Patent Publication Number: US-2009232725-A1

Title: Flow rate of gas in fluidized bed during conversion of carbon based material to natural gas and activated carbon

Description:
The present invention relates to fluid flow bed used in the process of converting carbon based matter into natural gas and activated carbon and more particularly related to the rate of fluid low and incorporates by reference, claiming priority from U.S. Provisional Patent Application 61/004,082, filed Nov. 23, 2007 and entitled CLOSED LOOP FLUIDIZED BED FLASH GASIFICATION SYSTEM and U.S. Patent Application 61/137,213, filed Jul. 28, 2008 and entitled LIQUIFACTION PROCESS FOR CHANGING ACTIVATED CARBON AND SYNGAS INTO DIESEL FUEL. 
    
    
     FIELD OF THE INVENTION 
     Background of the Invention 
     Coal has long been used as a source of fuel. As the search for alternative fuels increases, several inventors have been looking toward further developing technology related to the use of coal. These inventors has come to recognize that the natural gas found in coal is not limited to coal, but rather is found in various forms of man-made and naturally occurring substances including, but not limited to municipal solid waste, sewage, wood waste, biomass, paper, plastics, hazardous waste, tar, pitch, activated sludge, rubber tires and oil-based residue. 
     The question has generally not been where one should look for natural gas, but rather how to liberate the natural gas. This has led to several different confined gasification liquefaction techniques. These systems in general terms include the down draft gasification, updraft gasification, and fluidized bed gasification. 
     The down draft gasification, also called a “co-current configuration system”, relies on gravity to move the feedstock, which perhaps is coal. The ignition system flows with the feedstock with resultant ash or slag falling out the bottom. The ash or slag is hazardous waste and is treated as such. This system of partial combustion yields a low BTU gas that must undergo extensive cleaning. 
     The updraft gasification, also called a “countercurrent system”, uses a blower to direct the feedstock up through the system. The combustion source is generally directed in an opposite direction to the feedstock or perpendicular to it. The ash and slag falls out the bottom where it is collected as hazardous waste. This is a partial combustion system that results in low BTU gas and tars that must be cleaned prior to use. 
     The conventional fluidized bed uses sand, char or some combination thereof. The fluid, usually air or steam, is directed through the sand, to the feedstock thereabove. The environment is usually oxygen starved resulting in partial combustion. The temperatures are relatively low resulting in low BTU gas that must be extensively cleaned prior to use. The ash is corrosive, invoking the use of limestone to minimize the corrosive effect. Some examples of the fluidized bed technology follow: 
     Giglio (U.S. Patent Application 2006/0130401) discloses a method of co-producing activated carbon in a circulating fluidized bed gasification process. The carbonacious material is treated in a fluidized bed to form syngas and char. (¶ 14) In a subsequent step, the char is turned to activated carbon with steam and carbon dioxide. Giglio teaches using the activated carbon to clean the syngas and separation of the gas and activated carbon. The cleaned syngas and solids are separated in a dust. Giglio uses a separator to separate the activated carbon and natural gas from the feedstock. That is, the gaseous flows through the fluidized bed are not used to separate components of carbonacious material on the basis of density. 
     Jha et al. (U.S. Pat. No. 5,187,141) discloses a process for the manufacture of activated carbon from coal by mild gasification and hydrogenation. The coal is first heated to a temperature between evaporation of water and below removal of volitilization. The dry coal is the heated in a mostly non-oxygenous atmosphere to volatilize and remove the contained volatile matter and produce char. In a second step, the char is subjected to a hydrogenation process to activate the carbon. The gaseous flows through the fluidized bed are not used to separate components of carbonacious material on the basis of density. 
     Ueno et al. (United States Patent Application 2003/0027088) discloses a method for treating combustible wastes. Combustible wastes includes paper, plastics, coal, tar, pitch, activated sludge, and oil-based residue. ¶8. The combustible wastes are carbonized at a temperature of around 400-600 degrees C. The carbonized material is then subjected to a temperature around 1000-1300 degrees C. in an inert atmosphere. This drives off the volatiles and may activate the carbon. The carbonized product is blown into exhaust gas, e.g., volatiles, to purify the exhaust gas. (Exhaust gas is preferred to be from refuse incineration, electric power plants, steel-making electric furnace, scrap melting furnace, and sintering machine.). The volatiles are used as a heat source for the carbonization step, although they are acknowledged to have harmful substances contained therein. ¶40. 
     The rate of fluid flow has generally not been discussed nor has the benefits of the fluid flow rate been considered. What is needed is a flow rate of gas in fluidized bed during conversion of carbon based material to natural gas and activated carbon that yields beneficial results that extend beyond the speed of combustion or conversion. Desirably, the flow rate separates material desired to be suspended above the fluidized bed from the material not desired to be above the bed. 
     SUMMARY OF THE INVENTION 
     The present method of processing carbonacious material into natural gas and activated carbon may include the steps of: placing feedstock onto a fluidized bed; directing non-oxygenated gas through the fluidized bed; adjusting a velocity of the gas such that the gas is slow enough to leave the feedstock on the fluidized bed and fast enough to remove activated carbon and volatiles. 
     In a preferred method, the process may include the steps of placing feedstock onto a fluidized bed; directing superheated non-oxygenated gas through the fluidized bed; adjusting a velocity of the superheated gas such that the gas is slow enough to leave the feedstock on the fluidized bed and fast enough to remove activated carbon and volatiles; allowing cleaning of the volatiles using the activated carbon to form clean natural gas and activated carbon; separating the natural gas and the activated carbon; recycling a portion of the natural gas back to the fluidized bed; collecting a non-recycled portion of the natural gas; and collecting the activated carbon. 
     Advantageously, the plenum leading away from the fluidized bed may be in an elevated position from the fluidized bed, permitting immediate co-mingling of the volatiles with the activated carbon yielding clean natural gas and activated carbon. 
