Abstract:
The invention relates to a method and device for processing plastic-containing and organic fluids based on crude oil, cooking oil, fats or the like, wherein the substance mixture is fed into a reactor, is then melted in the melting zone of the reactor and the interfering substances are discharged from the melt. The long-chained polymers still present in the melt are cracked in a crack zone of the reactor until they assume a gaseous state. Then the gas phase is discharged from the reactor an condensed in a cooler. Impurities are then removed from the volatile liquid present after cooling and the volatile liquid is stored.

Description:
[0001]    This application is a National Stage completion of PCT/EP2007/007419 filed Aug. 23, 2007, which claims priority from German patent application serial nos. 10 2006 039 824.6 filed Aug. 25, 2006; 10 2006 046 682.9 filed Sep. 29, 2006; 10 2006 055 388.8 filed Nov. 22, 2006; and  10   2007   039   887 . 7  filed Aug. 23, 2007. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention concerns a process and the equipment for the preparation of waste containing plastic and organic liquids based on mineral oil, edible oil, fat and similar. 
       BACKGROUND OF THE INVENTION 
       [0003]    In view of the increasing cost of crude oil and the ever restricting obligations attached to the processing of waste material and the recycling of scrap, there is considerable interest in the processing of plastic scrap which, for example, might be separated from residual waste. 
         [0004]    From WO 2005/071043 A1 a procedure is known whereby plastic scrap is processed into oil. 
         [0005]    In this procedure the separated plastic scrap is hermetically sealed, compacted and delivered to a melt container. Then follows a separation into a first liquid phase, a first gas phase and residue. The liquid phase and the first gas phase are delivered to a vaporiser in which a second liquid phase and a second gas phase separation takes place. The second liquid phase is warmed further in a secondary heater. The third gas phase and the second gas phase are delivered from the vaporising container to a cracking tower in which long chain hydrocarbons are cracked. The resulting gas is then condensed into light liquid in a condenser. 
         [0006]    This complex process with a melt container, several vaporising or secondary heating containers, a separate crack installation and a condenser calls for a considerable investment in processing equipment. 
       SUMMARY OF THE INVENTION 
       [0007]    In view of this the object of the invention is to produce a process and the equipment with which to treat waste containing plastic with minimal investment in equipment. 
         [0008]    According to the invention the melting, vaporising, and cracking should be arranged in a single reactor in which the melting and cracking zone are split or are in two downstream switched reactors such that the equipment costs described at the beginning are significantly reduced. 
         [0009]    The gas phase after the crack zone will for example be taken to a distillation column that would operate such that short chain polymers condense and are then returned to the reactor crack zone. After the distillation column and the associated coolers those relatively short chained gaseous hydrocarbons can be used as fuel for energy. 
         [0010]    The process under the invention can be carried out particularly effectively if the temperatures in the melt zone are as low as possible—approximately from 250° C. to 350° C. max—and in the crack zone approximately from 420° C. up to 450° C. 
         [0011]    Any impurities in the reactor including non-molten plastics drop into the melting zone and into the crack zone and can be removed. 
         [0012]    These high calorie residues can be emulsified and also used as fuel for energy. 
         [0013]    After condensing while still in light liquid any impurities can be removed during processing for example by absorption. 
         [0014]    The reactor with the melting zone and/or the crack zone must be fitted with a device to ensure that the melt from the entering material is continuously monitored. This supply device can, for example, be a screw feeder attached to one of the zones. 
         [0015]    According to a preferred embodiment of the invention the material mixture, which is to be processed, can be fed to the reactor in at least two symmetrical points of entry. 
         [0016]    It is particularly advantageous that this material be compacted prior to being loaded into the reactor. 
         [0017]    The reactor is preferably laid out as a horizontal container. 
         [0018]    As an example a part of the liquid product after cooling and quenching can be taken as a coolant fluid through a cooler and used as a quenching fluid for cooling and condensing gases. 
         [0019]    The heating for melting in the melting and crack zones is preferably by means of pipes within the reactor which practically form a heat exchanger. The number of pipes, or more exactly, their heating surfaces being appropriate for the heating level required. 
         [0020]    As mentioned before a single reactor can be supplied with a melting zone and crack zone. As an alternative two reactors can be supplied switched downstream. For the heating of the suspension heating pipes are provided within the reactor. In one version of the invention the heat input and the distribution of the heat originate from the individual pipes at the front at one end of the reactor. The output distributor and the heat output are located at the opposite side of the reactor. As mentioned the pipes provide circulation with their associated distributors and coil for removing the scaling on the internal cladding of the reactor concerned. 
         [0021]    The single reactor with melting zone and crack zone or the two-switched downstream reactors have a heat exchanger in which the suspension or molten mass is warmed. 
         [0022]    In one preferred embodiment these heat exchangers are provided as pipe heat exchangers in which one pipe having suspension/molten mass has an inner pipe formed into a coil which runs with the suspension and considerably improves the heat transfer with the result that the heat exchanger can be made shorter than those normally available. 
