Abstract:
A waste rubber treatment process and appartus therefor for vaporizing rubber and separating the vaporized rubber into its usable components. The waste rubber treatment process and appartus therefor includes heating a quantity of rubber in an atmosphere at a negative pressure and at a temperature between 340 Celsius and 510 degrees Celsius such that the rubber is vaporized and defines a vaporized rubber. The vaporized rubber has a plurality of hydrocarbon constituents therein. A venturi separator sprays the vaporized rubber with oil having a boiling temperature greater than 175 degrees Celsius. The oil binds to heavy oil in the hydrocarbon constituents. A remaining portion of the vaporized rubber is condensed such that light oils in the hydrocarbon constituents liquefy and are separated from hydrocarbon gases.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to waste treatment devices and more particularly pertains to a new waste rubber treatment process and appartus therefor for vaporizing rubber and separating the vaporized rubber into its usable components. 
     2. Description of the Prior Art 
     The use of waste treatment devices is known in the prior art. More specifically, waste treatment devices heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements. 
     Known prior art includes U.S. Pat. Nos. 3,984,288; 6,018,471; 5,628,261; 5,720,232; 6,046,370; 4,846,082, 5,230,777; 4,740,270; 4,284,616; 4,235,676; 4,084,521. 
     While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a new waste rubber treatment process and appartus therefor. The inventive process includes heating a quantity of rubber in an atmosphere at a negative pressure and at a temperature between 340 Celsius and 510 degrees Celsius such that the rubber is vaporized and defines a vaporized rubber. The vaporized rubber has a plurality of hydrocarbon constituents therein. A venturi separator sprays the vaporized rubber with oil having a boiling temperature greater than 175 degrees Celsius. The oil binds to heavy oil in the hydrocarbon constituents. A remaining portion of the vaporized rubber is condensed such that light oils in the hydrocarbon constituents liquefy and are separated from hydrocarbon gases. 
     The procedures in the prior art do not deliver a product as clean as the present procedure which produces down to 4% sulfur oil. Also, the use of a heat exchanger, as discussed below, provides a more efficient system for heating the rubber and maintains a lower exhaust temperature. The venture separator makes the process unique for obtaining a very clean by-product which, would be, as fuel; direct replacement for #2 diesel or better. The process also prevents the need for expensive filtration methods as the system is enclosed and any gaseous by-products are stored in a tank and reused as fuel for future processes, producing negligible emissions. 
     Additional waste material which may be processed with this system include items such as general waste rubber, lubricants, sewage sludge, plastics, contaminated soils, tank bottoms, solvents, site contaminants, refinery wastes and waste wood products. The process, as shown below, is directed primarily to the vaporization and treatment of rubber obtained from tires. 
     In these respects, the waste rubber treatment process and appartus therefor according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of vaporizing rubber and separating the vaporized rubber into its usable components. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing disadvantages inherent in the known types of waste treatment devices now present in the prior art, the present invention provides a new waste rubber treatment process and appartus therefor construction wherein the same can be utilized for vaporizing rubber and separating the vaporized rubber into its usable components. 
     The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new waste rubber treatment process and appartus therefor apparatus and method which has many of the advantages of the waste treatment devices mentioned heretofore and many novel features that result in a new waste rubber treatment process and appartus therefor which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art waste treatment devices, either alone or in any combination thereof. 
     To attain this, the present invention generally comprises heating a quantity of rubber in an atmosphere at a negative pressure and at a temperature between 340 Celsius and 510 degrees Celsius such that the rubber is vaporized and defines a vaporized rubber. The vaporized rubber has a plurality of hydrocarbon constituents therein. A venturi separator sprays the vaporized rubber with oil having a boiling temperature greater than 175 degrees Celsius. All vapors entering the venturi separator having a boiling temperature greater than 175 degrees Celsius bind to heavy oil in the hydrocarbon constituents. A remaining portion of the vaporized rubber is condensed in a separate condenser such that light oils in the hydrocarbon constituents liquefy and are separated from hydrocarbon gases. 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. 
     It is therefore an object of the present invention to provide a new waste rubber treatment process and appartus therefor apparatus and method which has many of the advantages of the waste treatment devices mentioned heretofore and many novel features that result in a new waste rubber treatment process and appartus therefor which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art waste treatment devices, either alone or in any combination thereof. 
     It is another object of the present invention to provide a new waste rubber treatment process and appartus therefor which may be easily and efficiently manufactured and marketed. 
     It is a further object of the present invention to provide a new waste rubber treatment process and appartus therefor which is of a durable and reliable construction. 
     An even further object of the present invention is to provide a new waste rubber treatment process and appartus therefor which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such waste rubber treatment process and appartus therefor economically available to the buying public. 
     Still yet another object of the present invention is to provide a new waste rubber treatment process and appartus therefor which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith. 
     Still another object of the present invention is to provide a new waste rubber treatment process and appartus therefor for vaporizing rubber and separating the vaporized rubber into its usable components. 
