Abstract:
The present invention relates to recycling tires and the like utilizing a microwave service controlling the pressure from such a process enables a more even temperature and helps prevent the buildup of explosive gas.

Description:
COPYRIGHT NOTICE 
       [0001]    A portion of the disclosure of this patent contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. 
       BACKGROUND OF THE INVENTION 
     Field of the Invention 
       [0002]    The present invention relates to an apparatus, system and method for depropagating polymer based materials. In particular, depropagating polymers, especially those used in vehicle tires. 
       Description of Related Art 
       [0003]    In the field of petrochemicals the escalating energy costs for oil, natural gas, liquefied petroleum gas, and liquefied natural gas are of increasing concern to those involved in the processing of organic materials, chemicals, and petroleum products. With the inherent aging of the facilities, coupled with the ever-escalating energy and capital equipment costs, refurbishment and replacement costs of these plants becomes increasingly difficult to justify. Many efforts have been expended in those applications described in the technical field to produce directly useable fuels from scrap tires or plastics with substantially improved throughput, increased operating efficiency, reduced energy consumption, or without further treatment, but these efforts have failed due to economic or technical reasons. 
         [0004]    Considerable effort and expense has been invested in waste-to-energy and other alternative fuels programs, but have fallen short due to technical issues, limited throughput, expensive after-treatment costs, poor operating efficiency, high energy consumption, or non-commercially viable solutions. 
         [0005]    Some effort has gone into these programs, but all suffer from efficiency or problems with explosive gas accumulation or overheating issues. In particular, U.S. Pat. Nos. 6,618,957, 7,927,465, 8,283,616, and 8,382,957 (all incorporated herein by reference) all attempt to use microwave energy. However, they all have problems including the microwaves quick breaking or melting of windows in the system, microwaves not having acceptable initial targets, excessive release of cooled gasses (thus reducing operation temperature below functional temperatures) and, lastly, excessive pressures on the system as designed results in danger of explosions. Accordingly, the above patented systems are not currently in use. Accordingly, a new system designed to overcome one or more of these design problems is necessary. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    This invention addresses the problems of accumulation of waste products, including tires, plastics, roofing shingles, and construction debris, in ever-decreasing space in landfills. In the United States, as of the filing date of this application, only six hazardous disposal landfills remain available for an ever-increasing amount of industrial waste, contaminated soil, and materials removed from locations designated by the EPA as superfund sites. Considering that a new petroleum refinery has not been built in over approximately thirty years, discovery of new major sources of crude oil have been declining over the past decades, and the number of new landfills for waste materials, hazardous and non-hazardous, are not only decreasing, but existing landfills are reaching their capacity, a conversion of waste products into useable byproducts is a requisite to overcome these problems. The present invention overcomes the limitations and issues of the previous microwave type devices, as detailed further herein, and represents an improvement in those types of devices. 
         [0007]    Accordingly, in one embodiment there is an improved process for reducing an organic-containing solid material into lower molecular gaseous hydrocarbons, liquid hydrocarbons and solid carbon constituents utilizing a microwave oven system the improvement comprising:
       a) utilizing a ring vacuum pump to remove gasses from the microwave system; and   b) positioning at least two sources of microwaves in parallel alignment in a ceiling of the system, each source which feeds bifurcated waves into a leaky wave guide diffuser.       
 
         [0010]    In another embodiment there is an improved microwave oven system for reducing an organic-containing solid material into lower molecular gaseous hydrocarbons, liquid hydrocarbons and solid carbon constituents, the improvement comprising:
       a) a ring vacuum pump to remove gasses from the microwave system; and   b) at least two sources of microwaves positioned in parallel alignment in a ceiling of the oven, each microwave source which feeds bifurcated waves into a leaky wave guide diffuser.       
 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a diagram of the present system. 
           [0014]      FIG. 2  is a flow diagram of the process of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    While this invention is susceptible to embodiment in many different forms, there is shown in the drawings, and will herein be described in detail, specific embodiments, with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings. This detailed description defines the meaning of the terms used herein and specifically describes embodiments in order for those skilled in the art to practice the invention. The advantages are outlined in the definitions below and include the ability to process both solid and liquid organic material, unlike previous microwave systems which only process from solid starting materials. 
       DEFINITIONS 
       [0016]    The terms “about” and “essentially” mean ±10 percent. 
         [0017]    The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. 
         [0018]    The term “comprising” is not intended to limit inventions to only claiming the present invention with such comprising language. Any invention using the term comprising could be separated into one or more claims using “consisting” or “consisting of” claim language and is so intended. 
         [0019]    References throughout this document to “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation. 
         [0020]    The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive. 
         [0021]    The drawings featured in the figures are for the purpose of illustrating certain convenient embodiments of the present invention, and are not to be considered as limitation thereto. The term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting. 
         [0022]    As used herein the term “device or process for reducing an organic-containing solid material into lower molecular gaseous hydrocarbons, liquid hydrocarbons and solid carbon constituents utilizing a microwave oven system” refers to systems as taught in U.S. Pat. Nos. 6,618,957, 7,927,465, 8,283,616, and 8,382,957 (all incorporated herein by reference) which teach the use of microwaves positioned perpendicular to one another and tends to have a high buildup of gasses during processing. The present invention relates to a number of improvements which overall increases the safety and effectiveness of the system, especially when processing tires. 
