Abstract:
Systems and methods achieve the conversion of polymer containing material into petroleum products such as hydrocarbon gas, wax, crude oil and diesel. The reactor and its system are designed to subject the polymer containing material to pyrolysis in a way that results in a higher petroleum product yield than conventional existing systems. The system has controls which allow for the heating temperature, rotation of the body, and throughput rate, to be adjusted depending on the reaction time required for the material inside the reactor. The condensing system is able to separate the products into the desired petroleum products by percentage output ranging from wax to crude-like oil to diesel-quality oil.

Description:
Embodiments of the invention relate to systems and methods for converting polymer containing materials to petroleum products such as hydrocarbon gases, wax, crude oil and diesel. 
     BACKGROUND 
     Conventional technology is directed to converting polymer containing materials such as plastic into petroleum products including crude oil. Unfortunately, conventional technology is limited to relatively low crude oil and diesel yields, slower throughput, higher operating costs, and higher capital expenses. 
     SUMMARY 
     Embodiments of the invention address several limitations of other technologies. In some embodiments, the reactor, the system and the method used lead to a higher yield of crude oil and diesel, with a quicker throughput rate, on a lower operating expense, and at a lower capital expense. Specifically, the focus is on producing as much diesel-quality oil as possible and minimize the wax that other technologies create by ensuring an ideal reaction time, and allowing lower carbon chains more time to develop into diesel. Further, embodiments of the reactor allow for a shorter reaction time that results in more polymer containing materials converting into vapors that lead to petroleum products each minute and hence each hour and day. In addition, embodiments of the reactor are designed such that the process can be run continuously 24 hours per day, 7 days per week, thus increasing or maximising output. In some embodiments, the overall system is intended to be as automated as possible so that minimal intervention is required, thus requiring a small workforce of 1-3 employees. Finally, the design of the system, in particular the reactor, does not require significant capital expenditure to build. This means that the system can have a shorter payback period than others available for sale. 
     In some embodiments, the invention includes a system and method for producing petroleum products such as wax, gas and oil by the pyrolysis of polymer containing materials and the subsequent condensation of the resultant vapors. The polymer containing material is initially pre-processed as necessary depending on the composition of the polymer containing material (if known). Once the polymer containing material enters the system it is pre-melted and moved into the reactor body where it is subjected to a similar or higher temperature. The reactor includes a generally horizontal cylindrical body that has an inlet at the first end, at least one outlet at the other end and which is sealed (from outside atmosphere) on both ends, with an inclined slope of the body off of horizontal, external heating applied along one or more sides of the body, and one or more internal rotating augers. The body of the reactor is designed with the ability to rotate the body. Also, the ability to vary the revolutions per minute of the rotating body is possible and dependent on the reaction needs. 
     The condensers used in the invention include several in a process, as well as additional condensing systems. The pressure and temperatures within each condenser can be adjusted so that different percentages of petroleum products are produced. In some embodiments the system includes more than one reactor to be used either in sequence or in parallel. The additional reactors can be used for both additional polymer containing materials as well as for that which remains unreacted after going through a reactor. This allows for higher throughput rate, as well as higher yield. 
     In some embodiments the invention includes the use of a control mechanism which allows different parameters of the system to be captured and monitored. If certain parameters are found to be outside the desired range, they can be adjusted either manually by users or automatically through the control mechanism. In some embodiments the system and method includes processing the feedstock of polymer containing materials prior to them entering the reactor and reaction stage. This is done to remove unwanted particles such as dust and fibers, as well as to separate out undesired polymer containing materials. 
     Other aspects and advantages of embodiments of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrated by way of example of the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various embodiments of the present invention are shown and described in reference to the numbered drawings wherein: 
         FIG. 1  is a flow diagram of one embodiment of the system of the present invention. 
         FIG. 2  is a view of one embodiment of the feeder. 
         FIG. 3  is an alternative view of one embodiment of the feeder. 
         FIG. 4  is a view of the feedstock being fed into the reactor body. 
         FIG. 5  is an alternative view of the feedstock being fed into the reactor body. 
         FIG. 6  is a view of one embodiment of the feeder. 