     Yet another object of the present invention is to provide a new waste rubber treatment process and appartus therefor which includes heating a quantity of rubber in an atmosphere at a negative pressure and at a temperature between 340 Celsius and 510 degrees Celsius such that the rubber is vaporized and defines a vaporized rubber. The vaporized rubber has a plurality of hydrocarbon constituents therein. A venturi separator sprays the vaporized rubber with oil having a boiling temperature greater than 175 degrees Celsius. Heavy hydrocarbon gases with a boiling temperature higher than 175 degrees Celsius bind to the oil spray and condense at the bottom of the venturi separator. The remaining hydrocarbons travel through in a gaseous phase throughout the venturi separator into a condenser where all liquefied components will condense and separate from non condensing gases. 
     Still yet another object of the present invention is to provide a new waste rubber treatment process and appartus therefor that converts rubber into usable fuel in an efficient manner which does not release contaminants into the atmosphere. 
     These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
     FIG. 1 is a schematic view of a new waste rubber treatment process and appartus therefor according to the present invention. 
     FIG. 2 is a schematic perspective view of the furnace of the present invention. 
     FIG. 3 is a schematic perspective view of the apparatus of the present invention. 
     FIG. 4 is an exploded schematic view of the present invention. 
     FIG. 5 is an exploded schematic view of the present invention. 
     FIG. 6 is an exploded schematic view of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference now to the drawings, and in particular to FIGS. 1 through 6 thereof, a new waste rubber treatment process and appartus therefor embodying the principles and concepts of the present invention and generally designated by the reference numeral  10  will be described. 
     As best illustrated in FIGS. 1 through 6, the waste rubber treatment process and appartus therefor  10  generally comprises a furnace  12  having nitrogen gas introduced therein such that the furnace has an interior with an atmosphere has an oxygen gas content of less than 6%, the furnace. The furnace  12  is ideally a radiant heat furnace designed to contain a large amount shredded tires. Tires are placed into the furnace  12  and heated at a temperature between 340 Celsius and 510 degrees Celsius such that the rubber is vaporized and defines a vaporized rubber. The furnace  12  is monitored such that it is turned off after once the temperature reaches 510° C. The vaporized rubber has a plurality of hydrocarbon constituents therein. The hydrocarbon constituents include heavy oils having a boiling point greater than 175 degrees Celsius, light oils having a boiling point between 36 degrees Celsius and 175 degrees Celsius, and hydrocarbon gases having a boiling point less than 36 degrees Celsius. 
     A blower  75 , or pump, is in fluid communication with the furnace such that the interior of the furnace  12  has an atmospheric pressure of between −2 inches of water to −8 inches of water. The lowered pressure creates a more efficient process and helps to ensure that materials from the furnace do not escape into the atmosphere. A pressure sensitive valve releases the contents into an incinerator  22  if the pressure increases to unacceptable levels. The blowers  75  draw the vaporized rubber through the remainder of the apparatus. 
     A venturi separator  30  is in fluid communication with the furnace  12 . The venturi separator  30  contains a plurality of nozzles and horizontally sprays the vaporized rubber with oil having a boiling temperature greater than 175 degrees Celsius. The heavy oils are bound to the oil in the venturi separator and removed from the vaporized rubber. By altering the flow of the oil through the nozzles, the operating temperature of the venturi separator can be regulated which produces a cleaner product. 
     A heavy oil tank  31  is in fluid communication with the venturi separator  30 . The heavy oil captured by the venturi separator  30  is collected and stored in the heavy oil tank  31 . 
     The remainder of the vaporized rubber not captured by the venturi separator continues to a condenser  43  fluidly coupled to the venturi separator  30  such that the light oils and hydrocarbon gases may bypass the heavy oil tank and enter the condenser. The condenser  43  cools the vaporized rubber to a temperature of less than 30 degrees Celsius such that the light oils liquefy. The light oils are contained in a separate tank. 
     The hydrocarbon gases continue past the condenser  43  and enter a cyclone separator  52  fluidly coupled to the condenser  43  so that liquids in the hydrocarbon gases may be dried before continuing on to a tank for holding the gases. The blower  60  is in fluid communication with the cyclone separator such that the hydrocarbon gases are drawn through the blower. 
     The following is a list of the typical products of the system. 
     The hydrocarbon gases include by volume: 
     14.6% H 2    
     7.84% CO 2    
     8.07% C 2 H 6    
     31.17% CH 4    
     3.59% CO 
     27.11% heavy gasses containing 3 or more carbon atoms 
     The light and heavy oil percentages below are a percentage by weight of a mixture the heavy and light oils. 
