Distillation unit for carbon-based feedstock processing system

An apparatus for distillation of feedstock. Including a distillation chamber with an inlet for receiving feedstock and an outlet for discharging feedstock, and a plate for supporting the feedstock in the distillation chamber. The plate is positioned parallel to a substantially horizontal plane across a portion of the distillation chamber, and defines a plurality of transverse apertures extending transversely across a substantial portion of the width of the plate. A plurality of heating rods is included for insertion into the apertures of the plate to heat the plate. The apparatus also includes a conveyor enclosed within the distillation chamber and extending longitudinally across the distillation chamber, the conveyor having a plurality of paddles attached thereto that, when driven by the conveyor, move proximate and parallel to the plate to agitate feedstock on the plate, and to drive the feedstock from the inlet to the outlet of the distillation chamber.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to processing carbon-based feedstock, and in particular to a distillation chamber for use in a distillation process.

2. Description of the Related Art

Coal is an abundant natural resource capable of exploitation to produce large amounts of energy. Coal in its raw form, however, usually contains undesirable compositions in the form of a number of other chemical compositions or elements. One problem faced in the coal industry is that traditional means of extracting energy from coal have been the subject of concerns, due to possible adverse environmental consequences because of the undesirable compositions usually present in raw coal. For example, historically coal has been burned to create heat, such as to turn water into steam to power a turbine and generate electricity. This process generates large amounts of gaseous emissions containing small amounts of the undesirable compositions which harm the environment. As a result, the use of coal as an energy source can cause tension between the need for an economic way to produce energy on the one hand, and environmental concerns on the other.

During a typical coal processing operation, coal and other carbon-based products are often subjected to distillation processes in order to extract various products therefrom. A typical distillation process involves heating a coal feedstock in the absence of oxygen, as the feedstock is moved through a distillation chamber, leading to the creation of different products. In typical distillation processes, many of these products are emitted into the atmosphere and can harm the environment. While some efforts have been made to clean gases prior to their release into the environment, known processes for doing so are inefficient and expensive.

In addition to the above, a distillation process is most effective when the feedstock can be evenly heated, and constantly agitated throughout the process. Accordingly, one shortcoming of many known distillation units is an inability to effectively heat the feedstock, and to agitate the feedstock sufficiently so that the entire mass of the feedstock can be properly heated in an even way.

SUMMARY OF THE INVENTION

Briefly, the present invention provides an apparatus for distillation of feedstock, the apparatus including a substantially enclosed distillation chamber with an inlet for receiving feedstock and an outlet for discharging feedstock, and a plate enclosed within the distillation chamber for supporting the feedstock in the distillation chamber, the plate positioned parallel to a substantially horizontal plane across a portion of the distillation chamber, the plate defining a plurality of transverse apertures extending transversely across a substantial portion of the width of the plate. The apparatus also includes a plurality of heating rods for insertion into the apertures of the plate to heat the plate, and a conveyor enclosed within the distillation chamber and extending longitudinally across the distillation chamber, the conveyor having a plurality of paddles attached thereto that, when driven by the conveyor, move proximate and parallel to the plate to agitate feedstock on the plate, and to drive the feedstock from the inlet to the outlet of the distillation chamber.

In some embodiments, the paddles can be arranged in transverse rows, each row containing three or more paddles separated from one another a predetermined distance so that feedstock can pass between the paddles as the paddles move relative to the plate. In addition, the transverse position of the paddles in adjacent rows can vary so that the feedstock is constantly agitated as the rows of paddles move relative to the plate. Furthermore, each paddle can have a substantially V-shaped cross-section, with a leading edge and two sides that angle outwardly from the leading edge toward the sides of the distillation chamber, and behind the leading edge in a direction opposite the movement of the paddles, so that as the paddles move through the feedstock they separate and move the feedstock in a forward and lateral direction. In certain embodiments, each paddle can be positioned adjacent the plate so that it is agitating the feedstock, and each paddle can be positioned at a negative acute angle relative to the conveyor so that as the paddles move through the feedstock, the feedstock is driven upwardly over the top of the paddles.

