Method, apparatus and system for processing materials for recovery of constituent components

The present invention is directed to processing feedstock materials for recovery, recycling and/or reuse of the constituent components of the feedstock materials, and includes adding feedstock materials at a constant temperature to a thermal reactor, heating the feedstock materials at a temperature of 1,100° F. or higher in an anaerobic environment within the thermal reactor to produce cracked and gasified hydrocarbons and residual material, removing cracked and gasified hydrocarbons released from the feedstock materials from the thermal reactor, further processing the residual material to recover one or more constituent component of the feedstock materials, and oxidizing the cracked and gasified hydrocarbons removed from the thermal reactor having five or less carbon atoms in their molecular structure in order to produce heat to obtain the temperature of 1,100° F. or higher for the thermal reactor. The present invention further includes systems, reactors and apparatuses configured to perform the processes of the present invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to processing of a waste product and/or raw material in order to recover, reuse and/or recycle components of the product and/or material that may have useful economical, environmental, industrial and/or commercial value. More particularly, exemplary embodiments of the present invention generally relate to processes, apparatuses and systems for the processing of asphalt roofing shingles in order to recover, reuse and/or recycle the constituent components comprising the asphalt roofing shingles.

2. Description of Related Art

A great deal of waste products are generated as byproducts from industrialized societies, and substantial effort is used in the removal, disposal, recycling and/or containing of these waste products. Many waste products do not have any useful purpose or function once the useful life of the original product has expired, and these waste products may generally be disposed of and/or contained within ever increasing landfills. Furthermore, recycling processes, while potentially reducing the amount of waste products that are disposed of, may be uneconomical and produce inferior or less useful products from the recycled waste products. In particular, asphalt roofing shingles and other asphalt based roofing materials are removed from building structures, which produces many tons of waste roofing products. These waste roofing products may contain useful components, but prior asphalt roofing shingle recycling has not yielded desirable constituent components of the asphalt roofing shingles or useful products from the components of the asphalt roofing shingles that are able to be reused. Therefore, what is needed is a means for recovering, reusing and/or recycling the components of waste products, such as asphalt roofing shingles, so as to produce useful products from the waste products in an economical and/or environmental fashion.

SUMMARY OF THE INVENTION

The present invention is designed to overcome the above noted limitations that are attendant upon the use of conventional waste product processing and recycling techniques and, toward this end, it contemplates the provision of a novel method, apparatus and system for the processing of materials to recover the constituent components of the feedstock materials.

It is an object of the present invention to provide methods, apparatuses and systems that are configured to economically and efficiently process waste products and/or raw materials in order to obtain useful constituent components of the waste products and/or raw materials.

It is another object of the present invention to provide methods, apparatuses and systems that are configured to process waste products and/or raw materials in order to reduce the amount of waste products and raw material byproducts that need to be stored in waste disposal areas.

It is still another object of the present invention to provide methods, apparatuses and systems that are configured to process waste products and/or raw materials and use at least a portion of the constituent components obtained from the waste products and/or raw materials as inputs to drive the methods, apparatus and systems.

It is yet another object of the present invention to provide methods, apparatuses and systems that are configured to process waste products and/or raw materials in order to obtain a variety of useful constituent components of the waste products and/or raw materials that can be reused and/or recycled for a variety of different commercial and/or industrial applications.

It has now been found that the foregoing and related objects can be readily attained in an exemplary process that includes obtaining a waste product and/or raw material, processing, such as by grinding the waste product and/or raw material into a uniform size, conditioning the ground waste product and/or raw material to obtain a consistent moisture content throughout the ground waste product and/or raw material, and adding the ground waste product and/or raw material to an anaerobic reactor. The exemplary process may also include adding a hydrogen donor material to the anaerobic reactor in addition to the waste product and/or raw material. The exemplary process may further include heating the waste product and/or raw material in the anaerobic reactor to a temperature of 1,100° F. or greater in the absence of oxygen, continuing to heat the waste product and/or raw material within the reactor to produce a hydrocarbon gas mixture of cracked and gasified hydrocarbon, and removing these hydrocarbon gases from the reactor.