         [0023]    In another variant it is preferable if this winding or coil abuts the cladding of the inner pipe so that any residues may be removed. 
         [0024]    Since the suspension still contains a certain amount of solid matter, the pump and supply power units are subject to abrasive wear. To minimize this wear a version can be used with an electromagnetic clutch motor such that no part of the clutch unit is in contact with the suspension. 
         [0025]    Pump wear can be reduced when the pump is operated magnetically with the drive solenoid located outside the area of the suspension. Preferably a double action piston pump with two cylinders should be used separated from the piston and operated via the solenoid drive. 
         [0026]    This solenoid drive can have an external magnet covering the pump cylinder that is controlled by a linear actuator so that the stroke of the piston is in line with the linear actuator. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  represents a continually operating processing plant for mixed plastics and contaminated plastic materials separated from residual waste. Also PVC, PET and rubber are separated as foreign matter. At the time the following processes are shown as ready of which however only process (to WO 2005/071043 A1) is selected for continuous operation. The two other processes are batch driven installations and can when operating at least three units be described as continuous operation. These processes are described in JP 08 034978A (Patent Abstracts), U.S. Pat. No. 4,584,421 A and CN 12 284 537 A. 
           [0028]    A difference between the processes mentioned and the new process as in  FIG. 1  lies in the continuous feeding of at least two feed plants  20 / 22  in a horizontal reactor in which the following six process steps run simultaneously and use a commonly unseparated gas area. 
           [0029]    1) Continuous feeding  20 / 22  of plastic materials and organic liquids based on mineral oil or edible oil and fat. 
           [0030]    2) Melting the supplied material mixtures within the temperature range 250° C. and 350° C. to a liquid mass similar to stirred emulsion paint  10 . 3  in the area of the melting chamber  1 . 1 . 
           [0031]    3) Contaminants like sand and other non-organic substances like plastic materials that do not melt at 350° C. or non-organic paints  5  fall out and are delivered through the coil into the chute  6 . 1  to the special waste container that as a removable container will be disposed of in a special incinerator. 
           [0032]    4) Via the separating wall and the skimming wall  10 . 1  and  10 . 2  the molten masses released from the foreign matter  10 . 3  pass into the crack zone  1 . 2  in which with temperatures between 420° C. and 450° C. the long chained polymers are held at temperature until they are delivered as short chain hydrocarbons to the distillation column in the form of gas  10 . 5  and mixed with the gases  11  from the melting stage  1 . 1 . 
           [0033]    5) The distillation tower  23  is in this respect so designed that long chain hydrocarbons condense as C24 and return to the crack reactor  1 . 2  and remain there until they are shorter than C24. The bandwidth at cracking lies between C1 and C22 with the majority between C12 and C16 (predominantly methane) up to C4 (predominantly propane) remain at the specified temperature in the distillation tower  23  in the form of gas  32 . 4  for salt heating. 
           [0034]    6) Of high energy but not in the form of gas tar and bitumen type substances such as the hydrocarbon excess arising from cracking polymers sink in reactor part  1 . 2  and are delivered via the chute  8  and by the removal device  8 . 1  into a container  31 . 9 . This residue  7  can be emulsified with the water  27 . 7  from the product and water separation container and with the product similar to heating oil  27 . 1  in tank  31 . 9  by means of ultra sound  31 . 8  and disposed of as fuel for the salt heating in the multi-fuel stove  32 . 4  as high calorie liquid fuel  31 . 9  or optionally used in a liquid fuel stove. 
           [0035]    Since substrates similar to heating oils condensed contaminants, sulphur traces, particularly sulphuric acids, halogen acids e.g. hydrochloric acids (HC2) and possibly disturbing organic acids are present it is suggested to install equipment as indicated in FIGS.  7 , 8  and  9  absorption units to remove the above mentioned elements. In this connection basic reacting molecular sieves are suitable in the form of silica gel filter, which can be re-used after re-generation. After these elements have been removed the light liquid meets the quality requirements of low sulphur heating oil. 
           [0036]      FIG. 6.1  shows another form of development of a melting reactor  1 . 1  and a switched crack reactor  1 . 2  in which the heating input  9  is opposite the pipe distributor  9 . 3  the heating output  9 . 4  and the discharge  9 . 2 . Even in this variation the pipes  9  run with the feed coil  2 . 
           [0037]      FIG. 6.2  shows an embodiment of the melting reactor  1 . 1  in which preferably all drive elements for feeds and pumps are via magnetic coupling motors  34 , under which neither can content liquid leak outwards nor can atmospheric oxygen come into contact with the content liquid  10 . 3 . 
           [0038]    On account of the high ambient temperatures the magnets are made from a special cobalt alloy. 
           [0039]      FIG. 10  shows a double action piston pump with solenoid drive  35 . 5  which has no protrusion outwards e.g. piston rods, seals, etc. 