In some example embodiments, the cross-sectional shape of the distillation chamber can include a substantially horizontal bottom, two substantially vertical sidewalls, and a top having pitched sides meeting at a curved peak so that as gasses are produced by the distillation process the shape of the chamber will encourage mixing of the gasses in the top thereof.

Another embodiment of the present invention provides an apparatus for distillation of feedstock that includes a substantially enclosed distillation chamber with an inlet for receiving feedstock and an outlet for discharging feedstock, and a plate enclosed within the distillation chamber for supporting the feedstock in the distillation chamber; the plate positioned parallel to a substantially horizontal plane across a portion of the distillation chamber. In addition, the apparatus includes a conveyor enclosed within the distillation chamber and extending longitudinally across the length of the distillation chamber, the conveyor having a plurality of paddles attached thereto that, when driven by the conveyor, move proximate and parallel to the plate to agitate feedstock on the plate, and to drive the feedstock from the inlet to the outlet of the distillation chamber. The paddles are arranged in transverse rows, each row containing three or more paddles separated, from one another a predetermined distance so that feedstock can pass between the paddles as the paddles move relative to the plate, and the transverse position of the paddles in adjacent rows varies so that the feedstock is constantly agitated as the rows of paddles move relative to the plate.

In some alternate embodiments, each paddle can have a substantially V-shaped cross-section, with a leading edge and two sides that angle outwardly from the leading edge toward the sides of the distillation chamber, and behind the leading edge in a direction opposite the movement of the paddles, so that as the paddles move through the feedstock, they separate and move the feedstock in a forward and lateral direction. In addition, each paddle can be positioned adjacent the plate so that it is agitating the feedstock, and each paddle can be positioned at a negative acute angle relative to the conveyor so that as the paddles move through the feedstock, the feedstock is driven upward over the top of the paddles.

In additional embodiments, the plate can define a plurality of transverse apertures extending transversely across a substantial portion of the width of the plate, and a plurality of heating rods for insertion into the apertures of the plate to heat the plate. In addition, the cross-sectional shape of the distillation chamber can include a substantially horizontal bottom, two substantially vertical sidewalls, and a top having pitched sides meeting at a curved peak, so that as gasses are produced by the distillation process the shape of the chamber will encourage mixing of the gasses in the top thereof.

Yet another embodiment of the present invention provides a method of processing feedstock in a distillation device. The method includes the steps of introducing feedstock into a distillation chamber so that the feedstock rests on a substantially horizontal plate in the distillation chamber, inserting rods into apertures in the plate, heating the rods, so feat the rods transfer heat to the plate, which in turn transfers heat to the feedstock. The method further includes agitating the feedstock by driving paddles through the feedstock to move the feedstock laterally, as well as forward and vertically upward, and discharging the feedstock from the distillation chamber.

In some embodiments, the method can further include arranging the paddles in rows, the lateral position of the paddles of each row varied from that of the paddles in an adjacent row, to increase the lateral and forward movement of the feedstock as the feedstock is agitated. Other steps that may be part of the method include orienting the paddles so that as they pass through the feedstock, they move the feedstock vertically upward so that the feedstock is constantly circulated from a position adjacent the plate to a position removed from the plate, mixing gases within the distillation chamber prior to venting the gases from the chamber, and electrically heating the rods.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

InFIG. 1, there is depicted a distillation unit10according to an embodiment of the present invention. The purpose of the distillation unit is to provide a chamber wherein coal, biomass, or other carbon-based feedstock is subjected to a distillation process. According to such a process, the feedstock is heated in the absence of oxygen as the feedstock is moved through the distillation chamber13, leading to cracking of the feedstock, and the production of useful products.

The distillation unit10depicted inFIG. 1includes a housing12enclosing a distillation chamber13(shown inFIG. 2), the housing12having an inlet14for receiving feedstock118(shown inFIG. 17), and an outlet16for discharging feedstock118. The distillation unit10further includes, within the distillation chamber13, a plate18to support the feedstock118within the distillation chamber13, an insulation grid assembly19with a plate mounting block21(shown inFIG. 9), and a conveyor20with paddles22to assist in moving the feedstock118along a surface of the plate18from the inlet14end of the distillation chamber13to the outlet16end of the distillation chamber13.

