Patent Description:
Plastic conversion vessels, upon heating and having various chemical and physical reactions conducted therein, will inherently expand along the longitudinal length thereof and generally result in a deformed geometry of the vessel. For example, a highly heated region thereof will deform due to stress and temperature differences between the lower and upper surfaces of the vessel. This fact is undesirable in that it interrupts a desired constant or steady flow of waste material in the vessel that is transformed into chemicals, gases, and the like. In other words, the flow path of the waste material, instead of flowing at a constant generally horizontal or in a slightly upward direction, is interrupted such that the efficiency of the vessel is reduced and at times proper product output cannot be achieved. Contraction of the vessel as upon cooling will also produce vessel load or distortion problems. Such heat and stress differences can shorten the useful life of the vessel and potentially lead to failure.

The purpose of the present invention is to provide a smooth, even, and efficient transfer or flow of the waste material along the vessel bottom until it is converted to other materials or compounds. That is, the support system of the present invention is a dynamic operation whereby suspension cables serve to minimize stress along the length (i.e. longitudinally) of the vessel as well as to generally balance stress by increasing or decreasing suspension load at various contact points of the vessel.

In summary, the support mechanisms of the present invention comprise a vessel supported by suspension cables suspended from trollies that can move along the length (longitudinal) of a framework. The support system is such that the waste mass, even upon heating, cooling, etc., can constantly and smoothly move or flow through the entire system, with the vessel generally being in a natural, balanced shape.

In general, a support structure for selectively supporting a vessel, comprises: an overhead frame located above said vessel; a plurality of suspension cables; and one or more trolley devices attached to said overhead frame, said one or more trolley devices, independently, operatively, and movably securing said suspension cable to said overhead framework; at least some of said plurality of said suspension cables being operatively connected to said vessel at various longitudinal locations thereon; and said one or more trolley devices being capable of independently increasing or decreasing said tension on said individual cables.

A process for supporting a vessel from an overhead frame comprising adding a plurality of trolley devices independently to different longitudinal locations on said frame; a plurality of suspension cables, wherein each said suspension cable independently is connected to a different said trolley; operatively connecting said one or more suspension cables each, independently, to a different location on said vessel; and at least one cable adjustment device that increases or decreases the tension, on an individual suspension cable. The claimed invention is indicated in apparatus claim <NUM> as well as process claim <NUM>. Embodiments are indicated in claims <NUM>-<NUM> and <NUM>, <NUM>.

The foregoing and other features of the present disclosure will become apparent to those skilled in the art to which the present disclosure relates upon reading the following description with reference to the accompanying drawings, in which:.

The support structure <NUM> of the present invention generally comprises overhead framework <NUM> located above a plastic conversion vessel <NUM>, and, a suspension system <NUM> having one or more, e.g. a plurality of suspension cables <NUM> for selectively supporting vessel <NUM>. Framework <NUM> can be any conventional overhead framework such as conventional truss <NUM> that provides a strong, sturdy, overhead support in three dimensions. Truss <NUM> contains support rails <NUM> on which ride one or more trolleys <NUM> that have wheels <NUM> thereon. Rails <NUM> are connected to framework <NUM> in any conventional manner as by bolts, fasteners, or welding generally in a longitudinal direction, i.e. along the length of vessel <NUM>. Suspension cables <NUM> are independently, i.e. at least some and preferably all cables are, connected to framework <NUM> by trolleys <NUM>. Trolley wheels <NUM> ride along or on rails <NUM> so that the various suspension cables can be moved forward or backward, that is longitudinally along the length of reactor vessel <NUM>. The trolley <NUM> contains a cable tension adjustment device <NUM> that manually, but preferably automatically, adjusts the tension of any individual cable <NUM> to generally provide means to compensate the tension on the various cables to balance distresses generally on all vessel connection points as well as minimize the stress on vessel <NUM>. An example of a vessel connection point is lower cable fastener <NUM> that is fixed to vessel connection plate <NUM> in any conventional manner such as by welding, bolts, and the like. The cable tension adjustment device can comprise a commercial load reduction or increasing devices known to the art and to the literature. Examples of such tension devices include motorized rack and pinion devices, motorized gear reduction systems, hydraulic cylinders, air pressurized cylinders, motorized lift jacks, and the like.

