Process and equipment for the transformation of refuse using induced currents

Abstract: Procedure and equipment for the transformation of organic products and, in particular, the transformation of refuse, waste and similar, whereby the products to be processed are heated to a predetermined temperature without contact with the atmosphere and in the presence of water vapour. The products to be processed are first mixed with conductive bodies (k), whilst the heating of the products is effected by subjecting the mixture of products and conductive bodies (k) to a variable, electromagnetic induction field of high frequency.

Description: The present invention concerns the disposal of solid refuse and, in particular, refuse and waste containing organic substances and polymers, as well as the fibres of silicates such as glass and asbestos. More precisely, the invention concerns a procedure and relative equipment suitable for transforming solid refuse into gaseous or liquid combustibles, or into paraffin or olefinic waxes, via a process of pyrolysis. As is known, a pyrolysis procedure involves heating organic products with high molecular weights, with the possible addition of water, without contact with air. At temperatures above 800°C the pyrolysis reaction produces combustible gases such as carbon oxide, methane and hydrogen. The continuous pyrolysis equipment in use today is essentially composed of a rotating drum into which the materials to be processed are fed, with heating applied externally, through the drum walls. This system of heat transmission involves lengthy material heating times, with the consequent production of large amounts of undesired substances and a low energy yield. Due to the manner in which the heating occurs, temperatures greater than approximately 700°C, a temperature that is insufficient to vaporise the carbon that is formed, cannot be applied to the materials in these systems. In plants of this type, the eventual addition of steam only results in a further reduction of the temperature and the energy yield. In fact, one of the great difficulties in transferring heat to the mass of products to be processed is that when the walls are heated, blocks of molten plastic adhere to them and impede the transfer of heat to the inside of the processing reactor, plastic materials being optimal thermal insulators. Direct-fired heating systems are also well known, but there is little possibility of controlling the process temperature. Systems for the depolymerization of synthetic polymers, essentially composed of devices with external heating provided via electric resistances or other heating systems, are also known. In this case as well, due to localised overheating and the absence of steam in the system, carbon-based residues are formed which degrade the quality of the final products. Systems for the vitrification of silicate fibres, such as glass or asbestos, also exist. These contemplate the use of rotating drums with internal heating via direct-fire or electric arc systems. Other prior art documents concerning the pyrolysis of refuse and waste are DE-A-2 328 545 and US-A-5 423 891. The patent application DE-A-2 328 545 discloses a process for the pyrolysis of refuse, like sewage sludge or plastic, in an air- or oxidant-free environment comprising the introduction of at least a part of pyrolysis heat by means of electrically conductive material mixed with the refuse to be treated and which is heated by induced electrical currents. US-A-5 423 891 relates as well to a method for direct gasification of solid waste by heating solid waste materials continuously in the absence of air to high temperature to directly produce a high BTU gas. Another process concerning the generation of gas from coal and coke and aimed to increasing the yield in the manufacture of coal gas, wherein the heating is performed in presence of steam, is disclosed in GB-A-237 940. The present invention sets itself the goal of providing a procedure and the equipment for the transformation of refuse and waste that enable the problems of the known solutions to be surmounted and permit the best possible recovery of useful substances to be achieved from the transformation process. According to the present invention, this objective is achieved using equipment and a procedure possessing the characteristics forming the subject of the claims. According to the present invention, the material to be treated is mixed with electrically conductive bodies, typically metal spheres, and the mixture transferred, avoiding any contact with air, into a reactor where a powerful flux of variable electromagnetic induction of elevated frequency is created. The electromagnetic induction flux induces electrical currents in the conductive bodies that are capable of heating the conductive bodies and the material to be processed to an opportunely programmed temperature in a range between 300 and 1500°C, thereby producing a transformation