The exemplary process may also include condensing C6and greater hydrocarbons from the removed hydrocarbon gases, and capturing non-condensable removed hydrocarbon gases to be used as fuel for a heat source of the reactor. The process may further include removing a solid residue produced from the processed waste product and/or raw material from the reactor, and separating the solid residue by particle size. The exemplary process may also include further heating the solid residue or portions thereof to at least 1,500-2,000° F. in the absence of oxygen, and/or include heating the solid residue or portions thereof in the presence of oxygen at a temperature of 1,100° F. or greater.

The present invention may be further directed to processing feedstock materials for recovery, recycling and/or reuse of the constituent components of the feedstock materials, and includes adding feedstock materials at a constant temperature to a thermal reactor, heating the feedstock materials at a temperature of 1,100° F. or higher in an anaerobic environment within the thermal reactor to produce cracked and gasified hydrocarbons and residual material, removing cracked and gasified hydrocarbons released from the feedstock materials from the thermal reactor, further processing the residual material to recover one or more constituent component of the feedstock materials, and oxidizing the cracked and gasified hydrocarbons removed from the thermal reactor having five or less carbon atoms in their molecular structure in order to produce heat to obtain the temperature of 1,100° F. or higher for the thermal reactor.

The present invention may also be directed to a reactor configured to process feedstock materials for recovery, recycling and/or reuse of the constituent components of the feedstock materials and the reactor may include a feeding mechanism configured to the feed feedstock materials at a constant temperature to the reactor, a rotating drum configured for heating the feedstock materials at a temperature of 1,100° F. or higher in an anaerobic environment to produce cracked and gasified hydrocarbons and residual material, a condensing system configured to receive cracked and gasified hydrocarbons released from the feedstock materials from the thermal reactor, a discharge system configured to remove the residual material from the rotating drum without introducing oxygen into the rotating drum in order to recover one or more constituent component of the feedstock materials, and a combustion chamber configured for oxidizing the cracked and gasified hydrocarbons removed from the rotating drum having five or less carbon atoms in their molecular structure in order to produce heat to obtain the temperature of 1,100° F. or higher for the rotating drum.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter with reference to the accompanying figures, in which exemplary embodiments of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like reference numerals refer to like elements throughout.

Referring now toFIGS. 2-8, therein illustrated is an exemplary reactor, generally indicated by reference numeral100, according to the present invention. The reactor100generally includes a feeding mechanism, generally indicated by reference numeral110, that is configured to feed a waste product, for example asphalt roofing shingles, and/or a raw material, for example Canadian tar sands, for processing into the reactor100, which waste product(s) and/or raw material(s) are hereinafter generally referred to as feedstock materials. The reactor100also generally includes a combustion chamber121operatively connected to the feeding mechanism110and surrounding a rotating drum123, as shown for example inFIG. 5. It is understood that the configuration of the combustion chamber121and the rotating drum123may generally have the form of a calciner, and that the reactor100may be configured to apply heat from the combustion chamber121to the feedstock materials in the rotating drum123in order to process the feedstock materials in accordance with exemplary embodiments of the present invention. The reactor100further includes a condensing system125operatively coupled to the rotating drum123, and configured to collect and/or condense gas and other volatiles emitted from the feedstock materials fed into the rotating drum123. The reactor100further may include a discharge system127operatively coupled to the rotating drum123and configured to discharge the solid and/or residual components of the feedstock materials, and preferably discharge the solid and/or residual components of the feedstock materials without introducing oxygen into rotating drum123and/or reactor100.