A preferred tension adjustment device <NUM> is an air bag assembly such as shown in <FIG> wherein the one or more trolleys <NUM> contain an internal lower box <NUM> that resides below rail <NUM>. Air bag <NUM> resides within box <NUM> with the lower end <NUM> thereof that is connected to upper support <NUM> with box top end <NUM> residing within trolly <NUM>. The air bag is impervious to air or other gas, e.g. nitrogen, and thus is made of a rubber, or a flexible material such as polypropylene. Air bag <NUM> is filled with a pressurized gas such as air that can generally range from about <NUM> to about <NUM> psig, desirably from about <NUM> to about <NUM> psig, and preferably from about <NUM> to about <NUM> psig, depending upon the weight of vessel <NUM> as well as suspension cable <NUM> and the various components thereof. Should the load on tension on cable <NUM> be considered to be low, the pressure in air bag <NUM> can be increased so that internal lower box <NUM> is raised and exerts additional tension on suspension cable <NUM>. Conversely, should the load on cable <NUM> be considered to be too great, the air pressure therein can be reduced so that the tension on cable <NUM> is reduced. As noted throughout this specification, a desired aspect of a vessel support system is that generally loads on each cable are similar to the remaining cables to achieve a generally balanced load on all of the cables. That is, the various one or more trolleys, independently (i.e. at least some) and preferably all are capable of increasing or decreasing the tension on a cable.

As shown in <FIG>, upper support <NUM> that can be a flange or tab attached to lower box <NUM> and is also attached to a monitoring load cell or sensor <NUM> that, can be located on said trolley, and desirably, automatically analyzes and monitors the pressure on an individual cable and sends a readout to a control device such as a computer. Thus, the pressure in any one or more individual air bags can be adjusted so that the tension on any one or more sensor load cells is similar to other load cells sensors on any of the remaining cables, as for example, in any given area, or for all said cables. This is accomplished by the computer (not shown), that can be located on framework <NUM> sending a signal to a particular air bag to increase or decrease the pressure therein to thereby raise or lower a portion of the vessel.

The initial tension on cable <NUM> between vessel <NUM> and air bag <NUM> can be adjusted through turn buckle <NUM> or other similar device. Moreover, the top end of suspension cable <NUM> can be attached to load cell or sensor <NUM> in any conventional manner as by welding, use of bolts and u-shaped clamps, or the like to secure the cable end to the load cell, and the like.

Cables <NUM> can be metallic rods, metallic tubes, and the like with a metallic cable, such as steel, made of several strands of flexible steel, being preferred. Flexible cables <NUM> are desired inasmuch as they provide longitudinal movement of vessel <NUM>, as well as perpendicular movement thereof to (i.e. lateral or sideways) with respect to longitudinal axis <NUM>, of vessel <NUM>.

Uneven longitudinal and perpendicular (lateral) loads placed upon the individual cables can be caused by many items including uneven amounts of molten material located within vessel <NUM> along the longitudinal direction of vessel <NUM>, uneven expansion of various portions of vessel <NUM> as due to different heat temperatures of various sections thereof, lateral stresses on vessel <NUM> as caused by strong winds, and the like.

Such longitudinal and lateral movements of vessel <NUM> are readily managed individually, operatively, and moveably by suspension system <NUM>. Thus, the stress on vessel <NUM> at various locations thereof can be minimized, reduced, or abated, or alternatively, where needed, increased or amplified through trolley devices <NUM> and bags <NUM>.

That is, trolley device <NUM> through air bags <NUM> and generally load cells <NUM> balance and/or minimize the load on any particular or plurality of cables and achieve a more balanced load distribution so the pendent vessel retains a reduced stress shape thereby reducing thermal and mechanical stress throughout the vessel and produces a more even flow of molten waste material in vessel <NUM>.

As noted, the bottom or lower ends of at least some of the suspension cables <NUM>, i.e. independently, and preferably all of said cables, are operatively connected to vessel <NUM> at specific, desirably equal, distances along alternating sides of the longitudinal length of vessel <NUM> in any conventional manner known to the art and to the literature. For example, a first connection plate can be attached to the left front side of the vessel, a second connection plate is attached to the right side of the vessel downstream (longitudinally) from the first connection plate, with the remaining connection plates being alternating connected to the vessel so that desirably no such plates are located directly opposite (laterally) to each other along the longitudinal length of the reactor. Such alternative connections serve to adjust for lateral deviations of the vessel.