     The light oils include: 
     1.75% C 5 H 12  n-pentene 
     3.25% C 6 H 14  n-hexane 
     7.25% C 7 H 16  n-heptane 
     9.5% C 6 H 6  benzene 
     9.5% C 7 H 8  toluene 
     7.5% C 8 H 10  ethyl benzene 
     8.0% C 8 H 10  xylene 
     10.5% C 8 H 8  styrene 
     2.0% C 9 H 20  nonane 
     2.75% C 10 H 22  decane 
     The heavy oils include: 
     13.3% C 10 H 10  limonene 
     4.0% C 11 H 24  undecane 
     1.0% C 10 H 8  naphthelene 
     3.0% C 11 H 10  methyl naphthyl 
     3.0% C 12 H 26  dodecane 
     4.0% C 13 H 28  tridecane 
     2.7% C 14 H 10  anthracene 
     7.0% C 19 H x  waxes. 
     The furnace ideally has a plurality of steam vents therein for cleaning and purging the system. The waste products include recyclable metal and carbon black, both of which may be used in other manufacturing processes. 
     The gaseous material extracted may be used as natural gas while the liquid components may be used as fuels such as Diesel #1 and the heavy oils may be used also for fuels and for oil such as #4 oil. The carbon black is used in for inks, asphalt and water filters. The system is self-contained and operates under negative pressure to prevent contaminants from entering the atmosphere. 
     Additional valves and blowers may be used for safety reasons and keeping temperatures and pressures constant. A heat exchanger is envisioned for thermally coupling the furnace to the condenser for conserving energy during the process. 
     FIGS. 1,  4 - 6  show one embodiment of the system and is composed of a furnace  12  having a pressure indicator  13 , temperature control  14  and pressure control  15 . The temperature control  14  will shut down the burners  16  when the set temperature is achieved. The pressure control  15  modulates valves connected to the blower system controlling the furnace pressure to stay at a predetermined set pressure, and will shut the system down when the negative pressure of the furnace  12  exceeds a pre-set pressure. The steam injection system  17  cools and purges the furnace  12  to ensure the furnace is safe to be opened. The furnace  12  has an inspection port  18 . The furnace  12  preferably has one to three burners  16  which may be operated with oil or gas. These burners  16  are designed to fire in tubes  19 . Each tube  19  is equipped with preferably two heat exchangers  20 . A relief valve  21  sends the gases in the furnace  12  to an incinerator  22  if the pressure exceeds safe limits. Usable liquids are caught in a cyclone separator  23  between the incinerator and the furnace. 
     Gases travel from the furnace  12  through an outlet  24 , expansion joints  25 , isolation valve  26 , motorized valve  27  and a second isolation valve  28  into the venturi system  30 . An oil tank  31 , equipped with sight glass  32  and relief valve  34 , supply oil to a pumps  35  for pumping oil to the venturi system  30 . The oil travels through a metering valve  36  which is controlled by a temperature control  37 . If the temperature is below the set point of the temperature control  37 , the metering valve  36  closes to reduce the amount of oil injected into the venturi system  30 . A by-pass valve  38  may be added maintaining the metering valve  36 . Extra oil may be re-circulated through a relief valve  39  back to the oil pump  35  inlet. A second oi. 1  injection system supplies to the venturi system by a second metering valve  40  or through a back-up valve  41  to the venturi mixing nozzle  42 . The mixing of the gases from the vaporization of the rubber with the oil condenses the heavy oil at a pre-set temperature while releasing all of the light oil and hydrocarbon gases which move to the condenser  43  through another isolation valve  44 . 
     All light oils are generally expected to condense while passing through the condenser  43  and enter a tank  44  through a valve  45 . Gases which travel through the condenser  43  are now transferred to the heat exchanger  50  via a valve  51  for further cooling. The gases are transferred to a cyclone separator  52  where any liquid oil residue is separated from the remainder of the gases. 
     The gas is then drawn by a blower  53  and pumped through an after cooler  54  into an intermediate gas tank  55 . The intermediate gas tank  55  has a relief valve  56  and tank pressure control  57 . Gases from the gas tank  55  are allowed to re-circulate through a modulating valve  58  and isolations valves  59 . The modulation valve  58  keeps the furnace pressure at a set point by modulating open and closed to balance the draw on the furnace. Another blower  60  and after cooler  61  are supplied to perform two functions. The additional blower  60  will re-circulate gases through an intermediate gas tank via a modulation valve  64  and two isolation valves  63 . Also envisioned, when the pressure in the gas tank reaches a certain pre-set pressure, a modulation valve  62  opens and the modulation valve  64  closes to send gases to a larger holding tank, which is not shown. When the intermediate tank pressure is reduced, the two modulation valves  62 ,  64  reverse action. A check valve  65  prevents any reverse flow to the intermediate tank  55  from the large holding tank. 
     When the process is complete, isolation valve  26  is closed. Steam is injected from a boiler  70  to the bottom of the furnace  12 . Steam is used to cool the furnace  12  and purge unsafe gasses from the furnace to the boilers  70  for combustion. The steam/gasses mixture travel through an exhaust valve  71  back to a burner&#39;s combustion zone in the boiler  70  for complete combustion. A steam supply valve  72 .and exhaust valve  71  are closed after the furnace  12  is purged, at which time the furnace  12  may be reloaded with rubber waste. 
     As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided. 
     With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. 
     Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.