     As yet another advantage, the velocity keeps the fluidized bed with a fresh supply of carbonacious material and self purges the processed materials from the fluidized bed. 
     As still yet another advantage, the process is completely devoid of water and oxygen, which leads to partial combustion, e.g. charring, or complete combustion, e.g. ash, and thus allowing the carbonacious material to proceed directly to activated carbon. 
     As still yet another advantage, the velocity operates as a gravity separator relying on the change in density between the feedstock and mixture of activated carbon and volatiles. 
     These and other advantages will become clear from reading the below description with reference to the appended drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a flow chart showing the present inventive method; 
         FIG. 2  is a block diagram showing the present inventive apparatus; 
         FIG. 3  is a flow chart showing the first process of the present inventive method; 
         FIG. 4  is a diagram showing the first processor of the present invention; 
         FIG. 5  is a plan view of the fluidized bed of the first processor; 
         FIG. 6  is a schematic drawing of the airlock of the first processor; 
         FIG. 7  is a side view in partial phantom showing the blower assembly and seal assembly of the present invention; 
         FIG. 8  is a top or bottom view of the housing assembly of the blower of the present invention; 
         FIG. 9  is a bottom view of the seal assembly of the blower of the present invention; 
         FIG. 10  is a top view of the seal assembly of the blower of the present invention; 
         FIG. 11  is a right side portion of a partial cross-sectional view of the housing and blower assemblies of the present invention taken along the lines  11   a - 11   a  and  11   b - 11   b  of  FIG. 7 . 
         FIG. 12  is a flow chart showing the second process of the present invention; and 
         FIG. 13  is a schematic drawing showing the various components of the second processor of the present invention. 
     
    
    
     The figures are presented as being the best mode of the present invention and are not to be deemed limiting in any regard. 
     DETAILED DESCRIPTION 
     Definitions 
     The following terms, defined immediately below, have such meanings throughout the description and claims: 
     Activated carbon—a porous crystalline structure made primarily of hydrogen deficient carbon. The carbon-to-carbon bonding within the activated carbon may be varied, including single, double, triple and quadruple bonds structure in chains and rings and may include monomers and polymers randomly found in and throughout the activated carbon. Activated carbon is not achieved through an intermediate step involving char or ash or arrived at through combustion. 
     Activated char—not truly activated carbon, but rather an amorphous carbon compound. Activated char may have an intermediary step of charring and involves partial combustion. 
     Amorphous carbon—a carbon compound with no particular structural arrangement. Amorphous carbon may be hydrogenated or may be at a hydrogen deficit. 
     Char—Char is an amorphous carbon structure substantially hydrogen deficient. Char is often found as a by-product of incomplete combustion of organic compounds including fossil fuels and biomass due to a partial deprivation of oxygen. 
     Crystalline carbon—a carbon compound with a definite structure. Crystalline carbon may be fully hydrogenated or substantially devoid of hydrogen. Crystalline carbon and amorphous carbon as used herein are opposite terms. 
     Diesel—a fuel that may be represented by the chemical formula C 12 H 23 , on average, but is a mixture of hydrocarbons generally between C 10 H 20  to C 15 H 28 . 
     Feedstock—any carbon based material, preferably, but not limited to coal and activated carbon. The feedstock should be dried and may have a diameter range between 1/16 and ⅝ inches and a preferred diameter range of between ⅛ and ¼ inch when used in the preferred mode. 
     Gas—one of the three states of matter and does not necessarily denote the combustible matter. This invention is intended to be used in the production of combustible gas and where combustible gas is intended term the term combustible, natural, diesel or other such distinguishing term will be used. 
     Hydrogen deficient carbon—carbon compounds that lack sufficient hydrogen to convert to diesel without hydrogenation. 
     Natural gas—Combustable material driven off of feedstock or manufactured from carbon chains shorter, e.g. methane and ethane, than used in diesel fuel. Natural gas is used within the ordinary and common use of the term. 
     Volatiles—gaseous material driven off of feedstock, which is generally combustible. While possible that trace amounts of non-combustable material may be included in the volatiles, the levels may be trace or less. (None were found upon testing.) The components in testable quantities of first volatiles were entirely clean natural gas. The first volatiles are generally are 90+% methane with the balance being slightly longer hydrocarbons. The second volatiles are presently not determined, but are understood to contain natural gas and hydrocarbons longer than natural gas and shorter than diesel. 
     DESCRIPTION 
     Overview 
     The present invention is most readily understood in components, but may be joined, integral or otherwise, into a comprehensive whole apparatus  10 . Fully described below are components including first processor  130 , blower  210  and second processor  410  together with their respective manners of operation. In combination, these components  130 ,  210 , and  410  process feedstock  12  into diesel fuel  14  and natural gas  16 . Intermediary by-product, including natural gas  16  and activated carbon  18  may optionally be collected in user determined amounts. Under this section, description—overview, is a look at the overall process and is supported by the first processor, blower and second processor descriptions below. 
     Numerals as used throughout are in part determined by the component in which the numeral is used. The part numbers are two digit when the numeral is selected for description of the entire apparatus  10 , part numbers are three digit with a leading  1  when referring to first processor  130 , part numbers are three digit with a leading  2  when referring to the blower  210 , and part numbers are three digit with a leading  4  when referring to second processor  410 . Components such as activated carbon, natural gas and others have multiple numbers with the leading digit indicating the section in which the component is being discussed and the two digit corresponding to the other arts within the appropriate section. 
     The present inventive method of manufacturing diesel, may include the steps of providing a feedstock  12 , step  30  of  FIG. 1 ; processing the feedstock  12  to produce hydrogen deficient carbon material  20  and first volatiles  24 , step  32 ; hydrogenating the hydrogen deficient carbon material  20 , step  34 ; and processing the hydrogenated hydrogen deficient carbon material  20  into second volatiles  26  and diesel  14 , step  36 . 