         FIG. 7  is a view of the vertical section of the condenser. 
         FIG. 8  is a flow diagram of the embodiment of the invention with a second reactor body. 
         FIG. 9  is a flow diagram showing an embodiment of the invention with the vapor gas product used to heat the reactor. 
         FIG. 10  is a view of the back end of the reactor body with one additional auger to remove the residue. 
         FIG. 11  is an alternative view of the back end of the reactor body with a different auger to remove the residue. 
         FIG. 12  is a view of the front end of the reactor body and an embodiment of how the internal auger can rotate. 
         FIG. 13  is a view of the front end of the reactor body and an embodiment of how the internal auger can counter-rotate. 
         FIG. 14  is a view of the front end of the reactor body and an embodiment of how the internal auger can rotate around the body. 
         FIG. 15  is a view of the front end of the reactor body and an embodiment of how the internal auger can rotate with the use of a scraper. 
         FIG. 16  is a view of the front end of the reactor body and an embodiment of how two internal counter rotating augers can work. 
         FIG. 17  is an alternate view of the front end of the reactor body and an embodiment of how two internal counter-rotating augers can work. 
         FIG. 18  is a view of the front end of the reactor body and an embodiment of how two internal co-rotating augers can work. 
         FIG. 19  is a flow diagram showing an embodiment of the invention with two reactor bodies using two condenser systems. 
         FIG. 20  is a view of the longitudinal side of the reactor body with an embodiment of the mechanism which alters the slope angle. 
         FIG. 21  is a flow diagram showing an embodiment of the invention with a control system that monitors several parameters and has the ability to modify those parameters. 
         FIG. 22  is a side view of a pre-reactor process that includes several apparatus designed to prepare the polymer containing materials for conversion in the reactor. 
     
    
    
     It is intended that the drawings are illustrative of the broader scope and embodiments of the invention, and the embodiments of the invention are not limited to these figures. 
     Throughout the description, similar reference numbers may be used to identify similar elements. 
     DETAILED DESCRIPTION 
     It will be readily understood that the components of the embodiments as generally described herein and illustrated in the appended figures could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the present disclosure, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by this detailed description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 
     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussions of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize, in light of the description herein, that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the indicated embodiment is included in at least one embodiment of the present invention. Thus, the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     While many embodiments are described herein, an embodiment of an apparatus converts polymer containing materials into petroleum products (mostly oil) at various boiling ranges.  FIG. 1  shows that the apparatus includes a feeder part  12 , a reactor part  14 , and a condenser system part  18 . Polymer containing material is fed through an inlet  10  in the feeder, and heat is applied to the reactor  16 , while there is an outlet from the condenser for the product to exit from  20 . 
     The polymer containing material fed into the feeder can include chips, shredded, ground, or any other type of shape containing at least a portion of polymer material. The size of polymer containing material is only constrained by the size of the feeder. Using a smaller size (for example one-half inch minus) makes the bulk material denser and makes it easier to move the bulk material at a consistent mass flow. The polymer containing material may be fed from the feeder into the reactor as either a dry feed or a hot melt feed.  FIG. 2  shows that the polymer containing material feed is fed through an inlet  22  into the feeder  24  from which ambient polymer containing material at a temperature range of 30-125° F. exits  26 . 
       FIG. 3  shows that the same polymer containing material feed  32  can be put through the feeder  34  and heated to produce hot melted polymer containing material  36  which exits at a temperature range of 250-600° F. At this elevated temperature the material is melted to a point where it is closer to a liquid consistency. Having the material enter the reactor at an elevated temperature helps keep the reactor temperature steady as introducing colder material drops the overall temperature of material in the reactor. The feeder can be used to increase the density of the material as well as to pre-heat the material before it is brought to the reactor. 
       FIG. 4  shows that the polymer containing material  42  can be metered from the feeder  46  into the reactor  48  with an auger or screw  44 . The revolutions per minute of the auger or screw determine the mass flow rate of the material. The auger can be cooled with a cooling jacket to prevent the polymer containing material from pre-melting as it travels through the screw. In one embodiment, the feed mechanism extends from the feeder into the reactor body. 
