HYDROCARBON RECYCLING OF CARBONIZER HOT GASES

Abstract

Systems and process are provided for refining off-gases that are produced by a carbonizer with a controlled heated column. The controlled heated column performs hydro-carbon recycling, and acts as a cracking tower that takes the carbonizer off-gas as a feedstock and distills the off-gases into constituent parts under pressure and temperature conditions where the feedstock evaporates and condenses into a fractional column of distillates. The carbonizer uses anaerobic thermal transformation processing to convert waste into bio-gas; bio-oil; carbonized materials; non-organic ash, distillates, and varied further co-products. The carbonaceous waste is transformed into useful co-products that are re-introduced into the stream of commerce at various economically advantageous points including carbon, carbon-based inks and dyes, activated carbon, aerogels, bio-coke, and bio-char, as well as generate electricity, produce adjuncts for natural gas, and/or various aromatic oils, phenols, and liquids, all depending upon the input materials and parameters

Claims

1. A system for treating waste, the system comprising: a controlled heated column with a series of temperature zones; a carbonizer in fluid communication with said controlled heated column, where said carbonizer anaerobically thermally converts the waste and resultant hot gases produced from said carbonizer and are supplied to said controlled heated column; and one or more outputs that correspond to the series of temperature zones that supply distillates obtained from the supplied hot gases.

2. The system of claim 1 wherein the waste feed stock includes at least one of municipal solid waste, infectious medical waste, or bitumen that optionally contains non-reactive inorganics.

3. The system of claim 1 wherein said carbonizer employs anaerobic thermal transformation processing to treat the waste feed stock.

4. The system of claim 1 wherein said carbonizer utilizes a thermo-chemical reactor, where said thermos-chemical reactor is one of a drag-chain reactor, batch reactor, continuous-stirred-tank reactor, rotating drum, thermal oxidizers, or plug-in reactor.

5. The system of claim 1 wherein said carbonizer has a partial or complete vacuum.

6. A method of using the system of claim 1 for refining the hot gases that are produced by said carbonizer, the method comprising: adjusting a set of parameters of said carbonizer based on waste feed stock to be inputted; setting processing parameters for said controlled heated column based on anticipated distillates to be obtained from the hot gases supplied by the carbonizer; loading waste feedstock into said carbonizer; obtaining useable co-products and byproducts from said carbonizer; supplying hot gases from said carbonizer to said controlled heated column; and collecting usable distillates from the one or more outputs that correspond to the series of temperature zones of said controlled heated column.

7. The method of claim 6 further comprising disposing any non-useable output from said controlled heated column, or reintroducing the non-useable output into said carbonizer.

8. The method of claim 6 wherein the adjustable set of parameters for said carbonizer comprise one or more of temperature, conveyor speed, dwell times, and atmosphere.

9. The method of claim 6 wherein a processing parameter of said controlled heated column includes setting temperature zones.

10. The method of claim 6 wherein the waste feed stock includes at least one of municipal solid waste, infectious medical waste, or bitumen that optionally contains non-reactive inorganics.

11. The method of claim 6 wherein said carbonizer employs anaerobic thermal transformation processing to treat the waste feed stock.

12. The method of claim 6 wherein said carbonizer utilizes a thermo-chemical reactor, where said thermos-chemical reactor is one of a drag-chain reactor, batch reactor, continuous-stirred-tank reactor, rotating drum, thermal oxidizers, or plug-in reactor.

13. The method of claim 6 wherein said carbonizer has a partial or complete vacuum.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention is further detailed with respect to the following drawings. These figures are not intended to limit the scope of the present invention but rather illustrate certain attributes thereof.

[0018] FIG. 1 is a prior art functional block diagram of a typical industrial distillation tower;

[0019] FIG. 2 is a block diagram of a carbonizer with a controlled heated column for refining and recovery of carbonizer hot gases in accordance with embodiments of the invention;

[0020] FIG. 3 is a flowchart of a process for refining off-gases that are produced by a carbonizer in accordance with embodiments of the invention; and

[0021] FIG. 4 is a functional block diagram of a furnace to heat a feedstock prior to entry into a controlled heated column for refining and recovery of useable products in accordance with embodiments of the invention.