     Stated in differently, in breadth and terms, the present method of manufacturing diesel, preferably includes the steps of: providing a feedstock  12  having a hydrogen deficient carbon material  20 ; and processing the hydrogen deficient carbon material  20  into a mixture of volatiles  22  and diesel  14 . Included may be intermediary steps of: processing the feedstock  12  into a mixture of first volatiles  24  and hydrogen deficient carbon material  20 ; and processing the hydrogen deficient carbon material  20  into a mixture of second volatiles  26  and diesel  14 . The mixture of first volatiles  24  and hydrogen deficient carbon material  20  may be a mixture of natural gas  16  and activated carbon  18 , whereas the mixture of second volatiles  26  and diesel  14  may include natural gas  16 , hydrocarbons longer than natural gas  16  and shorter than diesel  14  and diesel  14 . 
     The feedstock  12  may be selected from the group of coal, activated carbon, char, biomass and other carbon based matter. The hydrogen deficient carbon material  20  typically is activated carbon  18 , but may be carbon in any crystalline, amorphous or combined configuration, including, but not limited to various chars. The first volatiles  24  preferably is natural gas  16 . The second volatiles  26 , while including natural gas  16 , includes hydrocarbons longer than natural gas  16 . 
     The present apparatus  10  for manufacturing diesel  14  may include a feedstock  12 ; a first processor  130 , the processor  130  being adapted to convert the feedstock  12  into a mixture of hydrogen deficient carbon material  20  and volatiles  22 . A blower  210  preferably is in fluid communication with the feedstock  12  and adjusted to separate the feedstock  12  from hydrogen deficient carbon material  20  and volatiles  22 . The blower  210  desirably is positioned partially within the first processor  130  and partially outside the first processor  130 . Optionally, a second processor  410  may be operably joined to the first processor  210  and adapted to convert hydrogen deficient carbon material  20  into a mixture of diesel  14  and volatiles  22 . 
     Stated differently, in breadth and terms, the apparatus  10  for manufacturing diesel  14  may include a feedstock  12  having hydrogen deficient carbon material  20  and a processor  410  adapted to convert the hydrogen deficient carbon material  20  into a mixture of diesel  14  and volatiles  22 . 
     DESCRIPTION 
     First Process/Processor 
     Reference numerals  110 - 126  are reserved for process steps and are found on the flow chart designated as  FIG. 3 . Numerals  130  through  300  are reserved for apparatus components and are found on  FIG. 4  through  FIG. 6 . 
     The present method of processing feedstock  134  into first volatiles  154  and hydrogen deficient carbon material  157  may have a first step  110  of selecting a feedstock  134  as shown in  FIG. 3 . Suitable material from which to generate feedstock  134  includes, but is not limited to, coal, municipal solid waste, sewage, wood waste, biomass, paper, plastics, hazardous waste, tar, pitch, activated sludge, rubber tires and oil-based residue. Coal is the preferred feedstock. The grade of coal is not significant, since this is not a process involving partial or complete combustion. However, wet material, including coal, should be dried. 
     The feedstock  134  is then placed onto a fluidized bed  144 , signified on  FIG. 3  as step  112 . This step preferably is done in a controlled manner to preclude oxygen and/or water from entering with the feedstock  134 . For instance, the feedstock  134  may enter through an airlock system  135 . 
     The airlock system  135  may include a feed hopper  136 , a screw auger  138 , a rotary airlock  140 , and a slide gate  142  with a sleeve  142   a  and aperture  142   b . Feedstock  134  from the feed hopper  136  is directed by the screw auger  138  to the rotary airlock  140 . Rotating the rotary airlock  140  drops feed stock  134  into the aperture  142   b  of the slide gate  142 . Oscillation of the slide gate  142  through the sleeve  142   a  directs the feedstock  134  over the chute  184 , whereupon the feedstock  134  falls onto the fluidized bed  144 . The feedstock  134  encounters a slightly elevated atmospheric pressure as it reaches the chute  184 . This pressurized atmospheric assures that any airflow through the air lock system  135  is in an outward direction, not inward. Other airlock systems are known to those of ordinary skill in the art and may be used in lieu of the disclosed airlock system  135 . 
     The feedstock  134  is suspended in the superheated natural gas  149  of the fluidized bed  144 . The feedstock  134  suspended on the fluidized bed  144  is done in such manner that the feedstock  134  is supported by matter that is in a gaseous state, e.g., the superheated natural gas  149 . Feedstock  134  is floated in a gaseous stream. Superheated gas  149  directed at the feedstock  134  forms the gaseous stream and is the preferred matter that is in the gaseous state. 
     Superheated natural gas  149  is directed, see  114  on  FIG. 3 , through the fluidized bed  144 , which converts the feedstock  134  into first volatiles  154  and hydrogen deficient carbon  157 . The hydrogen deficient carbon  157  preferably is activated carbon  156  and what is stated as to activated carbon  156  applies to hydrogen deficient carbon  157 . The temperature needs to be selected in consideration of the feedstock size, since the volatiles  154  should all be released sufficiently fast to activate the carbon. The feedstock  134  should be between 1/16 and ⅝ inches in diameter and preferably the size is between ⅛ and ¼ inches in diameter. This may be referred to as flash heating. The superheated natural gas  149  is clean, and may be natural gas  149  obtained from this disclosed process, herein referred to as recycled. The superheated natural gas  149  may be heated to a temperature between 1000 degrees F. and 1500 degrees F. and preferably is between 1000 degrees and 1200 degrees F. These temperatures are found desirable in that they flash heat the feedstock  134 , driving off the volatiles rapidly e.g., seconds. The rapid vaporization, expansion, of the volatiles  154  activates the carbon. 