       FIG. 5  shows the mechanical force  54  which results in viscous heating, in addition to external heating  56 , serve to melt the polymer containing material  52  while pushing the material forward. The RPM of the auger or screw determines the mass flow of the material. Once the material is sufficiently melted it can be pushed through a channel  60  into the reactor  62 . 
       FIG. 6  shows an alternative feeder  64 , in this case a melt vessel, in which the feed of melted wax, hot oil, melted material, or a combination thereof is fed. The material  68  is heated and mixed in the melt vessel and is then metered into the reactor  70  either by gravity or a hot pump  66 . 
       FIG. 7  shows an example of a four stage condensing system which condenses vapors at four different temperatures. The main purpose of the condensing system is to cool the hot vapors enough for condensation to occur and for them to be in a liquid phase. The condensing system can also be configured to do this cooling in stages in order to separate different boiling ranges of the product. The result of a four stage condensing system is the separation of four distinct liquid products. Hot vapor  71  that is produced in the reactor is drawn through the condensing system starting with the first condenser  72 . In some embodiments, the first stage condenser is used as a reflux column. The vapor leaves the first condenser as either a liquid  74  at a temperature between 200° F. and a maximum of what the temperature of the reactor is or as a vapor  73 . The vapor that exits the first condenser moves into the second condenser  76  where it is set at a lower temperature than the first condense but at least higher than 50° F. Again the vapor leaves the second condenser either in liquid form  75  or as vapor  77  that proceeds into the third condenser  78 . In this third condenser the vapor is again cooler further at a temperature lower than that of the second condenser but at least higher than 50° F. From this third condenser the vapor leaves as either liquid  79  or as vapor  80  into the fourth condenser  82 . In this fourth condenser the vapor is cooled down significantly between about room temperature to at least above −30° F. to capture the last of the available liquids  83  with the remainder exiting as vapor  81  which will typically be light hydrocarbon gases comprised of non-condensable gases usually with a carbon number less than 5. Although specific temperatures and/or temperature ranges are mentioned in this example, other embodiments may operate at other temperatures or temperature combinations. In another embodiment, the system includes an additional multi-stage condensing system having a distillation tower to control the percentage of each end product that is produced. 
       FIG. 8  shows another design in which reacted product from the first reactor  85  is fed back into a second reactor  90 . After the material  84  is fed in through the reactor  85  and exits as vapor it enters the first condenser  86 . From this first condenser the vapor can either move into the second condenser  87 , or exit as product  91 , in which case the product  91  can be redirected into the additional reactor  90  where it will be further subjected to further heating. This further reaction is done primarily to further crack heavy wax products with a high boiling point. From the second reactor, the liquid can either be redirected as oil feedback  88  back into the first reactor  85  for further heating or exit as liquid  91 . The vapor from the second condenser will enter the third condenser  89  where again it will exit as either liquid product  93  or as a vapor gas product  94 . In this example the vapor gas product  94  is not further cracked in a fourth condenser. 
       FIG. 9  shows an alternate design to  FIG. 8  in which the vapor gas product  94  from the condenser  87  is redirected to use as the energy source of the combustion heat source  95  that heats the first reactor  85 . 
       FIG. 10  shows the rear view of one embodiment of the reactor body  100 . Inside the body lays the main reactor chamber  102  in which there lies internal reactor augers  104  and  106 . In this example the first auger  104  rotates counter-clockwise and the second auger  106  rotates clockwise and hence they are counter-rotating augers. In some embodiments, the reactor augers help scrape the char and residue off the reactor wall and help carry it to the rear end of the reactor body. In the illustrated embodiment, a third excavating auger  108  is placed perpendicular to the reactor body to capture the unreacted residue as it exits the reactor. The third auger moves the residue to its exit point  110  where it can be captured and stored. 
       FIG. 11  shows an alternate setup to the one used in  FIG. 10 . The internal reactor augers  114  and  116  are co-rotating (i.e., in the same rotational direction) inside the reactor body  112 . The third excavating auger  118  is placed in line with the reactor body, directly underneath and behind the reactor body. The auger serves the same purpose as that of auger  108  in  FIG. 10 . 