Referring now toFIGS. 2-6, 8, 8A, 9 and 9A, the feeding mechanism110of the reactor will now be discussed in greater detail. The feeding mechanism110is configured to introduce the feedstock materials into the reactor100, and more particularly into the rotating drum123, so that the feedstock materials can be processed in accordance with the exemplary methods of the present invention, discussed further below. The feedstock materials may be stored and/or introduced to the feeding mechanism110by a hopper130, which is configured to hold the feedstock materials so that the feedstock materials can be introduced into the reactor100by a feed screw132operatively coupled to the hopper130. The feed screw132can have any suitable feed screw design as known by those of ordinary skill in the art, and the particular design of the feed screw132may be dependent upon the type of feedstock material that is desired to be introduced into the reactor100. Regardless of the type of feed screw132used for any particular application of the feeding mechanism110, it is understood by those of skill in the relevant art that the feed screw132operates by rotation around its longitudinal axis, and such rotation may be imparted to the feed screw132by any suitable drive mechanism134. The drive mechanism134may be comprised of a motor and gearbox assembly and be variable frequency drive controlled. The feedstock materials input into the hopper130may be gravity fed into the feed screw132, and the rotation of the feed screw132moves the feedstock materials along the longitudinal axis of the feed screw132into the rotating drum123. Proper precautions should be taken in order to prevent influx of atmospheric air and/or oxygen into the rotating drum123through the feeding mechanism110, for example by keeping the hopper130full of feedstock materials and/or providing a nitrogen purge into the hopper130to prevent introduction of atmospheric air into the rotating drum123.FIGS. 8 and 8Ashow how exemplary feedstock material18may be inserted and/or transported by the feed screw132into the rotating drum123. It is understood that the identification of the feedstock material18is merely exemplary, and that there may be additional feedstock material18within the rotating drum123that is not illustrated for purposes of clarity.

Still referring toFIGS. 2-6, 8, 8A, 9 and 9A, in order to facilitate introduction of the feedstock materials into the rotating drum123and/or introduce the feedstock materials into the rotating drum123at desired appropriate temperatures, the feeding mechanism110may also include a cooling system operatively coupled to the feed screw132in order to maintain the feed screw132and/or the feedstock materials at desired and/or constant temperatures. The cooling system includes a fluid reservoir136that contains an amount of a fluid coolant, for example water or other suitable liquid used in cooling systems, and the fluid reservoir136supplies the cooling system with the coolant. The fluid reservoir136is connected to a cool fluid effluent pipe138that is connected to a coolant jacket140that at least substantially surrounds the feed screw132. The coolant jacket140may preferably extend the entire length of the feed screw132and extend into the rotating drum123, and the portion of the coolant jacket140that extends into the rotating drum123may be covered by at least one insulation layer141, which may then be covered by a suitable non-combustible housing, such as a steel pipe. The insulation layer141acts to aid in keeping the feedstock material at the desired and/or constant temperature before being introduced into the rotating drum123. The insulation layer141also acts to prevent the coolant within the coolant jacket140from becoming heated by the combustion chamber121, thereby defeating the purpose of the coolant. The insulation layer141further acts to reduce and/or eliminate condensation of gases produced from the feedstock materials on the coolant jacket140, which greatly reduces the efficiently of the reactor100. It is understood that being able to maintain the feedstock material at the desired and/or constant temperature helps to ensure that the feedstock material has a constant consistency along the entire length of the feed screw132. The coolant jacket140includes an influent portion142that receives the coolant from the cool fluid effluent pipe138and an effluent portion144that allows the coolant to be pumped along the length of the feed screw132and absorbed heat from the feed screw132and/or feedstock materials to exit the coolant jacket140in order to return to the fluid reservoir136. The effluent portion144of the coolant jacket140is connected to a hot fluid return pipe146that provides the warmed coolant from the coolant jacket140to a radiator148configured to remove heat from the warmed coolant prior to the coolant returning to the fluid reservoir136by a cool fluid influent pipe150connecting the radiator148and the fluid reservoir136. The radiator148is configured to remove heat from the coolant prior to the coolant being transferred to the fluid reservoir136so that the coolant in the fluid reservoir136is maintained at appropriate temperatures. The radiator148may be any suitable heat transfer mechanism, and may be entirely air-cooled or may have supplement cooling systems including its own condenser, compressor and/or fan.

Still referring toFIGS. 2-6, 8, 8A, 9 and 9A, in addition to the coolant jacket140providing cooling around the feed screw132, the cooling system of the feeding mechanism110may further include the introduction of the coolant to an interior of the feed screw132. In order to effect cooling of the interior of the feed screw132in addition to the exterior, a cool fluid diverter line152may be connected to the cool fluid effluent pipe138in order to divert at least some of the coolant to a center inflow cooling pipe154running through the center of the feed screw132. The coolant runs the length of the center inflow cooling pipe154and then returns back along the length of the feed screw132by a center outflow cooling pipe156, which is ultimately connected to the hot fluid return pipe146by a return line158from the center shaft of the feed screw132. A two-pass swivel union assembly159may be used to connect the cool fluid diverter line152to the center inflow cooling pipe154, and the return line158to the center outflow cooling pipe156. The feeding mechanism110may be mounted to the rotating drum123assembly on the reactor100by a mounting plate160in order to secure the feeding mechanism110relative to the rotating drum123assembly. It is understood that the mounting plate160is positioned at a suitable location in order to allow the rotating drum123to operate without imparting rotational motion and/or force on the feeding mechanism110.