Referring toFIG. 2, there is shown a perspective view of the housing12surrounding and enclosing the distillation chamber13. The inlet14end of the housing can include an inlet chute24, configured for attachment to an infeed hopper or meter associated with an infeed hopper (not shown). In one embodiment, the infeed hopper and/meter may be positioned above the inlet chute24so that feedstock118can be gravity fed into the distillation chamber13within the housing12.

Along a majority of the length of the housing12, the upper portion26of the housing12can be domed or peaked. Such a domed or peaked shape induces the mixing of gases produced by the distillation process as the feedstock118moves along the lower portion of the distillation chamber13, which mixing can lead to the formation of beneficial products. The sides of the housing12can also include one or more manways28, designed to provide access to the interior of the housing12by an operator. Such access may be necessary to perform tasks such as maintenance or replacement of the equipment within the distillation chamber13, removal or manual agitation of feedstock118, etc. Although manways28are shown in the drawings, it is to be understood that any appropriate access port or opening can be provided.

In addition, access panels30can be provided along the length of the housing12to allow access to the plates18within the distillation chamber13, and in particular to heating rods within the plates, as described in detail below. A jackshaft assembly32can also be provided on the housing12coupled to a gear34(shown inFIGS. 1, 12A, and 12B) inside the distillation chamber13. The gear is configured to turn the conveyor20within the distillation chamber13. Furthermore, the outlet16(shown inFIG. 1) of the housing12may include a flanged chute36capable of carrying the feedstock118out of the distillation chamber13and into separate equipment, such as a cooler or condensing unit.

FIGS. 3A and 3Bdepict front and rear views of the housing12, respectively. The front end of the housing12has a front wall37fastened to the sides of the housing12and preferably sealed, so that oxygen, does not enter the distillation chamber13within the housing12. A man way28or other opening like those on the sides of the housing12may be provided in the front wall37to provide access to the distillation chamber13through the front wall37. Similarly, the rear end of the housing has a rear wall39fastened to the sides of the housing12and preferably sealed so that oxygen does not enter the distillation chamber13within the housing12. A manway28or other opening like those on the sides of the housing12and the front wall37may be provided in the rear wall39to provide access to the distillation chamber13through the tear wall39.

FIG. 4is a top view of the plate18used to support the feedstock118within the distillation chamber13. In some embodiments, the plate may be divided into multiple plate sections18a,18b,18c,18d. For example, in the embodiment ofFIG. 4, the plate18is divided into first plate section18a, second plate section18b, third plate section18c, and fourth plate section18d. When fully installed in the housing12, the plate18extends the majority of the length of the housing12. Also shown inFIG. 4are transverse heating apertures38and thermocouples40. The heating apertures38are configured to accept elongate heating rods41that heat the plates, which in turn heat the feedstock118. The thermocouples40may be provided to measure the temperature of the plate18so the temperature can be maintained within predetermined ranges.

First plate section18a, as best shown inFIGS. 5A and 5B, is designed for placement at the inlet end of the distillation chamber13. Thus, as feedstock118is fed into the distillation chamber13, it drops through, the inlet chute24(shown inFIG. 2), and lands on first plate section18a. As the feedstock118is driven along first plate section18a, as discussed in detail below, the surface of the first plate section18ais heated by the heating rods41in the transverse heating apertures38. The feedstock118may first contact the first plate section18aadjacent a first end42thereof, and from there it will be driven towards a second end44of the first plate section18a, The second end44of the first plate section18amay have a lip46, as shown inFIG. 5B, with apertures48for receiving fasteners (not shown). The lip46corresponds to a corresponding lip50(shown inFIG. 6C) of the second plate section18b, and the fasteners may pass through the lips46,50of both sections in order to fixedly attach the plate sections to one another. In FIG.5B, the apertures48are shown to be threaded, and are configured to accept threaded bolts. In practice, however, the apertures48may be unthreaded, and any appropriate type of fastener may be used. In addition, the apertures44are shown inFIGS. 5A and 5Bto be staggered across the width of the first plate section18a. Such a staggered pattern is advantageous because it helps to reduce stresses in the fasteners and plates. Such a staggered pattern, however, is not necessary, and any appropriate configuration of apertures44can be used.