           [0040]    Through an external linear drive  35 . 3  the piston moves in the direction  35 . 3  of the magnetic force. No plastic material can pass through the free moving valve flap  35 . 6  which is not completely melted 
           [0041]    The effectiveness of pump activity and energy consumed corresponds with an open non-clogging pump in wastewater applications. 
           [0042]      FIG. 11  shows a crack reactor  1 . 2  in its current version fitted with a pipe bundle heat exchanger  9 . 5 . Through the pump  35  the suspension goes into circulation  37 . 
           [0043]      FIG. 11.1  shows a variation ( 39 ) to the circulation pump ( 35 ). Through the supply coil ( 39 . 2 ) with pipe side ( 39 . 3 ) the circulation substrate ( 37 ) passes through the drive motor ( 39 . 5 ) in the direction of the reference numeral ( 39 . 1 ). In this case the outer pipe ( 39 . 4 ) has a jacket heater not shown here. 
           [0044]    The main crack process takes place in the dynamic part of the heat exchanger  9 . 5  at 420 to 450° C. This heat exchanger  9 . 5  has  3  parallel-switched streaming routes in which there is a rinsing coil  9 . 6 . In the waiting zone  38  the uncracked long chain hydrocarbons  8  separate. 
           [0045]      FIG. 12  shows a coil  9 . 6  of the heat exchanger which vortexes directly with the suspension  37  (approx. 1 to 20 rpm) across the surface  9 . 6 . Through this effect the surface contact between the suspension  37  and the heating surface (based on scientifically available measurements) is trebled. This means that such a heat exchanger based on the higher efficiency can be reduced to one third. 
           [0046]      FIG. 13  shows how under low voltage (against the outer surface of the pipe cladding) the existing coil  9 . 6  scratches the deposited carbon  8  and with the product flow  37 ,  9 . 7  removes it from the heating surfaces. In this way it is ensured that heat transfer is constantly maintained. Since the product consists of an oily mass containing a lubricant abrasion is considered to be very low. 
           [0047]      FIG. 14  shows a total concept for an alternative installation to execute the invention process in which instead of a single reactor with a melting and crack zone in accordance with  FIG. 1  two downstream reactors  8 ,  10  are used. As in the previously described example the plastic mix is delivered to the melting reactor through several feeders and melted down. This melting takes place at 250 to 350° C. in which the reactor  8  is warmed by the liquid salt heater  20  and the melt is heated by a heat exchanger  9  as in  FIGS. 12 and 13 , with which this heat exchanger is connected. 
           [0048]    The molten suspension then passes through an overflow to the crack reactor  10  in which the long chain hydrocarbons are cracked at 420 to 450° C. The construction of this crack reactor can be taken from  FIG. 11 . Also in this crack reactor  10  is a heat exchanger  10 . 1  consisting of two, three or several parallel pipes in which a rinsing coil  9 . 6  is incorporated with its own drive e.g. a solenoid drive. 
           [0049]    The gas arising from the cracking is condensed in a condenser  10 . 2  and passes to a Venturi cooler  11  and to a connected pipe bundle cooler  11 . 1  in which the condensate is cooled. This condensate/vapour mixture cooled down to 30° C. then passes to an intermediate container  15 . The high calorie gas can be used for a steam generator  19  or the liquid salt heater  20 . The residue taken from the intermediate container  15  can undergo several rinsing stages  22 . 1 ,  22 . 2 ,  22 . 3  in which under the process from  FIG. 1  contaminants will be removed by absorption. This process leaves light liquid with the quality of light heating oil. 
           [0050]    In the crack reactor  10  any remaining long chain hydrocarbons are removed and delivered to an emulsifying container  16  e.g. using ultra-sound and then used for energy in the units  19 ,  20  (steam generator, liquid salt heater) so that this energy is used for heating the suspension in the melting reactor  8  and in the crack reactor  10 . These processes are conducted preferably in an atmosphere of nitrogen under which the nitrogen arises for example from an air separation  25 . 
           [0051]    FIGS.  15 / 15 . 1 / 15 . 2  and  16  show another variation whereby molten plastic scrap in a melt pipe  9 . 5  and the melt using the supply coils ( 9 . 6 ) which is circulated and heated by a heating medium ( 9 ) is pumped in directly by the supply screw pump ( 39 ). 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0052]    The plastic scrap ( 20 ) passes into the hopper ( 21 . 1 ) of the feed screw. The feed screw ( 21 . 1 ) feeds the plastic materials to the compactor ( 22 . 2 ). Here the material is compacted and the air withdrawn using nitrogen. 
         [0053]    The compactor ( 22 . 2 ) feeds the material into the melt reactor ( 9 . 5 ). The loading of the melt reactor can be stopped using valves ( 18 ). 
         [0054]    The compacted material is pressed into the melted plastic ( 10 . 3 ) by means of the feed coils ( 9 . 6 ) and this way the liquefying of the plastic material is accelerated as a result of the dissolving effect of the already pre-heated material. 