As noted, a significant purpose of suspension system <NUM> of the present invention is to maintain a balanced support for vessel <NUM> as it changes shape upon heat-up thereof, as well as subsequent cool-down, i.e. termination of operation of the vessel, change in operating temperatures, and the like. Since the bottom of the vessel is heated more than the top portion, it "curves", that is it has a slight bent "U" shape because the bottom expands at a greater distance than the top of the vessel. The vessel support system of the present invention through load sensor <NUM> reacts to achieve a balanced system whereby the load on the various cables are minimized and/or the cable length is increased or decreased so that the geometric shape of the cylindrical vessel bottom, while not being exactly linear, typically is modestly bent toward its natural original shape so that essentially an even flow rate of a semi-molten waste material as well as the melted waste material therein is maintained. Also, the one or more trolleys, individually and separately, can move on rail <NUM> either forward along the feed direction (longitudinal) of vessel <NUM>, or backward thereto to generally maintain the cable in a vertical position and to achieve and/or maintain a natural, approximate, linear shape of the vessel such as the bottom thereof. For example, the loads on the various individual cables, individually and operatively, often are greater at the vessel feed entrance since generally only a small portion of the waste material has evaporated. Movement of the trolleys can thus further adjust the load on the cables located at the feed entrance to provide a more linear flow of the waste material as well as an even flow rate thereof. Thus, efficient thermal and chemical conversion of the waste material are obtained.

However, in some instances, a general balanced load of all of the cables cannot be obtained. For example, due to influx of the waste feed stream <NUM> into vessel <NUM> at one end thereof, the tensions on said cables tend to be higher. In this situation the number of suspension cables <NUM> can, and should be, increased so that the additional load upon any given area of cables in vessel tank <NUM> is equally supported by the original as well as the additional cables in said any given area. That is, the load (i.e. weight) on each of the cables, as in the waste feed stream area <NUM>, desirably is substantially the same. By the term "substantially", it is meant that the difference between a cable having a highest tension thereon or the lowest tension thereon is within about <NUM> or about <NUM> or desirably within about <NUM> wt. % of a preferred average cable tension supporting said vessel.

Plastic conversion vessel <NUM> can generally be any chemical vessel known to the art and to the literature, such as a pyrolytic vessel that is essentially free of oxygen as contained in air. That is, the amount of any oxygen within the free volume of vessel <NUM> is generally less than <NUM>% by volume, desirably less than about <NUM>% by volume, preferably at least <NUM>% by volume, and very preferred, nil, that is free of any air or oxygen. Free volume is defined by the vapor space within vessel <NUM> other than the molten mass of waste material therein. A preferred plastic conversion vessel is set forth in <CIT>, granted to RES Polyflow LLC and is hereby fully incorporated by reference including all aspects thereof. However, it is to be understood that many other types of vessels can exist.

Vessel <NUM> contains shroud <NUM> that is located substantially around the entire circumference of vessel <NUM>. A plurality of inner walls <NUM> connect shroud <NUM> of vessel <NUM> and form heating zones and/or reaction zones within the vessel. Heat is supplied to the vessel via standard or conventional heating units <NUM> that generally exist within each section of the vessel that is separated by inner wall <NUM>. The heat thus generally travels around the circumference of the generally cylindrical vessel <NUM> and exits therefrom through heat exhaust channels (not shown) at the top of the vessel. The heat in the different sections of vessel <NUM> generally volatize waste material <NUM> with the gases generated therefrom egressing from the vessel through product exhaust channels, not shown, where they are fed to a condensation unit, not shown, form many different types of products. Preferred products include various types of petroleum products such as naphtha, distillate such as diesel, jet fuel, gas oil such as heavy oil, wax, catalytic cracker feed, steam cracker feed, and the like.

A preferred thermal and chemical conversion vessel <NUM> contains a feedstock that comprises one or more plastic polymers, or hydrocarbonaceous waste materials <NUM>, or any combination thereof. Such waste material can generally be in any shape or form such as pellets, shredded material, and the like. Waste material <NUM> is obtained from many sources such as plastic bottles, containers, sheeting, furniture, bags, polymer scrap and the like. Such waste material is fed via waste feed stream <NUM> to vessel input <NUM> and subsequently heated to cause various chemical reaction including pyrolytic reactions. As set forth in <CIT>, the vessel has different heating zones that serve to propagate many reactions such as cracking, recombination, reforming, recracking, and the like, and form aliphatic and aromatic compounds. The vessel is generally heated as by hot air, steam, radiant heat, oil, or electric heat to high temperatures so that a substantial amount of chemical compounds thermally or chemically converted are in the form of a gas that exits the vessel through one or a plurality of product exhaust vents, such as one vent in each heating zone, not shown. Since the waste material fed to vessel <NUM>, via waste transfer device <NUM>, often contains inert matter such as various fillers, pigments, reinforcement materials, clay, silica, alumina, talc, glass, and the like, they generally remain within vessel <NUM> and by the means of helical screw <NUM> located within the vessel are removed through vessel discharge unit <NUM>.