     The velocity, see element  116  of  FIG. 3 , of the superheated natural gas  149  is adjusted such that the natural gas  149  is slow enough to leave the feedstock  134  on the fluidized bed  144  and fast enough to remove a mixture of activated carbon  156  and volatiles  154 . The velocity separates the feedstock  134 , activated carbon  156  and volatiles  154  based on density of the material, e.g. less dense material blows away (in a controlled manner). Feedstock  134  is more dense than activated carbon  156 , which is more dense than volatiles  154 . The velocity of the gas flow is thus set to move the less dense material, e.g. mixture of volatiles  154  and activated carbon  156  into a first plenum  152 , allowing the feedstock  134  to remain on the fluidized bed  144  for further processing. The velocity is slow enough so as to not remove the feedstock  134 . As the fluidized bed  144  continues to separate the volatiles  154  from the feedstock  134 , the feedstock  134  converts directly to activated carbon  156  without an intermediary step of charring. The system, devoid of oxygen, does not have partial or complete combustion and thus does not form char or ash. The flow rate depends on the size of the fluidized bed. A very small bed may have a flow rate of 10 cubic feet per minute, while a very large bed may have a rate of 20,000 cubic feet per minute. Desirably, the velocity is between 5500 and 6500 cubic feet per minute and most preferably is approximately 6000 cubic feet per minute. 
     A displacer  182  may be positioned in the chute  184 , perhaps vertically ocsillatable, may be used to adjust the size of the open area that is the fluidized bed  144 . This in turn increases the velocity of the natural gas  149 , assuming the overall flow rate, e.g., volume moved, remains unchanged. The displacer  182  beneficially allows for more efficient carbon removal from the fluidized bed  144  and keeps the fluidized bed  144  cleaner. In practice, a displacer  182  performs with better results than altering the velocity through the use of increased performance from one or more blowers  168 . The preferred blower  168  is as described below in the section titled Description—Blower. 
     The activated carbon  156  and volatiles  154  are co-mingled from the fluidized bed  144  until the vortex separator  158  as will be discussed, see element  118  of  FIG. 3 . The activated carbon  156  in the mixture (or co-mingled collection) of volatiles  154  and activated carbon  156  is allowed to clean the volatiles  154  to form clean natural gas  149  and activated carbon  156 . Harmful compounds, such as mercury, chlorine and sulfur compounds, gather in, are collected by and are stored in the activated carbon  156 . The harmful compounds found in feedstock  134 , commonly coal, are only known to liberate under conditions of combustion or application of a strong acid, neither one of which is found in the present invention. Accordingly, it is believed that harmful compounds do not liberate from the feedstock  134  and remain in the activated carbon  156  never being part of the volatiles  154 . Testing on the current process has not shown any harmful compounds to be in the volatiles  154  and that the volatiles  154  leaving the fluidized bed  144  are clean natural gas  149 . It should be noted that feedstocks  134  may have combustable gases that would be volatiles  154 , but be longer carbon chains than natural gas  149 . Cleaning, however, is allowed to occur to the extent any harmful substances do liberate. Cleaning the volatiles  154  using the activated carbon  156  to form clean natural gas  149  and activated carbon  156 , may start at least as early as when the volatiles  154  and activated carbon  156  are leaving the fluidized bed  144 , with the cleaning process continuing through completion. 
     The activated carbon  156  is separated from the natural gas  149  in a vortex separator  158 , see element  120  of  FIG. 3 . The vortex separator  158  is of the size and manner known to one skilled in the art. The natural gas  149  may be drawn by a blower  168  through a second plenum  162  attached to the vortex separator  158 , while the activated carbon  156  settles out the bottom of the separator  158 . The resultant natural gas  149  is medium BTU natural gas, (1000 Btu/SCF). The activated carbon  156  collected at the bottom of the vortex separator  158  may be cooled, screened, graded/processed and packaged for sale or may remain heated and be used in the second processor  410  as will be described below. The activated carbon  156  ranges in size between a powder to ¼ inch diameter. The activated carbon  156  may be cooled in sealed cooling conveyors. 
     In a step of recycling  122  of  FIG. 3 , a portion, perhaps 10%, of the natural gas  149  may be recycled back to the fluidized bed  144  and a portion, perhaps 5% or less, may go to be recycled to a burner  180  for combustion that is used to superheat the gas for the fluidized bed  144 . The non-recycled portion of the natural gas  149  may be collected as shown in step  124  of  FIG. 3 . Collecting  124  may include cooling, compressing and packaging the natural gas for sale. The activated carbon  156  collected at the bottom of the vortex separator  158  may be packaged for sale as identified in step  126  of  FIG. 3 . 
     Heretofore disclosed is a preferred method of processing feedstock  134  into natural gas  149  and activated carbon  156 . The process is not a burning or partial burning process, but rather a temperature and density based separation process. Hereinafter described is the preferred apparatus  130  in which to carry out the disclosed process. Reference will be made to  FIG. 4 . 
     The processing apparatus  130  may have a feed hopper  136  joined to an airlock system  135 . The airlock system  135  may have a screw auger  138 , a rotary air lock  140 , and a slide gate  142  positioned in a sleeve  142   a  and defining an aperture  142   b . The screw auger  138  draws feedstock  134  from the feed hopper  136  and directs it into the rotary airlock  140 . Turning the rotary airlock  140  drops feed stock  134  into the aperture  142   b  of the slide  142 . Oscillating the slide  142  in the slide  142   a , allows the feedstock  134  to drop through the aperture  142   b  into the chute  184  and to the fluidized bed  144 . 
     Alternative airlock systems  135  known to those of ordinary skill in the art may be used. No air or water is to pass beyond the airlock system  135 . Either lead to combustion, which is not part of the present process. 
