Patent ID: 6683227
Filing Date: 2004-01-27
Classification: C10G

Abstract:
A process for the thermocatalytic conversion of waste materials into reusable hydrocarbons comprising:a) feeding a feedstock comprising waste organic materials and catalyst comprising AlCl3 to a heated, stirred reactor, wherein the reactor is maintained at positive pressures, and wherein the temperature of the reactor is sufficient to maintain AlCl3 as a fluid; b) converting feedstock into vaporized hydrocarbons; c) removing an overhead portion comprising vaporized hydrocarbons and vaporized AlCl3 from the reactor; d) removing a reactor discharge portion comprising unreacted feedstock and catalyst from the reactor and providing the reactor discharge portion to a supplemental reactor; e) maintaining the reactor discharge portion in the supplemental reactor at a temperature sufficient to generate additional vaporized hydrocarbons and additional vaporized AlCl3; f) removing the additional vaporized hydrocarbons and additional vaporized AlCl3 catalyst from the supplemental reactor into a recycle catalyst condenser, the recycle catalyst condenser being maintained at a temperature selected to condense at least a portion of the additional vaporized AlCl3 and to maintain in the vapor state at least a portion of the additional vaporized hydrocarbons; g) removing the condensed portion of AlCl3 from the recycle catalyst condenser and providing said condensed portion AlCl3 to the reactor; h) removing for recovery the portion of additional vaporized hydrocarbons maintained in the vapor state from the recycle catalyst condenser; and i) removing any residue remaining in the supplemental reactor.