         [0055]    In the first zone of the melt reactor the material is heated to 120° C. max. Any dampness contained in the material (water) will condense and the light elusive components like plasticisers will dissolve and be removed via the bell ( 9 . 10 ) via the contact ( 11 ). 
         [0056]    Based on the special arrangement of the exchanger ( 9 . 5 / 9 . 6 ) heated by liquid salt ( 9 ) with a dynamic heat transfer under vortexing ( 9 . 10 ) and the scratching off of contaminants ( 7 ) heat transfer happens with a very low Delta-T. In this way a depolymerisation is largely prevented during the liquefying process. 
         [0057]    In the following zone the material is further heated until melting takes place. The melt is then transferred by the screw pump ( 39 ) into the crack reactor ( 9 . 5 ). 
         [0058]    A larger pipe from the crack reactor is fitted with a closed coil that delivers the melt to the sump ( 10 . 4 ) below. It is then further heated up to boiling point. In the other pipes ( 9 . 6 ) from the reactor ( 9 . 5 ) the melt is brought up from the sump ( 9 . 7 / 9 . 10 ) and also heated to not less than boiling point. 
         [0059]    The melt is thus constantly circulated and then delivered by the outer pumps ( 9 . 6 ) to the upper pot ( 10 . 4 ) of the crack reactor from where using a closed coil ( 39 ) it is delivered down below by the middle pipe and then mixed with new melt ( 10 . 3 ) from the melt reactor ( 9 . 6 / 9 . 7 ). 
         [0060]    Owing to the enormous heat energy input vapour arises on the pipe wall in the outer pipes which rises to the top and increased by the rotating movement of the screws which gives rise to strong vortexes ( 9 . 1 ) contributing to the degassing of the melt and the triggering of the crack process. 
         [0061]    The carbon deposits ( 7 ) on the pipe walls are rubbed off by the screws ( 9 . 6 ). These deposits together with the unmelted material at the specified temperature are dumped below using valves ( 18 ) into a clinker container if required. 
         [0062]    A part of the rising vapour ( 10 . 6 / 23 ) will condense ( 10 . 6 ) in the distillation column mounted directly over the crack reactor and flow back to the crack reactor. The following partial condenser ( 40 ) will receive only vapours that do not condense at the specified temperature. This fraction will be cooled later with product ( 27 . 1 . 1 ) in a steel rinsing pipe ( 50 . 1 ) and condensed. For the separation of the vapour/liquid phase a Zyklon is used. 
         [0063]    The liquid product quantity ( 27 . 1 . 1 ) required for the steel pipe cooler ( 50 . 1 ) is provided by the pump ( 27 . 8 ). This pump sucks the product from the provisional container ( 27 ) and feeds it through the heat exchanger ( 24 . 6 ) such that it is cooled to a temperature of 20 to 90° C. before going on to the steel rinsing pipe ( 50 . 1 ). 
         [0064]    From this closed product circulation system there is a partial current that takes off any excess to the product container ( 60 ). 
         [0065]    For the cooling of the compacting screw ( 27 . 1 . 1 ) and the product via the heat exchanger ( 24 . 6 ) a cooling unit is used. A regulating unit ( 40 . 5 ) is used for this in order to set the temperature in the partial condenser ( 40 ). 
         [0066]    The vapour ( 10 . 6 ) originating in the crack reactor consists of short and long chain hydrocarbon molecules and rises in the rectification column ( 40 ) upwards. By means of contra-flow (rectification) whereby the vapour ( 10 . 5 ) rises and the liquid mixture ( 10 . 6 ) flows downwards an initial thermal fine separation takes place. A column ( 23 . 2 ) is set up with a suitable packing. The column ( 23 . 3 ) and the following partial condenser ( 40 ) are arranged for the relevant crucial separation of hydrocarbons C10 up to C24 carbon atoms per molecule. The pre-fractioned vapour that leaves the column flows through a special distributor in the partial condenser ( 40 . 1 ) through which the condensate from the partial condenser is spread on to the column packing. 
         [0067]    In the partial condenser an exact temperature is set using cooling pipes. This temperature can be between 150° C. and 300° C. As a heat carrier (cooling medium) thermo-oil ( 40 . 2  and  40 . 3 ) is used. The regulating set ( 40 . 4 ) functions as a cold and hot battery that maintains the exact temperature for the thermo-oil. 
         [0068]    The unique selling point here is that the temperature flexibility in the partial condenser allows the exact setting of the chain length of the gases leaving the crack reactor. If, for example, the partial condenser ( 40 ) is run at approx. 300° C. in a following cooler ( 50 ) at more than 95% only those molecules are condensed which consist of a chain length of between approx. 10 C to approx. 24 C atoms with the main focus on C12 to C16. This means that the gases leaving the partial condenser at a temperature of approx. 300° C. will in the partial condenser be only those having molecules up to a maximum chain length of C24. Should the temperature be raised/lowered the molecular chain length will be correspondingly increased/decreased. 