Second plate section18bis shown inFIGS. 6A-6C, and includes first end52and second end54. Each of first end52and second end54of the second plate section18bcontain apertures56,58for fasteners that can attach the second plate section18bto adjacent plate sections. Apertures56pass through the lip50of the first end52which, as discussed above, corresponds and aligns with the lip46of the first plate section18a, so that the first and second plate sections18a,18bcan be attached by fasteners passing through apertures48of the first plate section18aand apertures50of the second plate section18b.

The second end54of the second plate section18bhas a lip60similar to lip46of the first plate section18a. Apertures pass through lip60, and correspond to apertures68in lip62of the third plate section18c(shown inFIGS. 7A and 7B). Although apertures56,58are shown in a staggered configuration across the width of lips50,60, respectively, it is to be understood that the apertures56,58could be arranged in any appropriate configuration, including in a straight line. Furthermore, although apertures56are shown to be threaded, they could alternatively be unthreaded. In addition, similar to the other plate sections, the second plate section18bincludes transverse heating apertures38for accepting elongate heating rods41(shown inFIG. 4), and thermocouples40.

The third plate section18cis shown inFIGS. 7A-7C, and includes first end64and second end66, Each of first end64and second end66of the third plate section18ccontain apertures68,70for fasteners that can attach the third plate section18cto adjacent plate sections. Apertures68pass through the lip62of the first end64which corresponds and aligns with the lip60of the second plate section18b, so that the second and third plate sections18b,18ccan be attached by fasteners passing through apertures54of the second plate section18band corresponding apertures in the lip62of the third, plate section18c.

The second end66of the third plate section18chas a lip72similar to lip60of the second plate section18b. Apertures pass through, lip72and into lip74of the fourth plate section18d(shown, inFIGS. 8A and 8B). Although apertures68,70are shown in a staggered configuration across the width of lips62,72, respectively, it is to be understood that the apertures68,70could be arranged in my appropriate configuration, including in a straight line. In addition, similar to the other plate sections, the third plate section18cincludes transverse heating apertures38for accepting elongate healing rods41(shown inFIG. 4), and thermocouples40. The third plate section18cmay also include mounting apertures76. The mounting apertures76may be used to accept fasteners for attaching the plate18to other components m the distillation chamber13, such as, for example, the insulation grid19, described in detail below. Thus, the plate18may be anchored in the distillation chamber13so that it stays in one place relative to the housing12while the feedstock118passes over the plate18.

The fourth plate section18dis shown in detail inFIGS. 8A and 8B, and includes first end78and second end80. First end78of the fourth plate section18dcontain apertures82for fasteners that can attach the fourth plate section18dto the third plate section18c. Apertures82pass through the lip70of the second end66of the third plate section18c, which corresponds and aligns with the lip74of the fourth plate section18d, so that the third and fourth plate sections18c,18dcan be attached by fasteners passing through apertures70of the third plate section18cand the corresponding apertures82in the lip74of the fourth plate section18d.

The second end80of the fourth plate section18dterminates the plate18at the discharge end of the distillation chamber13in the housing12. When the feedstock118falls off the second end80of the fourth plate section18d, it then leaves the distillation chamber13via outlet chute36, Although apertures82are shown in a staggered configuration across the width of the lip74, it is to be understood that the apertures68,70could be arranged in any appropriate configuration, including in a straight line. In addition, similar to the other plate sections, the fourth plate section18dincludes transverse heating apertures38for accepting elongate heating rods41(shown inFIG. 4), and thermocouples40.