of the material. The present invention also provides for the separation of the products of the reaction from the conductive bodies, which are then reutilised in a continuous cycle. The process and equipment described in the present invention are applicable to the processing of various types of refuse, including polyethylene and polypropylene, printed circuit board scrap, paper, wood, biomass, sanitary refuse, medicines, rubber, paints, oils, grease, resins and similar materials, even in the presence of fibreglass and asbestos. Application examples of the process and equipment described in the present invention are as follows: depolymerization of polythene and polypropylene waste with the production of waxes and plasticizers, elimination of printed circuit board scrap containing resins and fibreglass, with the production of gaseous combustibles, recyclable metals and vitreous slag, processing of metallic packaging contaminated with sludge and dregs, with the production of clean, reusable metal scrap, gasification of carbon-based refuse in general, with the production of gaseous combustibles, processing of refuse containing fibreglass and asbestos, with the production of a non-hazardous vitreous material. The process and equipment described in the present invention permit rapid heating of the material to be processed, and this heating takes place directly inside the refuse mass. With the addition of steam, this rapid heating allows the gasification of carbon-based substances as water gas, with the formation of negligible quantities of carbon resins'and, therefore, with a high energy yield. In addition, the presence of steam also provides an intrinsic safety effect as it impedes the formation of explosive mixtures. Additional characteristics and advantages of the present invention will become evident during the detailed description that follows, which is supplied purely as a non limitative example, and refers to the following enclosed drawings: figure 1 is a partially sectioned schematic view of equipment based on the present invention, figure 2 is a larger-scale schematic section of the part indicated by arrow II in figure 1, figures 3a, 3b, 3c, 3d, 3e and 3f are schematic plan views of different operative configurations indicated by arrow III in figure 1, figures 4a, 4b, 4c, 4d, 4e and 4f are sections along the IV-IV lines of the corresponding figures 3a, 3b, 3c, 3d, 3e and 3f, figures 5, 6 and 7 are the respective sections along the lines V-V, VI-VI and VII-VII in figure 2, figure 8 is a section of the part indicated by arrow VIII in figure 1, and figures 9 and 10 are the respective sections along the lines IX-IX and X_X in figure 8. With initial reference to figure 1, item 10 indicates the equipment according to the present invention for the transformation of refuse and waste using induced currents. The equipment (10) includes a grinding and mixing device (12), with a hopper (14) into which a load conveyor (not shown) feeds the materials to be processed from above and in the direction of the arrow (16). The equipment 10 includes a conveyor (18), which feeds the hopper (14) with a predetermined quantity of conductive bodies (k). The grinding and mixing device (12) grinds the refuse and waste and mixes the conductive bodies (k) with the mass of ground refuse. The size of the conductive bodies (k) is less than that of the fragments produces by the grinder (12) so that they can pass through the grinding device without interfering with the grinding members. For example, the refuse to be processed could be ground to an indicative fragment size of approximately 50 mm, while the conductive bodies (k) could be composed of metallic parts, such as steel alloy spheres for example, with a diameter of 40 mm. Preferably, the conductive bodies (k) should be hollow so as to have an apparent specific weight of substantially the same magnitude as that of the ground material. A hopper (20), linked with a feeder device (22), is arranged at the outlet of the grinding and mixing device (12). Preferably, the hopper (20) should be equipped with a nozzle (24), via which an inert scavenging fluid such as carbon dioxide could be introduced to eliminate air from the ground mass of refuse mixed with the conductive bodies (k). The feeder device (22) is constructed to feed the mixture of ground refuse and conductive bodies (k) to a transformation group (26), avoiding direct contact with the atmosphere. As will be more fully described in the following, the transformation group (26) includes a first reactor (28) composed of a tubular shell lined with refractory material and set up with its longitudinal axis more or less horizontal. With reference to figures 3a-3f and 4a-4f, the feeder device (22) incorporates two feed cylinders (30 and 32), combined with their respective pistons (34 and 36), which are driven by linear actuators (38 and 40), composed of a hydraulic cylinder for example, or a mechanical actuating