Referring now toFIGS. 2-8, 8A, 9 and 9A, the construction and operation of the combustion chamber121and the rotating drum123of the reactor100will now be discussed. It is understood that the combustion chamber121in combination with the rotating drum123may generally be in the form of a calciner to provide for indirect heated processing of the feedstock materials. The combustion chamber121may be any suitable furnace that generally includes a heat source, for example one or more fuel gas burners162, which may be for example natural gas burners, and one or more combustion and/or exhaust gas exits, for example a front exhaust stack164and a rear exhaust stack166. The front exhaust stack164and the rear exhaust stack166may be joined at an exhaust vent167that vents to the atmosphere or other suitable location. An exhaust blower169may be included on the exhaust vent167in order to facilitate the removal of exhaust gases and/or fumes from the combustion chamber121. However, it is understood that the front exhaust stack164and the rear exhaust stack166may be independently vented to the atmosphere without first being joined together. A front exhaust collector168may be positioned at the front of the combustion chamber121in order to facilitate collection and direction of the combustion and/or exhaust gases to the front exhaust stack164, and likewise, a rear exhaust collector170may be positioned at the rear of the combustion chamber121in order to facilitate collection and direction of the combustion and/or exhaust gases to the rear exhaust stack166. The combustion chamber121through the use of the one or more fuel gas burners162is configured to produce heat in order to heat the rotating drum123, in essence as understood by one of ordinary skill in the art, the combustion chamber121provides a heated environment in which the rotating drum123can be utilized.

Still referring toFIGS. 2-8, 8A, 9 and 9A, the rotating drum123is configured to rotate about its longitudinal axis and rotate independently of the combustion chamber121in which the rotating drum123is contained. The rotating drum123may be positioned at an angle relative to the combustion chamber121and/or a surface on which the combustion chamber121is installed.

For example, the rotating drum123may be positioned 0 to 5° relative to a line perpendicular to the combustion chamber121and/or a surface on which the combustion chamber121is installed, and even more preferably be positioned between 1 and 2° . The rotating drum123may have any suitable drive mechanism, for example a drive motor171having a chain drive172and sprocket assembly173. However, it is understood that any suitable drive mechanism capable of imparting rotation to the rotating drum123can be used for the present invention, and that the present invention is not limited to any particular type of drive mechanism for the rotating drum123. In order to allow the rotating drum123to rotate independently of the combustion chamber121and the other components of the reactor100, the rotating drum123is supported by a front bearing assembly175and a rear bearing assembly177. It is understood that appropriate mechanisms and/or tolerances, as known by those of ordinary skill in the art, may be incorporated with the rotating drum123in order to account for any thermal expansion of the rotating drum123as the result of heating the rotating drum123within the combustion chamber121. Such mechanisms and/or tolerances should be designed to allow the rotating drum123to continue to operate independently of the combustion chamber121, even after heating of the rotating drum123and also provide for air tight seals to prevent influx and/or escape of gases into and out of the rotating drum123. Appropriate insulation178may be installed around the front bearing assembly175and the rear bearing assembly177, and any portion of the rotating drum123that extends out of the combustion chamber121may also be covered with insulation178in order to moderate the temperature of the rotating drum123. The rotating drum123is operatively connected to the condensing system125at one end by exit piping180, and at a second end to the discharge system127. It is understood that it is preferable that the end of the rotating drum123connected to the condensing system125should be positioned at least a few degrees higher than the end of the rotating drum123connected to the discharge system127. This configuration allows the gases and other volatiles from the feedstock materials to be transported to the condensing system125, while the solid and/or residual components of the feedstock materials are transported to the discharge system127. As shown for example inFIG. 9, the rotating drum123may also include a star bar182positioned therein, and configured to roll around at the bottom of the rotating drum123in order to deagglomerate the feedstock materials. It is understood that the exit piping180is not affixed to the rotating drum123so that the rotating drum123is free to rotate relative to the exit piping180, but that suitable leak-tight and/or air-tight connections are made between the rotating drum123and the exit piping180to eliminate influx and escape of gases and other volatiles.