         [0069]    Equally the setting of the temperature in the cooler following the partial condenser is decisive in producing fuel of a particular type. For example should the temperature in the cooler be 70° C. instead of 30° C. the hydrocarbons C1 to C9 would remain in the form of gas whilst longer chain hydrocarbons condense. The so-called light boilers remaining from the gas phase can be removed and used as process energy. By this separation of the light boilers C1-C9 pure diesel fuel can be made direct. 
         [0070]    It must be emphasised that not only the packing ( 23 . 5 ) used but also the distributor between the column and the partial condenser are vulnerable to carbon deposits in case the crack process should be continued here. 
         [0071]    The vapour from the partial condenser ( 10 . 5 . 1 ) is fed into a quencher ( 50 . 1 ) by nozzle where this is condensed with product ( 27 . 1 . 1 ) into diesel. The nozzle can be filled with diesel at a temperature between 20° C. and 90° C. The two-phase mix from the quencher is separated later in a Zyklon ( 50 ). The vapours or gases that leave the Zyklon can be used as combustion gas. The separated liquid (diesel) passes to a water collector (phase collector) ( 60 ) whence it flows to a storage tank ( 27 . 10 ). 
         [0072]    In order to guarantee a constant supply from the quencher nozzle the product flows firstly into a float container ( 27 ) the so-called provisional container for the quencher. A pump ( 27 . 8 ) feeds the product from here via a heat exchanger ( 24 . 6 ) to the quencher nozzle. By means of the heat exchanger ( 24 . 6 ) the required temperature for the quencher can be set. An industrial cooler ( 25 ) supplies the necessary cooling water. 
         [0073]    Using a level control in the float container ( 27 ) and a flow regulator any excess product will be drawn off to a phase separator ( 60 ). 
         [0074]    The applicant undertakes to consider independent claims on the construction of the single reactor (integral reactor having melting and crack zones, melt reactor  8 , crack reactor  10 , the relative heat exchangers, pumps and drive units, also the medium used and the stages of the process as laid down in the process scheme in  FIGS. 1 and 16 ) by which the particulars of each sub claim can be made without recourse to the current claim in the matter of independent claims. 
       REFERENCE LIST 
       [0000]    
       
         
           
               1  Two-part reactor (interacting tank with overflow) 
               1 . 1  Melting chamber (L 1 ) 
               1 . 2  Crack chamber (L 2 ) 
               2  Feed and circulating coil and support for the pipe bundle heating unit. In the pipe bundle system a high degree of mixing is achieved and the heat input in the melt  10 . 3  and the crack material  10 . 4  is optimal under this regime. The feed and circulation coils can change the direction of turn and thereby move the product  10 . 3  and  10 . 4  forwards and backwards and stir. In normal operation one reverse turn follows two forward turns. 
               2 . 1  Torque transfer panel from the drive  1 . 2  via the heating distribution units  9 . 3 / 9 . 4 . 
               3  Coil to the feed pipe  22 . 1  and cleaning outer pipe  1 . 1   
               4  Wear tracks 
               5  Contamination (non-organic) 
               6  Output shaft for  5   
               6 . 1  Output unit shown here as a feed coil 
               6 . 2  Drive unit with storage and seal 
               7  Contamination (organic) 
               8  Output shaft for  7   
               8 . 1  Output unit shown here as a feed coil 
               8 . 2  Drive unit with storage and seal 
               9  Pre-heating (thermo salt method) 
               9 . 1  Pre-heating in the input area L 3  for the increasing of the heat input for melting the material in the reactor  1 . 1 . In the crack reactor  1 . 2  the internal pre-heating  9 . 1  is taken to the end of the pipe bundle L 4 . 
               9 . 2  Heating return 
               9 . 3  Pre-heating distribution 
               9 . 4  Heating distribution chamber return 
               9 . 5  Pipe bundle heat exchanger/melting reactor 
               9 . 6  Cleaning coil to  9 . 5   
               9 . 7  Inner pipe (product) 
               9 . 8  Heating outer pipe 
               9 . 9  Diversion chicane for the heating medium 
               9 . 10  Product vortexing 
               9 . 11  Heating surface 
               10  Maximum full level corresponds with the overflow height of the wall 
               10 . 1  (also skimming wall) 
               10 . 1  Skimming wall for separation between chambers  1 . 1  and  1 . 2   
               10 . 2  Diversion panel for the seal of the overflow  10 . 3   
               10 . 3  molten material between paste and liquid form 
               10 . 4  Boiling material in liquid form 
               10 . 5  Gas flow from the vaporised plastic material  10 . 4  from the crack chamber into the distillation column  23   
               10 . 5 . 1  Gas flow as in  10 . 5  into the quencher 
               10 . 6  Return of condensed plastic material parts  10 . 4  into the melting chamber  1 . 1 / 9 . 5   
               11  Gas flow from chamber  1 . 1  to chamber  1 . 2   
               12  Drive and storage units to chambers  1 . 1  and  1 . 2   
               12 . 1  Drive motor with panel and chain wheel 
               12 . 2  Chain wheel on drive shaft of the stirrer with power take-up via the heating pipe  9  or  9 . 2  and drive for the heating distribution units  9 . 3  and/or combination  9 . 3  with  9 . 4   
               12 . 3  Shaft seal 
               13 . 1  Level control  1 . 1  for controlling the filling quantity via the raw material inlet  22  and the overflow level gauge  19 . 2   
               13 . 2  Level gauge in the melting reactor 
               13 . 3  Temperature controls and monitoring in the melting reactor  1 . 1  within the range 250 to 350° C. 