     Beyond the airlock  135 , the feedstock  134  reaches the fluidized bed  144 . Typically, a fluidized bed relies on sand or char as the bed through which the gas passes through. The present invention uses a metal grate  146  with small apertures  148  therethrough; the apertures  148  being smaller than the feedstock particles  134 . The natural gas  149 , alternative gases not involving oxygen may also be used, directed through the fluidized bed  144  is superheated to a temperature described above. The natural gas  149  may be directed through one or more bed conduits  151 , the number of which is selected to keep the natural gas  149  moving at an even velocity substantially devoid of dead spots. The velocity, discussed supra, suspends the feedstock  134  and blows the volatiles  154  and activated carbon  156  into a first plenum  152 . The feedstock  134  is positioned on the fluidized bed  144 , while superheated natural gas  149  passes through the fluidized bed  144 . 
     The natural gas  149  passing through the fluidized bed  144  has a velocity. The velocity is adjusted to a point such that the natural gas  149  is slow enough to leave the feedstock  134  on the fluidized bed  144  and fast enough to remove volatiles  154  and activated carbon  156 . As such, the natural gas  149  flow is a separator of feedstock  134  from a mixture of activated carbon  156  and volatiles  154 , such separation occurring on the basis of density. 
     The volatiles  154  and activated carbon  156  are allowed to co-mingle in the first plenum  152  to clean the volatiles  154 , if any harmful compounds have been liberated, into clean natural gas  149 . (Upon testing, no harmful compounds were found to have been liberated at any point during the process and in the apparatus described herein, thus the volatiles  154  were clean natural gas  149 .) The plenum  152  is in fluid communication with the fluidized bed  144 , being a receptor of a mixture of volatiles  154  and activated carbon  156  mixture therefrom. The first plenum  152 , in fluid communication with the fluidized bed  144 , may be positioned at a point elevated above the fluidized bed  144  and be sized and adapted to receive the volatiles  154  and activated carbon  156 . Additional volatiles  154  are allowed to separate from the activated carbon  156  in the first plenum  152  which is maintained at or about the temperature of the fluidized bed  144 . 
     The first plenum  152  empties into a vortex separator  158 , which is a volatile/activated carbon separator  138 . Preferably, the vortex separator  158  is heated to maintain the temperature of the natural gas  149 . The vortex separator  138  separates the volatiles  154  (natural gas  149 ) from the activated carbon  156  based upon gravity. (Note: The volatiles  154 , after co-mingling with activated carbon  156  in the first plenum  152 , is clean natural gas  149  and, after the first plenum  152 , volatiles  154  and natural gas  149  are interchangeable terms.) In essence, the activated carbon  156  falls out an aperture  160  in the bottom of the vortex separator  158 . The volatiles  154  are drawn into a second plenum  162  designed for cooling, compressing, recycling, packaging natural gas as will now be described. 
     The second plenum  162  may include one or more blowers  168  positioned to maintain or adjust the velocity of the natural gas  149 . The second plenum  162  joins to third and fourth plenums  164 , 166  respectively. A portion, perhaps 10%, of the natural gas  149  may be directed through the third plenum  164  to a heat exchanger  170  and back to the fluidized bed  144 . (Insulation  147  may surround the fluidized bed  144  or the entire apparatus  130 .) The heat exchanger  170  superheats the natural gas  149  prior to entry into the fluidized bed  144 . The remaining natural gas  149 , perhaps 90%, is directed into the fourth plenum  166  where it may interact with a heat exchanger  172  for cooling, a low pressure compressor  174  and bulk storage  176 , ready for sale. A gas line  178  may lead from the bulk storage  176  to a burner  180  associated with the heat exchanger  170 . The burner  180  combusts the natural gas  149  and provides heat to the heat exchanger  170 . Post combustion gases, from the burner  180 , may be directed up the stack  150 . 
     The first processor and first process have been disclosed in a manner understandable to those of ordinary skill in the art with reference to figures, which form a part of the disclosure herein, describing the best mode of making and using the present invention as known to the inventor hereof. Those of ordinary skill in the art will discern alterations which may be made without departing from the spirit and scope of the present invention as set forth in the claims below. 
     DETAILED DESCRIPTION 
     Blower 
     The present high temperature blower with environmental seal  210  may include a blower assembly  220 , shaft  242 , motor  246 , housing assembly  260  and seal assembly  280 . These components cooperate to form a blower  210  suitable for operation in high temperature environs where the blower  210  and motor  242  need to operate in separate atmospheres. These components will be discussed in serial fashion. 
     The blower assembly  220  may be any blower assembly known to those skilled in the art. Shown in  FIG. 7  is a top plate  222  (also shown in  FIG. 8 ), a bottom plate  224 , a wrapper  226 , outlet plate  228  and outlet  230 , which cooperate to define a housing  232 . The top plate  222  shown in  FIG. 8  may be the same shape as the bottom plate  224 . The housing  232  defines a chamber  234  in which the fan blades  236  move the gas in a cyclonic motion and direct the gas out through the outlet plate  228 . Thus, gas may enter through an inlet  238 , be accelerated and moved out through the outlet  230  defined in the outlet plate  228 . Inside the housing  232 , may be fan blades  236  and a spider  240 . 
     The shaft  242  joins to the spider  240 , which in turn is joined to the fan blades  236 . The shaft  242  passes through a shaft opening  244  in the bottom plate  224  of the blower assembly  220 , through the housing assembly  260  and the seal assembly  280 , connecting to the motor  246 . The motor  246  turns the shaft  242  thereby effecting movement of the fan blades  236  to direct gas in through the inlet  238  and out through the outlet  230 . Various structural supports  248  may provide support between the blower assembly  220  and the motor  246 . A bearing  250  may stabilize the shaft  242  relative to the motor  246 . The housing assembly  260  is shown joined to the seal assembly  280 , which in turn is joined to the bottom plate  224 . A projection  252  on the seal assembly  280  may project into the blower assembly  220 . 