Referring now toFIGS. 2-7, the condensing system125of the reactor100will now be discussed. As mentioned above, the condensing system125is coupled to the rotating drum123by the exit piping180so that gases and other volatiles from the feedstock materials is permitted to escape the rotating drum123and be transported into the condensing system125. The condensing system125may have any suitable mechanisms known in the art to condense, collect and/or separate gases and/or volatiles into separate components, i.e. a gaseous and/or volatile mixture exiting the rotating drum123can be separated into its individual and/or related components. The condensing system125may include a “heavy ends” condensed oil collection pipe184positioned a suitable distance away from the rotating drum123to allow for collection of “heavy ends” oil in a “heavy ends” oil collection tank186. It is understood that the “heavy ends” oil may be condensed by increase in pressure and/or decrease in temperature as the result of ambient air cooling or additional cooling mechanisms, such as a fluid coolant system. Next the exit piping180may extend into a condensing system pipe188, which is connected to a “middle weight” condensed oil collection tank190. It is understood that the “middle weight” oil may be condensed by increase in pressure and/or decrease in temperature as the result of ambient air cooling or additional cooling mechanisms, such as a fluid coolant system. Further condenser piping192extends between the “middle weight” condensed oil collection tank190and a “light end” condensed oil collection tank194. The “light end” condensed oil collection tank194is further connected to a rotary screw gas compressor and regulator196that is configured to pressurize combustible non-condensable gas and other volatiles from the rotating drum123for feeding the one or more fuel burners162in order to provide heat to the combustion chamber121. It is understood that the reactor100may be configured to provide fuel for the fuel burners162entirely from the gases and/or volatiles produced from the feedstock materials or that the fuel burners162may be supplemented by additional fuel products, for example natural gas and/or propane. Any combustible or non-combustible gas that is not used by the fuel burners162may be cleaned, consumed, or otherwise properly processed prior to release to the atmosphere or other appropriate location by vent connector piping197extending past the last fuel burner162.

Referring now toFIGS. 4-8, the discharge system127of the reactor100according to the present invention will now be discussed. The discharge system127includes an airlock assembly198that is connected to the rotating drum123by at least a substantially air-tight connection so that the rotating drum123is free to rotate, but that no influx or egress of air or other gases is allowed in or out of the rotating drum123and the discharge system127. The airlock assembly198is configured to collect and/or retain solid and/or residual components of the feedstock materials after the feedstock materials have been heated in the rotating drum123. The airlock assembly198may include an airlock lid199that permits access to the airlock assembly198during maintenance and/or inspection of the discharge system127. The airlock assembly198is connected to an airlock201that is configured to allow discharge of the solid and/or residual components of the feedstock materials from the airlock assembly198for collection without allowing the influx of oxygen or other gases into the reactor100when the components are removed from the airlock assembly198.

Referring now toFIG. 1, an exemplary method according to the present invention is shown for the processing of feedstock materials in order to recover, reuse and/or recycle the constituent components of the waste products and/or raw materials. The exemplary feed stock material that may be processed according to the present invention could be asphalt roofing shingles, and the method of processing the asphalt roofing shingles according to the present invention is discussed specifically with respect toFIG. 1, with general references made toFIGS. 2-8, 8A, 9, 9A and 10as to how the exemplary reactor100according to the present invention can be used to implement the method outlined inFIG. 1. As shown in step S10a feedstock material, such as asphalt roofing shingles are obtained. The asphalt roofing shingles may be obtained from sources such as, waste from manufacturers of asphalt roofing shingles or asphalt roofing shingles that have been removed from structures after installation of the asphalt roofing shingles. In general, asphalt roofing shingles are comprised of approximately 20-30% bitumen, approximately 1-5% glass and/or natural fibers and approximately 70-80% minerals with mesh sizes between 320 and 10. Of the minerals, approximately two-thirds to one-half are silicon based minerals with a mesh size between 80 and 10, and approximately one-half to one-third are calcium based minerals with a mesh size 80 or higher. The intention of exemplary embodiments of the present invention is to process feedstock materials, such as the asphalt roofing shingles, in order to recover, reuse and/or recycle at least a useable portion of the components, such as the exemplary components discussed above with respect to the asphalt roofing shingles, of the feedstock materials.