DESCRIPTION OF THE INVENTION

[0022] An inventive system and method for refining off-gases that are produced by a carbonizer is provided with a controlled heated column for refining and recovery of the carbonizer hot gases. The controlled heated column performs hydro-carbon recycling, and acts as a cracking tower that takes the carbonizer off-gas as a feedstock and distills the off-gases into constituent parts under pressure and temperature conditions where the feedstock evaporates and condenses into a fractional column of distillates. The number of theoretical plates needed to exact a desired level of separation is readily calculated using the Fenske equation. The carbonizer may use anaerobic thermal transformation processing to convert waste into bio-gas; bio-oil; carbonized materials; non-organic ash, and varied further co-products. In the inventive technology presented herein, any carbonaceous waste is transformed into useful co-products that can be re-introduced into the stream of commerce at various economically advantageous points. The present invention has utility to support a variety of processes, including to make, without limitation, carbon, carbon-based inks and dyes, activated carbon, aerogels, bio-coke, and bio-char, as well as generate electricity, produce adjuncts for natural gas, and/or various aromatic oils, phenols, and other liquids, all depending upon the input materials and the parameters selected to process the waste, including real time economic and other market parameters which can result in the automatic re-configuration of the system to adjust its output co-products to reflect changing market conditions. Distillates extracted are appreciated to be a function of the chemical nature of the feedstock and the carbonizer conditions. Illustrative distillates include C2-C36 compounds of alkanes, alkenes, ethers, esters, phenols, aromatics, lignins, polycyclics; and substituted versions thereof where the substituent in place of a hydrogen atom is for example, a hydroxyl, an amine, a sulfonyl, a carboxyl, a halogen, or a combination thereof.

[0023] As used herein, the terms carbonized material, carbonaceous product and carbonaceous material are used interchangeably to define solid substances at standard temperature and pressure that are predominantly inorganic carbon by weight and illustratively include char, bio-coke, carbon, activated carbon, aerogels, fullerenes, and combinations thereof.

[0024] It is appreciated that a feedstock is readily treated with a variety of solutions or suspensions prior to carbonizer to modify the properties of the resulting inorganic carbon product. By way of example, solutions or suspensions of metal oxides or metal salts are applied to a feedstock to create an inorganic carbon product containing metal or metal ion containing domains. Metals commonly used to dope an inorganic carbon product illustratively include iron, cobalt, platinum, titanium, zinc, silver, and combinations of any of the aforementioned metals.

[0025] It is to be understood that in instances where a range of values are provided that the range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range. By way of example, a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.

[0026] Since a core element of the inventive process for refining off-gases that are produced by a carbonizer is carbonization, there are a wide variety of possible operating configurations and parameters to adjust product mixes and waste stream throughput. The system is readily re-configured, and system operating parameters changed, some in real time, to adjust co-product outputs and percentages thereof to reflect on-going market conditions. For illustrative purposes, wood, before entering the process, can have its moisture removed, but not so much as to burst the plant cells within the cellular structure of the wood, but rather to rendered contained water as steam and thus destroy the cellular fabric of the wood. The temperature range, duration of exposure, mixing rate, and other factors claimed as part of the inventive process, machine and system of systems herein are thus focused on controlling the many variables inherent in such anaerobic thermal transformation processes in order to produce results with utility for future use as opposed to just destruction.

[0027] System configuration in certain embodiments includes carbonization process heat source generators that run on a mixture of natural gas or electrical heat and reaction-produced carbonization process gases, if present, re-circulated to operate the drag chain reactor and thereby generate the heat needed to operate the carbonization process. This heat capture in turn produces more waste heat that is used to heat water and generate steam for turbines or steam reciprocating engines or subsequent distillation processes. This heat in some inventive embodiments is then also used to preheat feedstock or to produce electricity. The pre-processing heating system preheats feedstock material prior to entering the reactor tube.

[0028] A carbonization system in specific inventive embodiments also utilizes a thermo-chemical reactor which may be a drag-chain reactor, or others such as, but not limited to batch, continuous-stirred-tank, thermal oxidizers, or plug-in reactors.

[0029] Another important element of an inventive system is the use of an air-seal, which not only aids mixing and heat diffusion, but allows pressurization of, or the creation of a partial or complete vacuum within the reactor for various reasons, including preventing gaseous contaminants from escaping the reactor, managing pressures, and managing the flow of gases within the overall reactor and associated processing elements.