       FIGS. 9-11  show the housing assembly  260  and seal assembly  280 . As can be seen from  FIGS. 9 and 10  the housing assembly  260  and seal assembly  280  are generally cylindrical, but may include protrusions that allow for bolts or other fasteners to pass therethrough. 
     Turning to  FIG. 11 , the housing assembly  260  may include an outer housing  262 , which serves to encase a bearing  264 . The bearing  264  may further include a bearing sleeve  266  that engages the shaft  242  on a side opposite a ball bearing  268 . A grease port  270  preferably provides fluid communication with the ball bearing  268 . The housing assembly  260  joins to the seal assembly  280  perhaps with fasteners  272 . 
     It should be noted that the housing assembly  260  and seal assembly  280 , being generally cylindrical are generally symmetrical, when looked at in cross section. To increase clarity, only one half of the cross section, e.g. one-quarter of the whole, is shown together with a portion of the shaft  242 . 
     The seal assembly  280  may include a first housing portion  282  and a second housing portion  284  cooperatively define a coolant channel  286 . O-rings  288 , 290 , having differing diameters, provide a seal between the first and second housing portions  282 , 284 . Ports, not shown, are preferred to be on opposite sides of the seal assembly  280 . In this manner, coolant  292  may be directed into the coolant channel  286 , flow around each side of the seal assembly  280  and out an exit port. 
     Positioned between the first and second housings  282 , 284  and the shaft  242  is a sleeve  294 . The sleeve  294 , which adds rotational support, rotates with the shaft  242  and has a collar  296  positioned at one end and inner gland  295  at the other end. The collar  296  is secured via a spacer  297  which may be fastened with at least one bolt  298  to the first housing  282 . The inner gland  295  allows any heated gas that may pass through the shaft opening  244  to be received in a chamber  299 . The chamber  299  is positioned adjacent the first and second housing portions  282 , 284  on a side opposite the coolant channel  286 , thus defining a heat exchanger  300  therebetween. The gas within the chamber  299  remains relatively stagnant as there is no exit port and accordingly remains cooled by the coolant  292 . Unintended exit ports are sealed with o-rings and oil in an outer gland, yet to be described. 
     A rubber o-ring  302 , positioned in the sleeve  294 , prevents gas that passed through the shaft opening  244  from further movement along the shaft  242 . A gasket  304 , preferably formed of graphfoil, prevents gas that passed through the shaft opening  244  from escape around the outside of the first and second housing portions  282 , 284 . Thus, the o-ring  302  and gasket  304  preclude gas that passed through the shaft opening  244  from movement except into the chamber  299 . The seals blocking escape of the gas from the chamber  299  are incorporated into the machined housing  306  for maintaining the sleeve  294 . 
     The machined housing  306  maintains the sleeve  294  in alignment with the shaft  242  and seal assembly  280 . Positioned adjacent the collar  296  is a lip seal  308 . The lip seal  308  can be positioned in a void  310  containing oil  312  as a lubricant and as a seal to keep gas from the blower assembly  220  from escaping the seal assembly  280 . The lip seal  308  rotatably secures one end of the sleeve  294 . The oil  312  acts as a lubricant between parts that remain stationary relative to the seal assembly  280 , such as the lip seal  308 , and the components that rotate with the sleeve  294  as hereinafter described. 
     Moving from right to left,  FIG. 11  shows a pin  314 , which secures a mating ring  316  to the seal assembly  280 . The mating ring  316  is preferred to be formed of silicon carbide for its strength, friction co-efficient and heat bearing properties. An o-ring  318  precludes gas from movement around the mating ring  316  further sealing the chamber  299 . The lip seal  308 , the pin  314 , and the mating ring  316  do not rotate with the sleeve  294  and accordingly are lubricated with oil  312 . 
     Spring  320  is shown biased against and between a retainer  322  and a disc  324 . The disc  324  transfers the force of the spring  320  to a primary ring  326 . The spring  320 , retainer  322 , disc  324 , and primary ring  326  rotate with the sleeve  294  and apply pressure on the sleeve  294  in a direction away from the lip seal  308 , thereby providing secure control of the sleeve  294  as it rotates with the shaft  242 . The point of contact between the primary ring  326  and mating ring  316  is lubricated with oil  312 , since the two rings  326 ,  316  move with respect to each other. The retainer  322  may fasten the primary ring  326  to the sleeve  294 . An o-ring  328  may optionally be provided to further seal gas from the blower assembly  220  from escaping the chamber  299 . 
     As one can discern from reading the above with reference to the figures, heated gas from the blower assembly  220  is effectively sealed in the chamber  299  through various o-rings, gasket  304  and oil  312 . Thus, the gas remains stagnant and does not transfer heat from the blower assembly  220  to the o-rings. The shaft  242 , however, may be thermally conductive and can transfer heat from the blower assembly  220  and a cooling effect from the portion of the shaft  242  adjacent the motor  246  to the seal assembly  280 . Since the o-rings, and in particular o-ring  102  is closer to the blower assembly  220  than the motor  246  it could become heated especially in extreme temperature changes. However, the heat exchanger  300 , transfers heat from the shaft  242  and sleeve  294  to the coolant  292 , maintaining the o-rings, and in particular o-ring  302  at safe operating temperatures. 
     In use, the blower  210  includes the blower assembly  220  and seal assembly  280  joined to the blower assembly  220 . The seal assembly  280  may further include at least one seal, such as o-rings  302 ,  328 , gasket  304  or oil  312  and coolant  292 , the coolant  292  being in thermal communication with at least a portion of the seal. The blower  210  can be positioned in two separate environments. The first environment may have a first temperature and containing a gas of a first type, but not the second type; and the second environment, having a second temperature and containing a gas of a second type, but not the first type. 