Referring toFIG. 9, there is shown the insulation grid assembly19with the plate mounting block21, according to an embodiment of the invention. The insulation grid assembly19is positioned in a bottom portion of the distillation chamber13, as shown inFIG. 1, and the plate mounting block21serves as an attachment point for the plate18. Apertures84in the plate mounting block21correspond to apertures76in the third plate section18c, Fasteners can be passed through apertures84of the plate mounting block21and apertures76of the third plate section18cto attach the third plate section18cto the plate mounting block21, thereby limiting or eliminating movement of the plate18relative to the plate mounting block21.

The insulation grid assembly19also includes voids86which, when the insulation grid assembly19and plate18are mounted in the distillation chamber13, separate the plate18from the bottom of the distillation chamber13. In some embodiments, the voids86may be filled with insulation.

InFIG. 10, there is shown a conveyor support88for supporting the conveyor20(shown inFIGS. 1, 13A, and 13B). The conveyor support88includes chain guides90on upper and lower sides thereof, for guiding the chains associated with the conveyor20. Between, the upper and lower chain guides90are transverse support members92, which provide rigidity to the conveyor20and support the weight of the portion of the conveyor20located above the conveyor support88.

The conveyor support88is positioned, between, and is a part of, the bulkhead assembly94shown inFIGS. 11A-11D. The bulkhead assembly94provides a rigid support structure for many of the components in the distillation chamber13, and includes sidewalls96and an outer frame structure with longitudinal supports98, for providing strength and rigidity to the sidewalls96in a longitudinal plane in the distillation chamber13, and outwardly extending side supports100that extend from the bulkhead sidewalls96to the sidewalls of the housing12.

The side supports100of the bulkhead assembly94help to fix the components in the distillation, chamber13during operation of the distillation unit10, including fixing the position of the conveyor support88. To accomplish this, the conveyor support88can be fixedly attached to the sidewalls96and/or longitudinal supports98of the bulkhead assembly94.

Referring toFIGS. 12A and 12B, there is shown a conveyor20according to an embodiment of the invention. The conveyor20includes conveyor chains102that rotate around gears34, and that span substantially the entire length of the distillation chamber13from the inlet14to the outlet16(see alsoFIG. 1). The conveyor chains102carry crossbars104with extension members106having paddles22attached thereto. Each crossbar104includes a plurality of extension members106and paddles22, For example, in the embodiment shown, five extension members106with paddles22are attached to each crossbar104, although it is to be understood that any appropriate number of extension members106and paddles22may be used. As indicated by the arrows A inFIG. 12B, the conveyor20moves the paddles22in a counterclockwise direction, so that, as shown inFIG. 1, the paddles22on the bottom of the conveyor20move from the inlet14toward the outlet16. Also, as shown inFIG. 1, the paddles on the bottom of the conveyor20are positioned adjacent the plate18, on which sits the feedstock118, so that as the paddles22move toward the outlet16, they move through the feedstock118.

Referring back toFIG. 12A, the transverse position of the of extension members106and paddles22of adjacent crossbars104is shown to be staggered, so that the paddles22of adjacent rows are not longitudinally aligned, in fact, in the particular embodiment shown, there are three different paddles configurations, illustrated in detail inFIGS. 13A-13C. In13A, the group of five extension members106and paddles22is positioned in a centered arrangement, with the extension members106and paddles22spaced and equal distance from, one another, and the extension members106and paddles22on the ends each spaced equidistant from the ends of the crossbar104. Alternatively, inFIG. 13B, the extension members106and paddles22are shifted to the left, so that the left-most extension member106is attached to the left end of the crossbar104. Similarly, inFIG. 13C, the extension member106and paddles22are shifted to the right, so that the right-most extension member106is attached to the right end of the crossbar104. These three configurations are placed adjacent one another, as shown inFIG. 12A, with the pattern repeating.