[0030] Referring now to the figures, FIG. 2 is a block diagram of a system 100 with a carbonizer 102 with a controlled heated column 104 for refining and recovery of by-products from carbonizer hot gases. The carbonizer 102 may perform anaerobic thermal transformation processing that converts input (arrow A1) illustratively including, but not limited to municipal solid waste, infectious medical waste, and bitumen into useable products (arrow A8) such as bio-gas; bio-oil; carbonized materials; non-organic ash. Non-useable output (arrow A9) from the carbonizer 102 may either be safely disposed of, or recirculated back into the carbonizer 102 for further processing. A non-limiting example of a carbonizer operative with a controlled heated column 104 for refining and recovery of by-products from carbonizer hot gases is detailed in U.S. Pat. No. 8,801,904; the contents of which are incorporated herein by reference. Hot gases (arrow A2) generated by and in the carbonizer 102 are feed to the controlled heated column(s) 104 for hydro-carbon re-cycling (cracking). Temperature cut points (zones) within the controlled heated column 104 are signified by outputs 106A-106D that supply distillates represented by arrows A3, A4, and A5. Remaining hot gases or solids (arrow A6) that do not distill out as a useable by-product may either be further scrubbed and safely disposed of, or recirculated (arrow A7) into the carbonizer 102 for further processing.

[0031] FIG. 3 is a flowchart of a process 200 for refining off-gases that are produced by a carbonizer. The process 200 starts by adjusting the parameters of the carbonizer based on waste feed stock to be inputted (Step 202). Carbonizer parameters may illustratively include temperature, conveyor speed, dwell times, and atmosphere. Based on the inputted feedstock, processing parameters are set for the controlled heated column based on anticipated distillates to be obtained from the off-gas of the carbonizer (Step 204). For example, temperature zones may be set based on the anticipated distillates. In some inventive embodiments, once the carbonizer is at the required temperature, waste feedstock is loaded into the carbonizer (Step 206). Subsequently, useable byproducts obtained from the carbonizer are collected, and non-useable outputs are either safely disposed of or reintroduced into the carbonizer (Step 208). Hot gases that result from the carbonizer are supplied to the controlled heated column for hydrocarbon recycling (Step 210). It is appreciated that in some inventive embodiments, a conventional cracking catalyst is provided to promote bond scission in byproducts to promote formation of volatile by products. Organometallics and metals are exemplary of conventional cracking catalysts. Usable distillates are collected from temperature cut points (zones) (Step 212) and non-useable output from the controlled heated column is either collected as a sludge or reintroduced into the carbonizer (Step 214).

[0032] FIG. 4 is a functional block diagram of a system 300 with a furnace 302 to heat a feed stock in feed tubing 304 prior to entry into a controlled heated column 306 for refining and recovery of useable products. In the example shown in FIG. 4 the heated column 306 is divided into five temperature cut points or zones (Z1-Z5) that are divided with vented plates 308. It is appreciated that any number of cut points or zones may be introduced into the heated column 306 for a finer distribution of products. The zones (Z1-Z5) of the heated column have a series of outlets (310-320) that yield recovered products from the feedstock that is distilled in the heated column 306.

EXAMPLES

Example 1

[0033] In conjunction with FIG. 4, crude oil is feed via feed tubing 304 into furnace 302 to heat to a temperature of approximately 504 C. (940 F.) prior to entry into the controlled heated column 306 for refining and recovery of useable petroleum based products. The heated column 306 is divided into five heated zones as follows: Z1 is set at 400 C. (752 F.), Z2 is set at 370 C. (701.6 F.), Z3 is set at 300 C. (572 F.), Z4 is set at 200 C. (392 F.), and Z5 is set at 150 C. (701.6 F.). Lubricating oil, paraffin wax, asphalt drops out of the bottom outlet 310 from zone Z1 of the column 306. Fuel oil is yielded from outlet 312 of zone Z2. Diesel oil is yielded from outlet 314 from zone Z3 of the column 306. Kerosene is yielded from outlet 316 from zone Z4 of the column 306. Gasoline is yielded from outlet 318 from zone Z5 of the column 306. Gas rises from zone Z5 and is water cooled to 20 C. (68 F.).

[0034] As a person skilled in the art will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the preferred embodiments of the invention without departing from the scope of this invention defined in the following claims.