     For example, the preferred use of the blower  210  has the blower assembly  220  positioned in the first processor  130  where the temperature is at least 1000 degrees F. and most likely approximately 1200-1500 degrees F. and have a gas being combustible gas. The seal assembly  220  and motor  246  may be positioned in an environment where the temperature is no more than 100 degrees F. and the environmental gas is oxygenated. The shaft  242 , rotatably joining the blower assembly  220  to the motor  246 , may pass through both the first and second environments without the two environments intermixing. The seals preclude the gases from the environments from intermixing and the coolant  292  keeps the two environments at the preferred operating temperatures. (Note, mixing oxygen with the superheated combustible gas could cause undesired combustion and the motor  246  operates better at a temperature preferably at or below 100 degrees F.) 
     The coolant  292 , which desirably is water, could be any thermally conductive flowable material such as anti-freeze and temperature adjusted gases. The coolant  292  may be in thermal communication with the seals, perhaps in a water jacket, such as coolant channel  286 . Alternatively, the seal assembly may have any other heat exchanger  300  in thermal communication with the seals. 
     In operation, the motor  246  rotates the shaft  242 , which rotates the fan blades  236 . The seals, such as such as o-rings  302 ,  328 , gasket  304  or oil  312 , precludes commingling of gas from around the blower assembly  220  with that around the motor  246 . Flowing coolant  292  in thermal communication with the seals maintains a temperature at which the seals do not degrade and remain operable. That is, placing a heat exchanger  300  in thermal communication with the seals keeps the seals at an operable temperature. 
     The blower has been described with reference to the drawings in a manner to fully disclose the best mode of making and using the present invention. Substantive and material changes may be made without departing from the spirit and scope of the present invention. For instance, the blower assembly  220  may be in a super cooled environment, instead of super heated, from which the motor may need to remain removed. 
     DETAILED DESCRIPTION 
     Second Process/Processor 
     The second processor (a fuel processing device)  410  may include generating mechanism  420  and converting mechanism  430 . The converting mechanism  430  may further include reducing mechanism  440 , hydrogenating mechanism  450 , a microwave  460 , a catalyst  470  and a distillation apparatus  480 . A flow chart,  FIG. 12 , is provided to show the various steps in the second process and such process is generally discussed throughout. 
     A suitable microwave  460 , catalyst  470  and distillation apparatus  480  are described in the reference Thermal catalytic depolymerization (Rev. 15) Jan. 20, 2007, Bionic Microfuel Technologies, A.G. Such description is incorporated into this disclosure by reference. Each of these components will be described in serial fashion. 
     The generating mechanism  420 , shown schematically in  FIG. 13 , produces feedstock  222 , which may include activated carbon  424 , char  426 , coal  428  and/or other hydrogen deficient matter. Suitable generating mechanisms  420  include purchase of feedstock  422  on the open market. Production of feedstock  422  in the first processor  130  as described above. Production of feedstock  422  through manners described in the prior art, which is incorporated herein by reference, or manners known to those skilled in the art. 
     The reducing mechanism  440  of the converting mechanism  430  changes the feedstock  422  to a desired percentage of amorphous carbon  442 . The activated carbon  424  is anticipated to be consistent throughout a batch  431  and may range from 100% amorphous to 100% crystalline and everything in between. Together the amorphous carbon  442  and crystalline carbon  444  preferably make up the totality of feedstock  422 , e.g. 100%. The activated carbon  424  may be converted to amorphous carbon  442  allowing more complete hydrogenation. Accordingly, testing apparatus  446  may be provided for determining the percent concentration of amorphous carbon  442  and percent crystalline carbon  444  in a batch  431  of feedstock  422 . Such testing apparatus may be X-ray crystallography, powder diffraction (SDPD) as disclosed in information by such companies as Inel, Rigaku MSC and Bede Scientific Instruments Ltd or performed in any other manner known to those skilled in the art. 
     The crystalline (activated) carbon  444  may need to be decrystallized or depolymerized, which may be done in the microwave  460  described below. Accordingly, the knowledge of percent amorphous carbon  442  versus crystalline carbon  444  may be used to determine the process, dwell time, and energy applied to the crystalline carbon  444  to yield a desired percentage of amorphous carbon  442  with the lowest expenditure of resources. The desired level of amorphous carbon  442  may be 100% or a lesser figure. 
     The reducing mechanism  440  may include the microwave  460  described below or may be heat from any source, chemical depolymerization/decrystallization and/or other manners known to those of ordinary skill in the art of producing amorphous carbon  429 , including oxygen starved superheating. 
     The feedstock  422  has at least a useable portion that is devoid or substantially devoid of hydrogen atoms as is needed in the generation of diesel  490 . Substantially devoid, refers to a deficiency of adequate proportion to preclude full formation of the hydrocarbons in diesel  490 . Accordingly, the hydrogenating mechanism  450  joins hydrogen atoms to carbon atoms, while the carbon is in either a feedstock form  422 , e.g., activated carbon  424 , char  426 , short hydrocarbon chains (natural gas) and/or coal  428  and have either an amorphous carbon  442  or crystalline carbon  444  structure, preferred is amorphous carbon  442 . Such a chemical reaction is endothermic. The hydrogenating mechanism  450  may include a heat source  452  and hydrogen gas or any other suitable hydrogen source  454 . The heat source  452  may take the form of the feedstock  422  being pre-heated to a temperature between 340° F. and 650° F. at any point between and including the generating mechanism  420  and microwave  460  or being heated by the microwave  460 . While the feedstock  422  is heated to a temperature at or above 340° F., the feedstock  422  is subjected to the hydrogen gas  454 . Carbon, hydrogen and combinations thereof are volatile at high temperatures, allowing the hydrogenation. Accordingly, the feedstock  422  may be maintained at a temperature at or below the flash point of carbon, preferably at or below 300 degrees C. and/or maintained in a non-oxygenated atmosphere. 