               14 . 1  Level control and monitoring in the crack chamber  1 . 2   
               14 . 2  Maximum level corresponds with overflow separation panel  10 . 1   
               14 . 3  Minimum level in the crack and vaporising chamber  1 . 1  must be above the shaft seal  12 . 3 . Should it fall below this the following measures will be triggered: 
             a) Closing of the valves  16   
             b) Increased material flow  22 . 1  into the melting reactor  1 . 1   
               14 . 4  Temperature controls and controls in the crack reactor  1 . 2  within the range 420 to 450° C. 
               15  Heat insulation 
               16  Isolating valve between crack and vaporising reactor  1 . 2  and the distillation column  23   
               17  Emergency valve for discharging chambers  1 . 1  and  1 . 2  and the floating container  27  into the receptacle  33   
               18  Isolating valve and lock closure for products 
               18 . 1  Isolating valve for nitrogen 
               18 . 2  Nitrogen production from ambient air via membrane technology 
               18 . 3  Nitrogen low pressure saving for the storage of all container volumes. 
               18 . 4  Nitrogen pressure flasks for the storage of all container volumes 
               18 . 5  Nitrogen connections 
               18 . 6  Rinse exhaust gases 
               18 . 7  Quick acting connection with metal hose 
               19  Change-over valve 
               20  Plastic material (raw material) 
               20 . 1  Equipment (shown here as feed coil) 
               21  Hopper 
               21 . 2  Hopper discharge unit (shown here as feed coil) 
               22  Compacting unit (shown here as piston pump) 
               2 . 1  Input pipe 
               22 . 1 . 1  Input coil 
               22 . 2  Compacted plastic material in pallet form 
               22 . 3  Through heat input dissolving plastic suspension (goo) 
               22 . 4  Cold chamber for the liquid plastic material at a frozen tap such that at storage, movement, valves  18  and piston pump  22  repairs and overhaul can be carried out without draining the container  1 . 
               22 . 5  Cooling medium in the form of liquid nitrogen 
               22 . 6  Cooling sleeve for the cooling of the input product  22 . 2  and the output product  5  and  7  such that input units  22  and  18  and the drive unit  6 . 2  and  8 . 2  and the valve  18  are protected from the effect of the heat emanating from the product of the melt chamber  1 . 1  and from the crack chamber  1 . 2 . 
               23  Distillation column 
               23 . 1  Container 
               23 . 2  Outer heating elements shown here with four sub-circuits. As required the number of elements can be reduced or increased by the introduction of additional heater elements 
               23 . 3  Electric heating controls to maintain gas temperatures from 420 to 450° C. 
               23 . 4  Temperature controls for  23 . 3   
               23 . 5  Metal body filling to increase the reaction surface 
               24  Cooler/condensation column (quench) 
               24 . 1  Container 
               24 . 2  Rinsing chamber 
               24 . 3  Spray unit of circulation product  27 . 1  that as a solvent releases deposits at intervals in the pipe coil cooler. 
               24 . 4  Solenoid valve for the control and the setting of the spray intervals  24 . 3   
               24 . 5  Pipe coil cooler 
               24 . 6  Cooler for the cooling of the circulating medium  27 . 1  for the cooling and condensing of the gas flow  10 . 5   
               24 . 7  Spray unit for the cooled circulating product  27 . 1  for the cooling of the gas flow  10 . 5 . The circulating medium consists of the end product in the form of light heating oil and/or diesel fuel, i.e. the unit is cooled with a finished product. The medium  27 . 1  with a temperature of approx. 30° C. is reduced to a temperature of approx. 10° C. sprayed over the individual quench zones  24 . 10  with the spray unit  24 . 7  and emerges in the increasingly cooling and condensing  27 . 1  gas flow  10 . 5  as a liquid mixture of new product and circulating medium  27 . 1  at the outlet of the column as product  27 . 2 . 
               24 . 8  Regulating valve for the cooled circulating medium  27 . 1   
               24 . 9  Temperature regulator for  24 . 8   
               24 . 10  Metal body filling to increase the reaction surface. The individual quench elements shown here with spray units  24 . 7  and body filling  24 . 10  can be reduced as required in the process or increased with additional elements. 