       FIG. 12  shows the inside of the reactor body. In this embodiment, the reactor body  120  is rotating clockwise  122  and the internal rotating auger  126  is also rotating clockwise. 
       FIG. 13  shows an alternative embodiment of the invention. The reactor body  130  is rotating clockwise  132  whereas the internal rotating auger  134  is rotating counter-clockwise. 
       FIG. 14  shows a third alternative embodiment of the invention. In this case, the reactor body  140  is rotating counter-clockwise  142  and the internal rotating auger  144  is also rotating counter-clockwise  146 . 
       FIG. 15  shows a fourth embodiment of the invention. In this case, the reactor body  150  is rotating counter-clockwise  152 . In addition to a rotating auger  154 , there is also a scraper  156  that removes solids that have fallen. 
       FIG. 16  shows a fifth embodiment of the invention. In this case, the reactor body  160  is rotating clockwise  162 . There are two internal counter-rotating augers  164 . One is rotating counter-clockwise  166  and one clockwise  168 . 
       FIG. 17  shows a sixth embodiment of the invention. In this case, the reactor body  170  is rotating clockwise  172 . There are two internal counter-rotating augers  174 . The first is rotating counter-clockwise  176  and the second clockwise  178 . 
       FIG. 18  shows a seventh embodiment of the invention. In this case, the reactor body  180  is rotating clockwise  182 . There are two co-rotating augers  184 . The first is rotating clockwise  186  and the second is also rotating clockwise  188 . 
       FIG. 19  shows an embodiment of the invention in which two reactors and two condensers are used. The feed in  190  is fed into the first reactor  192  out of which both gas vapor  194  and char/residue  196  exit. The gas vapor enters the first condenser  198  from which two products  200  and  202  exit. The second product  202  as well as the char/residue from the first reactor enter the second reactor  204 . Gas vapor  206  exits the second reactor and enters a second condenser  208 . A third product  210  is created from the second condenser. 
       FIG. 20  illustrates how the feedstock  211  enters the reactor body  212  and the one or more augers or scrapers  213  push the feedstock forward. The reactor body is kept at an incline  214  which is off horizontal and between 0 and 30 degrees. This incline helps with the reaction, allowing for adjustments to achieve an optimal residence time that increases the yield. 
     The reactor is rotated at a RPM as per the operating conditions and desired fuel output. The ideal RPM of the rotation of the reactor is guided by the RPM of the internal augers which mix the polymer containing materials inside the reactor. The rotating action of the reactor facilitates stirring and mixing of the feed materials on the inside and also allows for even heating of the exterior wall of the reactor chamber. The reactor heats and stirs the polymer containing material or wax to a state of being a liquid material. In one embodiment, the liquid in the reactor temperature is 400-550° C. In other embodiments, the liquid may be a higher or lower temperature. The reactor includes a longitudinally situated cylindrical tube which is indirectly heated on the exterior. This could be heated with hot gases from a combustion source or hot gases from an electric source. 
     In other embodiments, there can be a heating source which heats the length of the outer wall of the reactor. The temperature of the outer wall of the reactor as well as of the inner wall of the reactor may be monitored and controlled to ensure proper and stable reaction conditions. If the temperature is not steady it can be adjusted through the heating source to ensure a stable reaction. This helps to avoid both under-heating and over-heating the reaction which can lead to lower yields. 
     Inside the reactor chamber, there may be one or more augers which serve to stir the liquid reactant as well as scrap material from the reactor tube&#39;s interior walls. The augers are rotated such that the linear speed at which they carry material forward is controlled—the material that is moved is the dry char which is to be carried out of the reactor. The augers must be fast enough to accommodate the excavation of the char so that the char does not backup inside the reactor. The auger(s) pitch and diameter are designed to operate within the necessary speed range to carry any solid char material out of the reactor at a rate that is equal to or greater than the rate at which char is produced. 
     In the reactor the liquid material is reacted through pyrolysis which breaks the long molecules into shorter molecules. When a molecule is sufficiently cracked and is heated to the chosen reaction temperature, typically between 400-550° C., this molecule will be changed to a vapor or gas phase. However, the exact temperature or range may depend on the type of reactants that are cracked and/or the combinations of products that are mixed with the reactants. 