device. The two feed cylinders (30 and 32) are arranged with their longitudinal axes at angles to each other. In the example shown in the figures, the cylinders (30 and 32) are set at 90° to each other. The first feed cylinder (30) is connected to the hopper (20), while the second feed cylinder (32) is connected to the first reactor (28) via a joint (42) that permits thermal dilatation. Operation of the feeder device (22) is as follows. In figures 3a and 4a, both pistons (34 and 36) are at rest in the closed position. In the next phase, shown in figures 3b and 4b, piston 34 remains closed while piston 34 is brought to the fully-open position. A dose of the mixture (44) thus falls from the hopper (20) into the first feed cylinder (30) (figure 4b). In the next phase, shown in figures 3c and 4c, piston 34 is brought to the partially closed position whereby it blocks the descent of material from the hopper (20) and advances the dose of mixture (44) inside the first feed cylinder (30). Then, as shown in figures 3d and 4d, piston 34 remains stationary while piston 36 is opened completely. Subsequently, in the phase shown in figures 3e and 4e, piston 36 remains stationary in the open position while piston 34 closes completely, advancing the dose (44) even further, where it enters the zone of influence of the second feed cylinder (32). Finally, as shown in figures 3f and 4f, piston 36 is brought to its closed position, making the dose (44) pass into the first reactor (28). The above operational phases are cyclically repeated, producing a stepwise advancement of material inside the first reactor (28) in the direction indicated by arrow 46 in figure 1. The feed cylinders (30 and 32) can have cross sections of various shapes, but square or circular sections are preferable. It may be noted that to avoid air entering the first reactor (28), during all of the operating phases of the feeder device (22), the internal part of the reactor (28) is never in direct contact with the hopper (20). With particular reference to figure 2, the first reactor (28) is composed of materials capable of supporting the expected temperatures of the specific process that it is intended to develop, without fusing or losing the necessary mechanical characteristics. The reactor (28) is made using graphite or special alloys capable of supporting high temperatures, such as alloys containing nickel, chrome, tungsten, molybdenum or niobium. The first reactor (28) can have different types of cross section, circular for example. As shown in figure 5, the first section of the reactor has a filled zone (48) in the upper part, which then becomes a hollow (50) in a successive zone (see figure 6). The hollow zone (50) terminates in correspondence with a point in the reactor (28) indicated as 54 in figure 2. Beyond this point, the internal cross section of the reactor (28) increases with respect to the previous section. Thanks to this configuration, a free zone (56) is created downstream of point 54 where the steam can be insufflated via a nozzle (52) and in which the reaction gases can develop. The transformation group (26) includes an inductive heating system incorporating one or more coils (58) that encircle the reactor (28). The coils (58) consist of metallic tubular elements wound in a spiral, the ends of which (60) are connected to a highfrequency alternating current power source (not shown). A coolant liquid can be circulated through the tubular elements that form the coils (58) to remove the heat that forms in the coils (58) due to the passage of electric current. The frequency of the alternating current applied to the terminals of the coils (58) can vary from a few hundred to millions of Hertz. The inductive heating system includes an insulation layer (62) of refractory material with a high index of softening and a layer of lagging material (64), as well as a metal casing (66) for protection and shielding. One or more sensors (68) are positioned at the bottom of conduits, which pass through the layers 62 and 64 so that these can optically inspect certain zones of the reactor's (28) external walls that are not covered by the insulation. The sensors (68) detect infrared emissions from the wall of the reactor (28) and supply an indicative signal of the temperature inside the reactor. These signals are transmitted to a control unit (not shown) that is programmed to adjust the current or supply frequency of the coils (58) to ensure that the mixture of materials to be processed is maintained at a predetermined temperature. This temperature can be changed according to the type of transformation that is wished to carry out (gasification, depolymerization or fusion). The coils (58) create a variable electromagnetic flux of very high frequency that links with the mixture of materials that advances inside the reactor (28). The alternating electromagnetic flux induces induced currents in the conductive bodies (k) and in any metallic elements