One advantage to staggering the paddles22in this manner is that as the paddles move through the feedstock118in the distillation chamber13, each paddle22separates and moves the feedstock118that it contacts both forward and laterally. The staggering of the paddles22ensures that as subsequent rows of paddles22pass through the feedstock118, the feedstock318is continually moved forward and also laterally, thereby increasing movement of the feedstock118within the distillation chamber13. Although the paddles22and extension members106have been shown herein to be arranged in particular configurations, it is to be understood that these configurations are exemplary only, and many different configurations could be used without departing from the spirit and scope of the invention.

FIG. 14shows the shape of an individual paddle22, according to an embodiment of the invention. The paddle22includes a leading edge108that slopes forward to a point110, Each side112of the paddle22slopes outward and away from the leading edge108. One advantage of this paddle shape is that, as the paddle22moves through feedstock118, the forward slope of the leading edge18of the paddle22pushes the feedstock118upward from the point10toward the extension member106. Thus, feedstock118located at a lower end of the paddle22is circulated upward. At the same time, the outward slope of each side112of the paddle pushes the feedstock118laterally outward. Thus, the staggering of the multiple paddles22, combined with the shape of each individual paddle22, combine to thoroughly agitate and mix the feedstock118as the paddles22move through the feedstock118.

FIG. 15depicts an inlet guide chute114, configured for positioning at the inlet end of the housing12, and to help guide the feedstock118that drops through the inlet14onto the plate18as necessary. In the embodiment shown, the lower portion116of the inlet guide chute114has a unique concave shape, which may help to guide the feedstock118more gradually onto the plate18, and which accommodates the movement of paddles22past the inlet guide chute114as the conveyor turns. Similarly,FIG. 16depicts an outlet guide chute118, configured to be positioned at the outlet end of the housing12, to help guide the feedstock118from the plate18through the outlet16of the distillation chamber13.

FIG. 17depicts the distillation unit10, including the paddles22, plate18, insulation grid assembly19, and bulkhead assembly94, all confined within housing12. Also shown inFIG. 17is the feedstock118, positioned on the plate18as the paddles move through and agitate the feedstock118.

In practice, the purpose of the distillation unit10is to provide a chamber wherein feedstock118is subjected to a destructive distillation process. As discussed above, according to such a process, the feedstock is heated in the absence of oxygen as the feedstock is moved through the distillation chamber13, leading to cracking of the feedstock, and the production of useful products. Initially, feedstock118is introduced to the distillation chamber13via the inlet chute24. The feedstock118can be provided to the inlet chute24from an infeed hopper, and may pass through a meter attached to the inlet chute24. Inside the distillation chamber13, the feedstock118contacts a plate18that may be heated by inserting elongate heating rods41into transverse heating apertures38in the plates18. The elongate heating rods41may be heated by any appropriate means, such as, for example, by electricity.

Once the feedstock118is in position on the plate18, the feedstock is agitated by the paddles22, which are driven by the conveyor20. The paddles22can be staggered, and specially shaped, as discussed above, to maximize agitation of the feedstock118, driving the feedstock118forward, but also laterally and upwardly to circulate the feedstock118. Once the feedstock118has been driven by the paddles22across the length of the plate18, it is discharged through the outlet16of the distillation chamber13.

As the feedstock118is heated and agitated, as described herein, gases are produced within the distillation chamber13. The shape of the housing12can include a domed or peaked upper portion26of the housing, which can help to mix the gases to create useful, products.

The invention shown and described herein is capable of converting raw coal and/or biomass, and producing at least three marketable products, including a cleaner, higher energy coal product, a liquid hydrocarbon/chemical feedstock, and a low energy gas stream. In turn, these products can be used to create many additional useful products, such as, for example, cosmetics, pharmaceuticals, plastics, cleaner fuels, etc.

The invention has been sufficiently described so that a person with average knowledge in the matter may reproduce and obtain the results mentioned in the invention herein Nonetheless, any skilled person in the field of technique, subject of the invention herein, may carry out modifications not described in the request herein, to apply these modifications to a determined structure, or in the manufacturing process of the same, requires the claimed matter in the following claims; such structures shall be covered within the scope of the invention.

It should be noted and understood that there can be improvements and modifications made of the present invention described in detail above without departing from the spirit or scope of the invention as set forth in the accompanying claims.