     Changing the degree of the incline of the reactor so that it slopes between 0-30% grade allows for the throughput rate to be increased or decreased depending on the need. A plug or a baffle may be used near the back of the reactor body to reduce the heat loss and ensure the vapor does not condense at the exit where the char is being removed. 
     In some cases more crude oil will be desired, and at other times diesel. Once the gases are of the desired carbon length range, they are condensed in the condenser system to yield oil at the preferred boiling temperatures. The vapor that exists in the reactor will be drawn into the condenser system via a slight vacuum pressure differential. The vacuum in the reactor is in the range of −0.25″ to −1.5″ WC, whereas the vacuum in the condenser is in the range of −0.5″ to 2.0″ WC. 
     The condenser is used to cool the hot vapors that are produced from the reactor. When these vapors are cooled, a large portion of them will change from a vapor phase to a liquid phase. This cooling can be done in stages which will separate the vapors into different liquid product streams based on boiling point temperatures. The products are removed from the condenser at approximately the same rate they are produced. 
     In the condenser system the vapor hydrocarbon gases are systematically condensed by decreasing the temperature and thus condensing into chosen boiling ranges. The yield of oil from the feedstock can be impacted by the type of polymer containing material which is fed into the system, as different materials have different molecular structures which impact the potential oil yield. 
     A refrigerated condenser can condense more vapor—for example if one condenser is set at approximately normal room temperature it can get the light oil out of the product stream. The different products can be blended or used separately for specific end purposes such as diesel fuel, gasoline, crude oil, fuel oil, etc. 
     The inventors have used different catalysts with the invention and have found that some decrease the reaction time as well as increase the yield of oil. The use of particular catalysts improve the invention and can be added to the feedstock uniformly as it enters the reactor body. 
       FIG. 21  illustrates one embodiment of a control system that allows users of the invention to both monitor the overall reaction process, as well as automate or manually alter operating conditions. The inputs  216  which are different parameters that are monitored can include but is not limited to the feed rate and temperature of the polymer containing material, the RPM of the reactor, the temperature and pressure inside the reactor, the temperature and pressure inside the condensers, the oil level inside the condenser, the oil production rate, the yield of oil, the breakup of which types of oils are produced and in what percentage, the non-condensable gas flow rate, the gas yield, the char production rate, the char production yield, etc. The process monitor display  218  allows users to track each of the parameters.  218  can also include a controller which can either automatically adjust the parameters to ensure it remains within a targeted range (e.g. if the oil yield is low, the feed rate of the polymer containing materials can be slowed down), or can be manually altered by users (e.g. if more crude oil is desired, the user can manually alter the temperature and pressure inside one or more of the condensers). The outputs  220  are the reaction controls and include the feed rate of the polymer containing material, the heating source of the reactor, the mechanism which rotates the reactor, the pressure inside the reactor, the pressure inside the condensers, the oil drain rate of the condensers, etc. 
       FIG. 22  is an example of how the polymer containing material can be prepared pre-reaction. Polymer containing materials enter at  221  where they are typically polluted with unwanted fibers and dust. They are placed into the first apparatus  222  in which the material is dropped. The lighter undesired particles such as dust tend to float above  224  while the actual polymer containing materials drop to the bottom  223  where they are captured and pushed into the second apparatus  225 . In the second apparatus  225  a fluid with a known density is chosen so that the polymer containing materials are separated by their densities. Those with a lower density will float at the top and those with a higher density will sink to the bottom  226 . What floats can be then directed  227  into the third apparatus  228  in which the polymer containing materials are dried. Once the fluid has been separated out  229  in this drying process, the dry polymer containing materials  230  are ready for reaction. 
     In the above description, specific details of various embodiments are provided. However, some embodiments may be practiced with less than all of these specific details. In other instances, certain methods, procedures, components, structures, and/or functions are described in no more detail than to enable the various embodiments of the invention, for the sake of brevity and clarity. 
     Although the operations of the method(s) herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operations may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be implemented in an intermittent and/or alternating manner. 
     Although specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the invention is to be defined by the claims appended hereto and their equivalents.