contained in the mixture of materials to be processed. These induced currents cause rapid heating of the metallic bodies which then transfer the heat to the non metallic parts of the mixture to be processed. Heating of the mixture occurs in an endogenous manner and requires only a few seconds. The process temperature can be varied within a range from 300 to 1500°C by adjusting the voltage, frequency or intensity of the supplied current. The process temperature can be adapted in real-time to variations in composition of the materials to be processed. The equipment permits rapid process start-up and stoppage, as well as prompt regulation based on examination of the quality of the products obtained from the reaction. Subjecting carbon-based substances to high temperature in an oxygen-free environment, in the known manner, invokes a series of endothermic reactions that provoke the scission of the molecules' chemical links, resulting in so-called pyrolysis or cracking, which produces substances with smaller molecular weights according to the temperatures applied and the manner of application. In the known types of pyrolysis oven, the material is heated in rather a slow manner. This implicates the evaporation of water and then, in sequence, the formation of carbon dioxide and acidic substances at temperatures between 180 and 400°C, followed by the formation of gas and carbon at temperatures between 400 and 700°C. These effects generally give rise to a low yield of combustible gases. Instead, the equipment described in the present invention allows a temperature in excess of 800°C to be rapidly applied in the presence of steam. In this way, a gasification process is achieved in which the water vapour attacks the organic carbon as indicated in the following reaction: C n H m + nH 2 O = nCO + (n+m/2)H 2 producing oxides of carbon and hydrogen, both gases and combustibles. This reaction can also be written as the result of two partial reactions, whereby the substances are transformed into carbon, which, since the temperature of the system is above 800°C, in turn reacts with water to form the carbon and hydrogen oxides: C n H m = nC + m/2H 2 NC + nH 2 O = nCO + nH 2 The gasification to water gas reactions for cellulose and polyethylene are as follows: Cellulose: (C 12 H 20 O 10 ) + 2H 2 O = 12CO + 12H 2 Polyethylene: (C 2 H 4 ) + H 2 O = CH 4 + CO + H 2 As can be easily calculated, this type of transformation requires 11 grams of water vapour for every 100 grams of cellulose and 64 grams for every 100 grams of polyethylene. The absence of these essential quantities of steam, together with the low process temperature, are the causes of the formation of significant quantities of carbon and tar-like substances in the known types of pyrolytic ovens. Always referring to figure 2, the transformation group (26) incorporates a second reactor (70) composed of a shell with its axis more or less vertical and without a floor plate. The outlet section of the first reactor (28) communicates with the internal volume of the second reactor (70). An outlet nozzle (72) is provided at the top of the second reactor (70) for extracting the products of the reaction in gaseous form. A spray device (74) produces a shower of water for washing the gaseous reaction products in countercurrent. A deflector (76) is arranged to prevent the water spray from interfering with the outlet section of the first reactor (28). The second reactor (70) is equipped with feet (78) that rest on the bottom of a tank filled with water up to the level indicated by 82. The open bottom of the second reactor (70) is submerged beneath level 82, but is distanced from the bottom floor of the tank (80) by the feet (78). The tank (80) is equipped with an overspill nozzle (84), regulated to ensure that the liquid in the tank (80) is kept at level 82. The second reactor (70) can also be equipped with an inspection window (85). The liquid in which the open lower end of the second reactor (70) is immersed forms a wet seal that prevents gaseous substances from escaping. In consequence, the gaseous substances can only leave the second reactor (70) via the outlet nozzle (72). The gas that leaves the outlet nozzle (72) is conveyed to collection tanks (not shown). The first reactor (28) and the second reactor (70) are maintained just above atmospheric pressure, regulating the backpressure of the gas collection tanks downstream of the outlet nozzle (72). The gas produced by the transformation group (26) can be used for feeding an electric power generator group, including an alternator combined with a gas or turbine engine, which produces the electrical energy necessary for running the equipment as well as an excess of approximately 0.6 kW for each kilo of refuse that is processed. The electrical power required for running the equipment depends on the dimensions, capacity and operating conditions of the equipment. To process one kilo of material, approximately 1 