     For instance, where the generating mechanism  420  is the first processor  130  as described above, the activated carbon  424  in the vortex separator is at an elevated temperature and as such may be subjected to hydrogen  454  in a non-oxygenated atmosphere. As described below, the feedstock  422  in the microwave  460  is held at a sufficiently high temperature, 300° C. or perhaps higher, and may be subjected to hydrogen gas  454  at that point. The preferred point of positioning the hydrogenation mechanism  450  is at the microwave  460 , since the feedstock  422  is reduced to amorphous carbon  442 , rendering higher yields of hydrogenation an ultimately diesel fuel  490 . 
     The microwave  460  operates in conjunction with a catalyst  470  in the presence of feedstock  422  and preferably in the presence of hydrogen gas  454 . Accordingly, the microwave  460  and catalyst  470  is structure and adapted to polymerize hydrocarbons shorter than twelve hydrocarbons, reduce activated carbon  424  to amorphous carbon  442 , hydrogenate activated carbon  424 , char  426  and/or coal  428  while in an amorphous carbon  442  or crystalline carbon  444  structure, and break hydrogenated carbon chains at or around the twelve to fourteen carbon length. The reducing mechanism  440 , hydrogenating mechanism  450  and microwave  460  can be separate units as indicated in  FIG. 13  or be combined into a single unit within the microwave  460 , with the combination being preferred. Through testing, the preferred operational perimeters are: frequency is 2.45 gigahertz, dwell time of one second to ten minutes, based on a preferred particle size of ¼ inch to ⅜ inch. The preferred catalyst  470  is zeolite (alumina-silicate). 
     The polymerization process may include true polymerization processes in which carbon atoms double bonded to other carbon atoms, such as may be found in activated carbon  424 , have the double bond broken creating cites for attachment of another monomer. Polymerization may also include breaking the crystalline structure of activated carbon  424 , rings and the like, temporarily forming elongated hydrocarbon chains of varying lengths, e.g., amorphous carbon  442 . 
     The zeolite catalyst  470  responds to the microwave at a frequency of 2.45 gigahertz. At this point, the zeolite  470  polymerizes the feedstock  422 , forming single bond carbon chains with the otherwise vacant bonding cites. At or above the temperature 250° C. hydrogen atoms from the hydrogen gas  454  join to the vacant bonding cites forming hydrogenated carbon chains. At a second temperature of 350° C., the zeolite  470  generally breaks the carbon chains at the 14 to 16 carbon length. The carbon length is believed to relate to the frequency of the microwave energy. 
     The microwave  460  applies energy to the feedstock  422 , which may be coal  428 , at a temperature at or about 300° C. Essentially, the catalyst  470  forms a temporary bond with the prepared feedstock  422 . The catalyst  470 , with applied energy shakes/vibrates, forming hydrogenated and elongated carbon chains. Eventually, the carbon chains reach such a length that the vibration of the catalyst  470  breaks the carbon chain. Through testing, it has been determined that the vast majority of the carbon chains were between 14 and 16 carbon atoms in length, which is high grade diesel fuel  490 . 
     The microwave  460  does not simultaneously convert all feedstock  422  to diesel  490 . Accordingly, a distillation process may be used to separate the various residue from the diesel  490 . The distillation apparatus  480  may include a condenser  482 , a thermometer  484  and containers  486 . The high temperature feedstock  422  is above the evaporation point coming out of the microwave  460 . The condenser  482  cools the gaseous feedstock  422 . At various temperatures, condensation will form, indicating a quantity of a particular compound. Condensation that forms at 340° F.-650° F. degrees is diesel  490  and is directed to the containers  486 . The distillation apparatus  480  is structured and adapted to separate hydrocarbon chains generally between twelve and fourteen carbons in length. Gases still yet to condense are generally short hydrocarbon chains to be recycled. 
     There are essentially two non-recycled by-products. The first is the desired diesel fuel  490 , which is collected, cooled, packaged and delivered to a point of further distribution or use. The second by-product is residue  488 . The residue  488  may include unreacted activated carbon  424  which maintains the mercuric sulfides and other inorganic compounds, a portion of the catalyst  470  and other inorganic compounds. The residue  488  is collected and disposed of according to lawful standards. Condensation that forms at alternate temperatures is generally shorter length hydrocarbon chains to be recycled back into an electrical generator  492 , which may power the microwave  470 . 
     Example 1 
     A sample was prepared according to the present disclosure. In particular, activated carbon was secured from a first processor  130 . The sample of activated carbon was measured and weighted. Catalyst was added and the sample was transferred to a reactor flask. The flask was placed in a microwave reactor and processed at the desired temperature and dwell time. The resultant distilled diesel fuel had the characteristics that would meet or exceed ASTM D 975 standards. Meeting or exceeding ASTM D975 would allow the diesel fuel to be sold to the public. 
     The second processor  410  has been described with reference to the appended drawings and the best mode of making and using the present invention known at the time of filing. One can see that various modifications can be made without departing from the spirit and scope of the present invention as is set forth in the claims below. 
     CONCLUSION 
     The apparatus  10  and method associated therewith has been fully described above including the first processor  130 , the blower  210  and the second processor  410  together with their respective manners of operation. In combination, these components  130 ,  210 , and  410  process feedstock  12  into diesel fuel  14  and natural gas  16 . Intermediary by-product, including natural gas  16  and activated carbon  18  may optionally be collected in user determined amounts. The description of the apparatus  10  and overall process has been supported by the descriptions of the first processor, the blower and the second processor. 
     The apparatus  10  has been described with reference to the appended drawings and the best mode of making and using the present invention known at the time of filing. One can see that various modifications, some of which have been mentioned can be made without departing from the spirit and scope of the present invention as is set forth in the claims below.