         [0023]    As used herein, the term “ring vacuum pump” refers to the positioning of a ring vacuum pump to remove gasses which build up in the oven of the microwave system. In working with the prior art devices, it was discovered that when filling an oven the process of microwaving releases a huge amount of combustible gasses at temperatures far below the operating temperatures (680° F.) taught for such a system. In addition to cooling the system and having produced explosive gasses, the release produces an excessive pressure of 2 to 3 times normal ambient pressure in the oven, resulting in broken wave guide quartz pressure windows and extreme condensation of gasses, making it difficult to remove liquids produced. By engaging a ring vacuum pump to the oven cavity and maintaining a slightly positive pressure on the ovens, removal of accumulated gasses can be accomplished without introducing outside oxygenated air. The present invention aids in startup heating and reduces the dangers associated with high pressure and combustible gasses. 
         [0024]    As used herein, the term “two sources of microwaves in parallel alignment, wherein the sources feed bifurcated waves into a leaky wave guide diffuser” refers to placement of the microwave sources. In the prior art, microwave sources were positioned perpendicular to one another, but it has been discovered that by positioning them parallel in the ceiling of the oven one gets better directed penetration and this eliminates the need for microwave activators, which increase activity within the oven. One other advantage is that, instead of waveguides made of low loss aluminum guides which are expensive and tend to not preserve microwave power, the present invention positioning allows use of regular, otherwise untreated, aluminum for the waveguides. 
         [0025]    As used herein, the term “a high heat auger utilizing a gas purging collar ” refers to an auger for removal of the carbon black from the system instead of the rotary feed value or drawer/purge system of the prior art. The system of the present invention utilizes a gas purge and, in one embodiment, it is nitrogen gas. This can, in one embodiment, feed to a liquid chilled auger and then an electromagnetic separator drum to remove steel residual pieces before the carbon black is augured to a bagging system for removal. 
         [0026]    As used herein in one embodiment, any doors utilized to seal any produced gasses in the oven are at least ¾ inch thick flat aluminum doors which bolt on an inside of the system and the seams of the doors are sealed by taping with woven fiberglass tape positioned as a gasket for the doors. 
         [0027]    As used herein, the system will not use elaborate liquid scrubbers which can utilize thousands of gallons of water per day. The liquid scrubbers have been replaced, in one embodiment, with a solid medium, forced air dry system for removing impurities. Such devices are readily available, such as the Schlumberger® SulfaTreat® adsorbents, however this scrubber has not been utilized for this kind of system before this invention. 
         [0028]    In one embodiment, the size of the oven interior is increased to better accommodate the size of the conveyor belt and the accompanying drive system that is utilized in the system. In this embodiment, the interior dimensions of the oven are a multiple of the magnitude of the 915 MHz microwave length with a minimum dimensions in one embodiment of 12 ft. long, 6 ft. wide and 4 ft. tall. 
         [0029]    As used herein, the term “belt” refers to the conveyance system for transporting the material into the oven for processing. In the present invention, in one embodiment, efficiencies and cost improvements are achieved by replacing the standard taught belt with a microwave transparent, high heat plastic (e.g. Dupont® VESPEL®) belt. This change causes less microwave reflections within the system during processing and, thus, gives better control of the temperature. 
         [0030]    In one embodiment, a blanket of nitrogen is provided on any windows in the oven sufficient to prevent gasses produced in the process from condensing on the windows. 
       DRAWINGS 
       [0031]    Now referring to the drawings,  FIG. 1  is a diagram of the improvements of the present invention. In this view, one can see the microwave oven system  1 . The system  1  comprises an oven  2  wherein tire particles  3  are introduced through the oven  2  via microwave transparent belt  4 . Positioned in oven  2  are parallel microwave emitters with waveguides  5  positioned in the ceiling for even distribution of microwaves. The oven  2  has door  6  and window  7 , the window  7  having nitrogen purge  8  for keeping the gasses from condensing on the window. The door in this embodiment is ¾ inch thick flat aluminum which is bolted on the inside and sealed at the seams with woven fiberglass tape. A ring vacuum pump  10  removes gasses as they accumulate to lower pressure and to keep the cooler gasses from lowering the temperature in the oven. After passing through the heat exchange condenser  19  and past the forced air dryer/purifier  18  liquids  11  are removed by the previous known methods. Impurities are removed via a replaceable solid medium forced air dry system. Solids such as carbon black  12  are removed via a high heat auger  13  using a nitrogen purge  14 . Following that, the carbon black is fed to a chilled auger  15 , after which an electromechanical drum separator  16  removes steel pieces  16   a  from tires, such as are found in steel belted radial tires. Following their removal, carbon black is bagged  17 . 
         [0032]      FIG. 2  depicts an embodiment of the process of the present invention. In the process, organic solid containing material such as tires  20  are processed in a microwave oven system having parallel aligned microwave sources  21 , and gasses are removed via a vacuum pump  22 . Ring vacuum pump  22  removes the gasses from the oven while a high heat auger removes carbon  23 . The carbon is chilled with a chilled auger  24  before steel being separated  25  and then remaining carbon black bagged  26 . 
         [0033]    Those skilled in the art to which the present invention pertains may make modifications resulting in other embodiments employing principles of the present invention without departing from its spirit or characteristics, particularly upon considering the foregoing teachings. Accordingly, the described embodiments are to be considered in all respects only as illustrative, and not restrictive, and the scope of the present invention is, therefore, indicated by the appended claims rather than by the foregoing description or drawings. Consequently, while the present invention has been described with reference to particular embodiments, modifications of structure, sequence, materials and the like apparent to those skilled in the art still fall within the scope of the invention as claimed by the applicant.