kW is needed in the case of polyethylene depolymerization, 0.8 kW for processing printed circuit board scrap containing resins and fibreglass, and 1 kW for the complete gasification of carbon-based substances, such as paper and polyethylene. In the second reactor (70), the gaseous substances are rapidly cooled and washed by the water spray, discharging static electricity and also blocking the retrogradation of carbon oxide to carbon dioxide and carbon, which could take place if cooling was slow. The solid materials and conductive bodies (k) that are discharged from the first reactor (28) fall down due to gravity. The conductive bodies (k) and the solid products of the reaction cool rapidly in contact with the water and produce steam which comes into contact with the material leaving the first reactor (28), where it contributes to completing the gasification reaction and prevents the formation of carbon. Lighter solid materials, such as waxes and plasticizers, gather above the water level (82) while the conductive bodies (k) and heavy solid products collect on the bottom of the tank (80). With reference to figures 1 and 2, the equipment (10) includes a first and a second collection system (86 and 88) for recovering solid products. The first collection system (86) comprises a conveyor equipped with a motor-driven chain and drainage scoops that skim the top of the liquid (82) and collect the lighter solid materials and discharge them into a collecting vessel (90). The second collection system (88) also consists of a conveyor equipped with a motor-driven chain and collection scoops, but the scoops skim the bottom floor of the tank (80) and collect the heavy solid materials. As can be seen in figure 1, conveyor 88 feeds the conductive bodies (k) and heavy solid materials to a rotary separator (92), spinning around a horizontal axis (94) and driven by a motor (96). With reference to figures 8, 9 and 10, the separator device (92) has a cylindrical wall (98) forming a grill and two parallel ends (100 and 102) equipped with openings (104 and 106 respectively). The separator device (92) is kept in turning around its axis (94) and the conductive bodies (k), together with other heavy solid materials (metals and similar) enter via opening 104. The separator device (92) crushes vitreous slag which is then expelled by gravity through the grill (98) and collected in a container (108 in figure 1). The separation can also be carried out with the addition of a water spray. With reference to figure 1, the conductive bodies (k) and metals exit from opening 106 of the rotary separator (92) and are transported to a vibratory separator (110) where the conductive bodies (k) and solid products are separated, with the latter being collected in another container (112). The conductive bodies (k) are picked up at the outlet of the vibratory separator (110) by a chain conveyor (18) that transports them to the hopper (14), where they start a new cycle. The process and equipment described in the present invention are particularly useful for the gasification of carbon-based products, such as paper, wood, rubber, polyethylene, polypropylene, plastic materials in general, resins, paints, oils, greases, biomass, and organic compounds with high molecular weights. Processing these products at a high temperature of approximately 800°C generates gaseous products with low molecular weight, mainly CO, H 2 , CH 4 , CO 2 , etc., giving rise to a combustible gas. The process and equipment described in the present invention also find valid application for the elimination of printed circuit board scrap. This scrap contains resins, fibreglass, copper, tin, silicon, steel, silicates etc. and is destined to increase with time due to the progressive increase in the scrapping of obsolete computer systems. The disposal of such scrap in waste dumps necessitates the utilisation of special plants, which are also necessary for disposing of the waste produced if this scrap is incinerated. When processed by the equipment described in the present invention at a temperature of approximately 1100°C, this scrap produces combustible gases, recyclable metallic scrap composed of bronze and steel, as well as vitreous slag. Applying the process and equipment described in the present invention to the processing of polyethylene scrap, and operating at a temperature of 500°C, precious, solid paraffin waxes with a melting point of around 70°C are obtained, while using a temperature of approximately 600°C produces low liquid polymers that can be used as plasticizers. Another interesting application of the present invention consists in the processing of metallic packaging that has contained refuse of an organic nature and is contaminated with dregs and sludge. When this contaminated packaging is subjected to a temperature between 300 and 500°C, combustible gases and vapours are released together with clean metal scrap, ready for despatch to the steelworks.