Desirably, as noted, the waste stream fed to vessel <NUM> can be one or more polymers, and/or hydrocarbonaceous material. Examples of preferred waste material polymers that essentially contain only hydrogen and carbon atoms include polyethylene, high density polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, polybutylene, polystyrene, and the like. Other suitable commercial polymers include polyesters, polyvinylchlorides, polycarbonates, polymethyl methacrylates, nylons, acrylonitrile-butadiene-styrene (ABS) copolymers, polyurethanes, polyethers, poly(oxides), poly(sulfides), polyarylates, polyetherketones, polyetherimides, polysulfones, polyvinyl alcohols; and polymers formed by polymerization of dienes, vinyl esters, acrylates, acrylonitrile, methacrylates, methacrylonitrile, diacids, diols, or lactones, or any combination thereof. Still other polymers include block copolymers of the preceding, and alloys thereof. Polymer materials can also include thermoset polymers such as, for example, epoxy resins, phenolic resins, melamine resins, alkyd resins, vinyl ester resins, crosslinked polyester resins, crosslinked polyurethanes; and also crosslinked elastomers, including but not limited to, polyisoprene, polybutadiene, styrene-butadiene, styrene-isoprene, ethylenepropylene-diene, and blends thereof.

Examples of hydrocarbonaceous materials include various bitumens including bitumen tailings as from a mine, various heavy fractions of a fractionating column that include various heavy oils, greases, semi-asphalt compounds, and the like that by the present invention, are reduced to lighter components, and are mostly various types of hydrocarbon-containing gases.

Biopolymers, that is biomaterials that are sustainable, carbon neutral or renewable because they are made from plant materials which can be grown indefinitely, are not utilized. Examples of such biopolymers include, but are not limited to, polylactic acid (PLA) and polyhydroxyalkanoate (PHA) that are used in multi-layer sheet for food packaging applications, agricultural films, industrial equipment wrapping films and the like. Other biopolymers include polybutylene succinate-co-adipate (PBSA), polybutylene sebacate-co-terephthalate (PBST), and polybutylene adipate-co-terephthalate (PBAT). Still other examples of biopolymers include rubber, suberin, melanin and lignin. If utilized, the feedstock in the reactor at any given point in time based upon the weight of the biopolymer and the feedstock, is essentially free thereof. That is, generally is less than about <NUM> wt. %, desirably less than about <NUM> wt. %, and preferably, nil, that is no amount of biopolymer, in said feedstock.

With respect to start up or initiation of vessel <NUM> to pyrolyze plastic or hydrocarbonaceous waste materials, the vessel is heated and since, as noted above, the bottom portion thereof and generally the central bottom portion thereof expands more than other portions of the vessel, the vessel will deform. The same introduces added stress on the suspension cables located in the vicinity of the deformed central vessel portion. In order to compensate for the same, sensors or load cells <NUM> of the stressed suspension cables will record an increase in the stress above a normal load and send a message to a computer. Upon sensing higher stress on the noted suspension cables, a control device such as a computer (not shown) will send a signal to trolley <NUM> to reduce the air pressure in air bag <NUM> thereby causing cable tension adjustment device <NUM> to reduce the load thereon as by increasing the distance to the vessel. The combined load cells of the support system will also provide a precise weight of the vessel so that the accumulation of material or excess material fed to the vessel can be continuously monitored. When needed, for example when excess waste material is added, the feed rate can be adjusted, as by reducing or increasing the same to maintain a desired weight of material within the vessel. The response to these and to other situations result in generally a balanced load on the various suspension cables such that the rate of waste material equilibrates to a steady state condition with only slight variation therefrom. In other words, a smooth, generally even, and efficient transfer of waste material <NUM> is achieved as it progressed through vessel <NUM>. The result is a maximum efficiency of the use of the vessel with regard to converting waste material to suitable end use products such as naphtha, gas oil, diesel fuels, and the like that are produced and the problem of proper disposal of such waste material is improved whereby reduced ecological harm to planet Earth is achieved.

Claim 1:
A support structure (<NUM>) for selectively supporting a vessel (<NUM>), the vessel comprising a plastic feedstock conversion vessel or pyrolytic reactor, comprising:
an overhead frame (<NUM>) located above said vessel (<NUM>);
a plurality of suspension cables (<NUM>); and
a plurality of trolley devices (<NUM>) attached to said overhead frame (<NUM>) so that they are longitudinally movable along a length of the overhead frame (<NUM>), each of said plurality of trolley devices (<NUM>), independently, operatively, and movably securing at least one of said suspension cables (<NUM>) to said overhead frame (<NUM>); at least some of said plurality of said suspension cables (<NUM>) being operatively and independently connected to said vessel (<NUM>) at various longitudinal locations thereon; and said plurality of trolley devices (<NUM>) being capable of independently increasing or decreasing tension on said individual cables (<NUM>).