Still referring toFIG. 1, the method for processing feedstock materials, such as asphalt roofing shingles, may also include a step S20in which the asphalt roofing shingles are ground with a suitable grinding apparatus into pieces with sizes of one inch or less. However, it is understood that the present invention is not limited to grinding the asphalt roofing shingles to any particular piece size, as sizes larger than one inch may also be compatible with asphalt roofing shingles and other feedstock materials according to the present invention. It is understood that water may already be present in the asphalt roofing shingles when obtained in step S10, or additional water may be added in order to facilitate the grinding step S20. The method may also include a step S30of conditioning the ground asphalt roofing shingles, for example by allowing the ground asphalt roofing shingles to drain freely, drying either through application of heat, reduction of vapor pressure or conditioning at ambient temperatures, in order to obtain a consistent moisture content throughout the ground asphalt roofing shingles. Preferably, the moisture content of the ground shingles may be approximately 2% water by weight.

Once the moisture content of the ground asphalt roofing shingles has reached a consistent level the ground asphalt roofing shingles may be fed into the reactor100discussed above with respect toFIGS. 2-8. Preferably, the reactor100is configured as an anaerobic reactor capable of processing the asphalt roofing shingles in the absence of oxygen. Any suitable feeding mechanism may be used in order to feed the ground asphalt roofing shingles into the reactor100, including the feeding mechanism110discussed above with respect toFIGS. 2-8. Preferably the feeding mechanism should be capable of keeping oxygen out of the reactor and be insulated and/or non-thermally conducting so that the heat from the reactor is not transferred to the feeding mechanism, such as is accomplished with the feed screw132and coolant jacket140of the feeding mechanism110discussed above. As an alternative, a ram feed system (not shown) may be used that is insulated from the reactor100. Even more preferably the feed screw132of the feeding mechanism110should be kept at a temperature, either though the insulation141and/or the coolant jacket140, that is outside the range of 100-800° F. However, it is understood that the present invention is not limited to any particular temperature or temperature range for the feeding mechanism110, and the temperature and/or operation of the feeding mechanism110may be correlated to the feedstock material being fed into the reactor100. Furthermore, as shown in FIG.1, the method of the present invention may also include an optional step S35of adding a hydrogen donor material, for example, waste polymer, ground coal, charcoal and/or pyrolized wood, or other plastics and rubbers, such as plastics containing glass fill, to the reactor100in addition to the asphalt roofing shingles. This donor material, may be fed into the reactor100in the same manner as the other feedstock material, and either mixed, either before or after being put into the hopper130, with the feedstock material or added separately from the feedstock material.

While the exemplary reactor100discussed above with respect toFIGS. 2-8may be used in accordance with the process of the present invention,FIG. 10shows a simplified version of a reactor that includes a rotating drum123that may be used for the exemplary method of processing asphalt roofing shingles shown inFIG. 1. In general, the reactor should be capable of providing high heat, for example approximately 1,100° F. or greater, in the absence of oxygen in order to thermally decompose the organic material in the asphalt roofing shingles, or other organic waste product or raw material, and also be capable of mixing and/or agitating the asphalt roofing shingles. Other exemplary reactors that may be used with the present invention include fluidized beds and other reactors with mechanical mixing means. As shown inFIG. 10, and as previously discussed, the rotating drum123may be positioned at an incline in order to direct the processed asphalt roofing shingles from one end of the reactor to the other. In addition, as shown inFIG. 10, heat is applied to the rotating drum in order to pyrolyze the asphalt roofing shingling that have been fed into the rotating drum.