             Central cooling unit for the maintenance of the coolant  24 . 5 ,  24 . 6  and  6  off  22 . 6   
               25 . 1  Cooling output 
               25 . 2  Cooling return 
               26  Heat return from the pipe coil cooler  24 . 5  for the heating of equipment not directly connected with the unit or heat exchanger (e.g. room heating, absorption cooler, etc.) 
               26 . 1  Input cold 
               26 . 2  Return warm 
               26 . 3  Heat exchanger 
               26 . 4  Input warm to the consumer 
               26 . 5  Return cold to the consumer 
               27  Product output and separation container 
               27 . 1  Product and/or circulation medium 
               27 . 1 . 1  Cooled product or circulation medium 
               27 . 2  Highest water level 
               27 . 3  Lowest water level. With gas flow  10 . 5  water moisture is also taken along and in the quencher  24  condensed out. As the product is lighter than water the water  27 . 7  sinks to the bottom of the container with the other impurities  27 . 5 . 
               27 . 4  With float detection the separation between light liquid  27 . 1  and the water  27 . 7  can be defined to the last millimetre. Should the maximum level  27 . 2  be reached the solenoid valve  27 . 5  will open until the lower level  27 . 3  is reached. 
               27 . 5  Organic matter 
               27 . 6  Collecting and storage containers 
               27 . 7  Water 
               27 . 8  Circulation medium  27 . 1  feed pump to the cooler  24 . 6   
               27 . 9  Overflow level for absorption treatment unit  28  and  29   
               27 . 10  Purified end product (diesel fuel) in storage tank  30   
               28  Absorption treatment unit Version  1  with temporary containers  28 . 1  to  28 . 3  for the separation of sulphur containing matter, halogen matter such as HCL (hydrochloric acid) and any other foreign organic acids. Shown here ( FIG. 7 ) are two groups  28 . 5  and  28 . 6  that are run on an alternating basis. If one group is loaded so it changes to the other group. If one group is emptied or individual containers changed the feed  27 . 6  is stopped  18  and nitrogen  18 . 5  applied over the open valves  18 . 1  and then the outflow valve ( 18 ) opened and via the connection  18 . 7  and  28 . 8  the residual liquid  28 . 9  is pumped back to the container  27 . At the same time as the emptying process the container content  28 . 4  is filled with nitrogen and rendered inert. Then all valves are closed and the container uncoupled with the fasteners  18 . 7 , filled with nitrogen and then by opening the valves  18  re-started. 
               28 . 1  Up to  28 . 3 ×N removable containers 
               28 . 4  Absorption packing materials such as silicate gel etc. that absorbs and binds foreign matter from the product  27 . 1 . 
               28 . 4 . 1  Loaded absorption matter 
               28 . 5  Absorption group  1   
               28 . 6  Absorption group  2   
               28 . 7  Feed pump for emptying  28 . 8   
               28 . 8  Emptying liquid in the containers  27   
               29  Absorption treatment unit Version  2 . Contrary to absorption treatment unit Version  1   28  the containers remain but the absorption packing  28 . 4  is fed inwards and outwards by sluices  29 . 2  and  29 . 8 . 
               29 . 1  Filling hopper for absorption material  28 . 4   
               29 . 2  Filling sluice with nitrogen rinsing  18 . 5  before filling 
               29 . 3  Containers in packing  28 . 4   
               29 . 4  Non-continuous downstream of the packing  28 . 4   
               29 . 5  Output unit for loaded packing  28 . 4  shown here as a screw or coil feed. 
               29 . 6  Feed for the light liquid  27 . 9  to be treated 
               29 . 7  Filter for the packing flow  28 . 4   
               29 . 8  Outlet sluice with nitrogen  18 . 5  for the loaded absorption material  28 . 4 . 1   
               29 . 9  Circulation system between the absorption treatment unit  28 . 4  shown here as three elements. If necessary the number of elements  29  can be reduced or increased. 
               30  End product tank unit for diesel fuel  27 . 10   
               31  Emulsion unit for reclaiming as fuel for the production of intrinsic energy. 
               31 . 2  Collection and emulsion container 
               31 . 3  Feed line for materials  31 . 2   
               31 . 4  Pump for the supply of intermediate product  27 . 1   
               31 . 5  Feed line for mixed product from  31 . 2  and  31 . 4  in containers  31 . 1   
               31 . 6  Circulation and mixed pump via cooler  22 . 6   
               31 . 7  Static mixer 
               31 . 8  Ultra-sound emulsifier for the production of a combustible high calorie emulsion from the organic materials  8  liquids from the crack reactor  1 . 2  and from the material mixture  31 . 5   
               31 . 9  Emulsion 
               32  Heat generating plant for the heating of the thermo salt for the heat consumer. 
               32 . 1  Exhaust gasses from the product collection container  27   
               32 . 2  Gas movement fan 
               32 . 3  Transport and pressure increasing pump 
               32 . 4  Multi-fuel burner for the production of energy from gas  32 . 1  and from emulsion  31 . 9   
               32 . 5  High temperature boiler for the heating of thermo salt above 500° C. 
