 6.sub.10 are listed in TABLE 2.
TABLE-US-00002 TABLE 2 LOAD INCREASE STEADY DECREASE UNLOAD 6.sub.1 t0-t2 t2-t5 t5-t8 t8-t11 t11-t13 6.sub.2 t2-t4 t4-t7 t7-t10 t10-t13 t13-t15 6.sub.3 t4-t6 t6-t9 t9-t12 t12-t15 t15-t17 6.sub.4 t6-t8 t8-t11 t11-t14 t14-t17 t17-t19 6.sub.5 t8-t10 t10-t13 t13-t16 t16-t19 t19-t21 6.sub.6 t10-t12 t12-t15 t15-t18 t18-t21 t21-t23 6.sub.7 t12-t14 t14-t17 t17-t20 t20-t23 t23-t25 6.sub.8 t14-t16 t16-t19 t19-t22 t22-t1* t1-t3* 6.sub.9 t16-t18 t18-t21 t21-t24 t24-t3* t3*-t5* 6.sub.10 t18-t20 t20-t23 t23-t2* t2*-t5* t5*-t7*
[0123] As is evident from TABLE 2, the offset of the processing for each of the furnaces 6.sub.1, 6.sub.2, 6.sub.3, 6.sub.4, 6.sub.5, 6.sub.6, 6.sub.7, 6.sub.8, 6.sub.9 and 6.sub.10 distributes the use of the system facilities so that no facility presents a bottleneck for processing. For example, each of the furnaces 6 is allocated a different time for the LOAD step so that loading is evenly distributed at the load station 7. Similarly, each of the furnaces 6 is allocated a different time for the UNLOAD step so that unloading is evenly distributed at the unload station 9. The pyrolysis processing times for the INCREASE, STEADY and DECREASE steps balance the load on the vapor unit 4-1 and vapor unit 4-2.
[0124] In FIG. 35, enhanced oil recovery (EOR) is done in an oil field 12. In oil fields like the oil field 12, as a result of the lowering of temperature of the oil as well pressures are reduced, deposit and crystallization of paraffin occurs causing the clogging of down-well pump parts and the spaces in the oil-bearing strata so that entrapped ground oil frequently cannot be efficiently recovered. Such conditions often results after primary and secondary recovery has occurred in the oil field. The oil field 12 includes a production well 1 including piping 21 extending down into the oil field 12. An inhibitor injector 11 connects to and supplies an injection stream in piping 13 to transport an inhibitor down the core 21. The injection stream in piping 13 is forced down the core 21 under substantial pressure from the inhibitor injector 11.
[0125] In FIG. 35, the production well 1 includes a pump 20 connected through the well core 21 to the down-hole pump 22. Oil and gas is pumped from the down-hole pump 22 through the well core 21 for processing and storage in the oil unit 23 and the gas unit 24. An inhibitor injector 11 injects, through piping 13, an inhibitor 10 into the production well 11 or into the oil unit 23 or gas unit 24. The inhibitor increases the flow of ground oil from the strata and through all extraction system components by dissolving, solubilizing or fragmenting paraffin and asphaltenes deposits to help withdraw the oil from the ground and improve the flow of the oil throughout the extraction system components. Also, the inhibitors in some embodiments are heated to make them more effective.
[0126] In FIG. 35, the inhibitor 10 is applied in different manners. In general, the inhibitor 10 is applied to pipe 13. The inhibitor 10 is applied by direct injection whereby the inhibitor 10 is left in the well 1. In some embodiments, the inhibitor 10 is passed through and removed like flushing along with other injection methods. The cleaning process using the inhibitor 10 includes injecting the inhibitor 10 as part of a maintenance process. For example, during the operation of the well 1, one to five gallons are injected on a regular schedule that typically is daily or every two/three days to maintain a cleaner ongoing well free of paraffin and asphaltenes. The injection of an inhibitor is typically also done into storage tanks, piping systems and pumps. Not only are the wells cleaned using the inhibitor, but the pipes and other support equipment and systems are also cleaned.
[0127] In FIG. 36, a block representation of typical non-polar components 14 and polar components 15 of the inhibitor 10 are shown for one example of pyrolysis processing. The total non-polar solvents in the one example are 5.33% in accordance with laboratory gas chromatography-mass spectrometry (GC-MS) testing. The effect of the non-polar components in the inhibitor 10 is potent. The approximately 5% of non-polar components in an inhibitor 10 operate for paraffin and asphaltenes control. Other major constituent components in the inhibitor 10 are polar substances that don't provide a direct contribution towards paraffin and asphaltenes control. However, the polar components play an important role as carriers for dispersing the non-polar components. The percentages of non-polar and polar components, and the actual components themselves, in the inhibitor 10 varies as a function of the chemical constituency of the tires or other organic material introduced into the furnace for pyrolysis processing. Typically, for conventional tires, the typical range of non-polar components is from 4% to 7% but other ranges are possible.
[0128] While the invention has been particularly shown and described with reference to preferred embodiments thereof it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention.