Referring again toFIG. 1, the exemplary method according to the present invention may also include a step S40of heating the asphalt roofing shingles in the reactor100to a temperature of 1,100° F. or greater in the absence of oxygen. It may also be preferable to set up a temperature gradient in the reactor100so that the temperature increases from the feed side of the rotating drum123to the exit side of the rotating drum123. This can be accomplished through use of multiple fuel burners162, and modifying the heat output of each fuel burner162to create a temperature gradient along the combustion chamber121of the reactor100. However, it is understood that the temperature gradient may also increase and decrease along the length of the reactor100, and may increase or decrease a number of times along the length of the reactor100. As a result of the application of heat in step S40the constituent components of the asphalt roofing shingles begin to separate. The bitumen component of the asphalt roofing shingles liquefies and cracks to produce non-condensable hydrocarbon gases and medium length (C6or more) hydrocarbon liquids and oils. Continued heating of these hydrocarbon products within the reactor produces a hydrocarbon gas mixture of cracked and gasified hydrocarbon, and in step S50these hydrocarbons are removed from the rotating drum123of the reactor100. For example, these hydrocarbons may be released out of the exit piping180of the rotating drum123. The flow of the hydrocarbon gas mixture may be aided by the flow of the inert gas, for example nitrogen, that is provided into the rotating drum123at the other end of the rotating drum123from the exiting piping180for the hydrocarbon gas mixture. The glass fibers and mineral components of the asphalt roofing shingles then remain in the rotating drum123as a solid residue.

Referring again toFIG. 1, the hydrocarbon gas mixture released from the reactor is provided to the condensing system125in step S60in order to condense C6and greater hydrocarbons to produce products such as crude oil or light gas oil in step S62. C6and greater hydrocarbons are hydrocarbons that contain at least six carbon atoms in their molecular structure. These hydrocarbons may be condensed in a single condensing unit or they may be condensed and separated further based on whether the hydrocarbons are considered to be “high,” “medium” or “light” hydrocarbons. The C1-C5non-condensable gas hydrocarbons that are not condensed in the condensing system125are captured in step S64by the rotary screw gas compressor196and may be redirected to be used as fuel for the fuel burners162in step S66as the heat source used for the reactor100. It is also contemplated that the non-condensable gas hydrocarbons may also be used as a fuel source for other systems, such as a building heating system, and any unused non-condensable gas hydrocarbons may be cleaned, consumed, or otherwise properly processed prior to release to the atmosphere or other appropriate location. Accordingly, the vent connector piping197may connect to a vent (not shown) that directs the non-condensable gases to be cleaned, consumed, or otherwise properly processed prior to release to the atmosphere or other appropriate location.

Still referring toFIG. 1, the processed aggregate that includes the solid residue of the asphalt roofing shingles may be removed from the reactor100in step S70for further processing. This processed aggregate includes the glass fibers and mineral components, as well as a carbon residue that includes coke and/or petroleum coke that may be coated on the mineral components. The processed aggregate or a portion thereof may then be separated into small and large particles in a step S72in order to provide small particles with coke in step S73and large particles with coke in step S74. Alternatively, the processed aggregate or a portion thereof may be heated to at least 1,500-2,000° F. in the absence of oxygen in step S75in order to release oxygen from the minerals to oxidize the coke and/or petroleum coke residue on the minerals in order to provide a clean aggregate mix in step S78. It is understood that this step S75may occur in the reactor100prior to the solid residue of the asphalt roofing shingles being removed from the reactor100. Alternatively, the processed aggregate or a portion thereof may be heated in step S80in the presence of oxygen at a temperature of 1,100° F. or greater in order to combust the coke and/or petroleum coke residue that may be present on the minerals to provide a clean aggregate mix in step S78. The heat generated from the combustion of the coke and/or petroleum coke may be recycled for use in the process or used for other systems, such as a building heating system.

Still referring toFIG. 1, the small particles including coke, such as calcium based minerals, e.g. CaCO3, from step S73may be used as a processing additive in other industrial processes. The large particles with coke from step S74may be processed in step S82that is similar to step S80in order to combust the coke and/or petroleum coke residue on the large particles to produce a cleaned aggregate mix. The clean aggregate mix from step S78and the cleaned aggregate mix produced from step S82may then be separated into individual components though classification and sieving in step S84. Step S84may then produce glass fibers, coarse minerals, medium minerals and fine minerals. These materials may then be reused and/or recycled to produce new products, such as being used to produce new asphalt roofing shingles.

It is to be understood that all of the present figures, and the accompanying narrative discussions of corresponding embodiments, do not purport to be completely rigorous treatments of the invention under consideration. It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the scope of the present invention.