Claims: A process for the transformation of organic products, in particular for the transformation of refuse, waste and similar, whereby the products to be processed are heated to a predetermined temperature, without contact with air, wherein the products to be processed have been previously mixed with conductive bodies (k) and the heating of the products is effected in a reactor (28) by subjecting the mixture of products and conductive bodies (k) to a variable electromagnetic induction flux of very high frequency, characterized in that water vapour is insufflated into the mixture of the products to be processed and conductive bodies (k) in a free zone (56) of said reactor (28) in which reaction gases develop at a temperature above 800°C. A process according to Claim 1, characterized in that the heating is effected with the mixture of products and conductive bodies (k) subjected to the aforementioned electromagnetic induction flux passing continually through the first reactor (28). A process according to Claim 2, characterized in that after the non-stop passage through the said reactor (28), the aforementioned conductive bodies (k) and the resulting products of the reaction are subjected to a phase of rapid cooling with water. A process according to Claim 1, characterized in that the aforementioned conductive bodies (k) are composed of metal spheres. A process according to Claim 1, characterized in that the aforementioned conductive bodies (k) have an apparent specific weight substantially similar to the apparent specific weight of the products to be processed. A process according to Claim 1, in which carbon-based products to be processed are converted into combustible gases. A process according to Claim 1, in which products of a polymeric nature to be processed are depolymerized with the formation of substances with lower molecular weight. A process according to Claim 1, in which fibres of silicates such as glass, asbestos and similar present in the materials to be processed are fused and transformed into non-hazardous vitreous slag. A process according to Claim 1, in which metallic parts present in the materials to be processed are depurated of their contaminants. A process according to Claim 1, in which the temperature induced in the material to be processed is controlled by modifying the characteristics of the electromagnetic flux in which the products to be processed are immersed. Equipment for the transformation of organic products, in particular for the transformation of refuse, waste and similar, which includes: a reactor (28) inside which the products are moved along without contact with the atmosphere, means of heating for bringing the said products to a chosen temperature, and wherein the plant includes a mixing device (12) positioned before the said reactor (28) suitable for mixing the products to be processed with the conductive bodies (k) and the said means of heating include an induction device (58) capable of generating a variable electromagnetic induction flux of very high frequency inside the said reactor (28), characterized in that the plant includes means (50 and 52) for introducing.a jet of water vapour inside the said reactor (28) in a free zone (56) and control means for adjusting the current or supply frequency of the coils (58) to ensure that the temperature in the free zone (56) is above 800°C. Equipment according to Claim 11, characterized in that it includes a grinding device (12) for grinding the products to be processed and inside which the mixing of the said conductive bodies (k) and the products to be processed occurs. Equipment according to Claim 11, characterized in that it includes a feeder device (22), for feeding the said reactor (28) with a continuous flow of products to be processed mixed with conductive bodies (k); the feeder device (22) incorporates a pair of feed cylinders (30 and 32), at angles to each other and combined with their respective pistons (34 and 36), actioned according to a specific cycle to avoid contact with the atmosphere inside the reactor (28). Equipment according to Claim 11, characterized in that the aforementioned induction heating device includes at least one coil (58) positioned coaxially and external to the said reactor (28). Equipment according to Claim 14, characterized in that the aforementioned coil is formed by at least one tubular conductor in which a coolant fluid circulates. Equipment according to Claim 11, characterized in that it includes sensors (68) for determining the temperature inside the reactor (28) by detecting the thermal radiation emitted by a portion of the wall of the reactor (28). Equipment according to Claim 16, characterized in that it incorporates a control unit for modifying the characteristics of the electromagnetic induction flux in function of the signals arriving from the said sensors (68). Equipment according to Claim 11, characterized in that it includes a second reactor (70) positioned to receive the products of reaction and the conductive bodies (k) when processing inside the first reactor (28) is completed and that the second reactor (70) is equipped with means (74 and 82) for the rapid cooling of the products of reaction and the conductive bodies (k). Equipment according to Claim 18, characterized in that the second reactor (70) is includes a spray device (74) for producing a water spray in countercurrent with respect to the flow of gaseous products. Equipment according to Claim 17, characterized in that the second reactor (70) has an open bottom immersed in a water bath in which the solid products and conductive bodies (k) leaving the first reactor (28) are collected. Equipment according to Claim 20, characterized in that it includes a first and a second collector device (86 and 88) arranged to respectively collect light solid products that float on top of the aforesaid water bath and heavy solid products that are deposited on the bottom of the tank (80) containing the aforesaid water bath. Equipment according to Claim 21, characterized in that it includes means (92 and 110) for separating the aforesaid conductive bodies (k) from the solid products that are deposited together with the said conductive bodies (k) on the bottom of the said tank (80).

Inventors: MORGANTINI GIANPIERO, PELLEGRIN RUGGERO, MORGANTINI, GIANPIERO, PELLEGRIN, RUGGERO
Applicants: DONIZETTI SRL
Application year: 2000
Main classification: C10B49
IPC codes: B01J8, C10B53, C10G1, C10B19, B01J19, C10B49