               32 . 6  Thermo salt circulation 
               32 . 7  Thermo salt pre-run 
               32 . 8  Thermo salt return 
               32 . 9  Heating oil tank for average operation 
               33  Safety and emergency overflow measures. In normal or revision the entire reactor content  1  must be fed into the collection container  33 . 1  so that the material mixture  10 . 3  and  10 . 4  remains compatible with the pump. 
               33 . 1  Steel tank filled with nitrogen  18 . 5   
               33 . 2  Heating jacket with thermo salt heating 
               33 . 3  Circulation and refill pump 
               33 . 4  Thermo salt heated heat exchanger 
               33 . 5  Emergency outlet from the reactor  1  chambers  1 . 1  and  1 . 2  into the container  33 . 1  via valves  17   
               33 . 6  Circulation through the heat exchanger  33 . 4   
               33 . 7  Supply for the refilling from the container  33 . 1  via the pump  33 . 3  and the multi-way valve  19  into the feed line  33 . 7  to chamber  1 . 1   
               34  Solenoid drive or motors with special cooling 
               35  Product circulation pump in the form of a rotary pump or as a double action piston pump (see  FIG. 10 ) 
               35 . 1  Drainage duct 
               35 . 2  Pressure duct 
               35 . 3  Piston movement 
               35 . 4  Linear drive 
               35 . 5  Magnet 
               35 . 6  Flap valve 
               36  Circulation for heating and melting of the suspension  22 . 3  in the feed pipe  22 . 1   
               37  Suspension circulation in the crack reactor 
               37 . 7  Pump body 
               38  Idle zone 
               39  Outer pipe coil pump 
               39 . 1  Pump direction coil pump ( 39 ) 
               39 . 2  Coil 
               39 . 3  Central pipe 
               39 . 4  Outer pipe 
               39 . 5  Solenoid drive or motor with special cooling 
               40  Partial condenser 
               40 . 1  Cooling hoses 
               40 . 2  Cooling return 
               40 . 3  Cooling pre-run 
               40 . 4  Thermo oil heater 
               40 . 5  Electric heater 
               40 . 6  Circulation pump 
               40 . 7  Controls between ( 40 . 8 / 40 . 6 / 40 . 5 ) 
               40 . 8  Temperature measurement 
               41  Gasses 
               42  Condensate hydrocarbons 
               50  Combined quenching/steel pipe cooler ( 50 . 1 ) with Zyklon separator ( 50 . 2 ) 
               50 . 1  Steel pipe cooler 
               50 . 2  Wet Zyklon 
               50 . 3  Moistened surfaces 
               60  Combined hopper with water separator 
               60 . 1  Container 
               60 . 2  Division 
               60 . 3  Sinking water 
           
         
       
     
       REFERENCE LIST FOR FIG.  14   
       [0000]    
       
         
           
               1  Supply station 
               1 . 1  Dosing bottom discharger 
               1 . 2  Piston pump 
               2  Upper supply 
               3  Distribution 
               4 . 1  Loading silo I 
               4 . 2  Loading silo II 
               5 . 1  Filling coil I with solenoid drive (MMA) 
               5 . 2  Filling coil II with solenoid drive (MMA) 
               6  Material coil 
               7  Inlet and pre-melt coil with MMA 
               8  Melting reactor 250-350° C. 
               8 . 1  Supply coil with MMA 
               8 . 2  Foreign body removal 
               9  Heat exchanger with coil cleaner with MMA and heating medium in melted salt 
               10  Crack reactor 420-450° C. 
               10 . 1  Heat exchanger as item  9   
               10 . 2  Condenser 
               10 . 3  Carbon output 
               11  Venturi cooler with cold liquid from the product 
               11 . 1  Pipe bundle cooler 
               11 . 2  Wet detonation arrester 
               11 . 3  Gas detonation arrester 
               12  Bench cooler 
               13  Compressor cooler 
               14  Pipe bundle cooler 
               15  Intermediate product container (30° C.) 
               15 . 1  Water and intermediate product mixture 
               16  Emulsion container 
               16 . 2  Emulsion unit (ultrasound) 
               17  Foreign body container (for thermo disposal) 
               18  Emergency collection and revision container for the whole melting, crack and intermediate product content (with steam heating) 
               19  Steam generator 
               19 . 1  Water preparation for  19   
               20  Liquid salt heater (500° C.) 
               20 . 2  Liquid circulation pump for the heat consumers 
               21  Gas flare unit 
               22  Intermediate product take-off with dosing pump and detonation arrester 
               22 . 1 . 3  Cleaning steps (e.g. silicate gel for the absorption of foreign matter) 
               24  Diesel fuel/or light heating oil 
               25  Nitrogen (N2) generated from air separation pressure vessel