Patent Description:
The invention has been developed primarily for use in pyrolysing and combustion, waste material, in particular, hydrocarbon-containing waste material for the production of electricity and other commodities or coal for the production of electricity or natural gas or silica and calcium carbonate and coal for the manufacture of cement. These inputs yield flue gases comprising products that can be used as commodities to offset the associated costs of the pyrolysis method with combustion, while the remainder of the flue gases is rendered carbon neutral for the environmentally safe disposal thereof, and will be described hereinafter with reference to this application. However it will be appreciated that the invention is applicable in broader contexts.

The following discussion of the background to the invention is intended to facilitate an understanding of the invention.

The disposal of hydrocarbon-containing waste material HC, is fraught with many problems, conventional methods of disposing C0<NUM>, CO and all hydrocarbons of such waste material typically involve either burning the waste material in a furnace or burying it in a landfill site. In either case, the waste material degrades, resulting in the formation of highly toxic compounds that pollute the environment. Such pollutants often leach into the groundwater, the atmosphere and ultimately lead to the contamination of the food chain.

Coal/Natural Gas: The disposal of hydrocarbons and toxins given by coal fire power stations or gas fired power stations is also problematic. In conventional methods the disposal of CO<NUM>, CO and toxins in coal or gas typically involves burning the coal or natural gas in a furnace or turbine to generate electricity. Regarding coal, roughly half the ash is recycled, and the other half is placed in landfill sites. Toxins from the landfill ash are released in the environment. Such pollutants often leach into the groundwater, the atmosphere and ultimately leading to contamination of the food chain. Regarding electricity production from natural gas, toxins are released into the atmosphere, such us CO and CO<NUM>.

Cement: The disposal of the hydrocarbons from coal generated in the manufacturing of cement also comes with many problems. In conventional methods for the disposal of CO<NUM>, CO and toxins in cement manufacturing involves burning the coal in a furnace to manufacture cement. Half the ash is recycled and the other is placed in land sites, leading to toxin and pollutant release problems as mentioned above.

The present invention seeks to provide an apparatus and method for pyrolysing with combustion, a material such as waste material, coal, natural gas, silica and/or calcium carbonate. This process may provide for the manufacture of cement. This methodology will overcome or substantially improve at the majority of the deficiencies of the prior art, or to at least provide an alternative.

Publication <CIT> discloses a pyrolysis gasification furnace for garbage disposal comprising a rack, a furnace body, a furnace hearth, a secondary combustion chamber and a driving unit. The top of the furnace body is provided with a feeding port and a flue gas outlet, the bottom of the furnace body is provided with a slab outlet, and the side wall of the furnace body is provided with a plurality of furnace doors and a plurality of observation holes.

Publication <CIT> discloses a refuse incinerator capable of extinguishing smoke and odor of exhaust gas emitted from combustion of the refuse just after incineration of the refuse is started, wherein exhaust gas emitted into an exhaust gas chamber is introduced into a combustion chamber and burnt so as to extinguish the smoke and odor.

Publication <CIT> discloses waste disposal equipment, wherein hydrogen and oxygen is mixed to a gas that is upwardly and obliquely jetted from nozzles of gas burners toward central part and ignited.

According to a first aspect of the present invention there is provided an apparatus for pyrolysing and combusting a material, the apparatus comprising:.

The pyrolised gases from the pyrolysis crucible(s) are mixed and injected into the heating tubes in the presence of hydroxy gas for pyrolysis and combustion. The methodology and design for the treatment of natural gas requires an apparatus that does not require crucibles.

Preferably, the material received within the crucible is pyrolysed and combusted using the heat generated within the or each heating tube during pyrolysis and combustion of the byproduct by the heating tubes.

For the manufacture of cement utilising our method and our apparatus for pyrolysis and combustion of a material, we require two crucibles, a crucible with around <NUM>% silica and around <NUM>% calcium carbonate and a separate crucible with around <NUM>% coal to make one tonne of cement. No emissions of CO and CO<NUM> are releases into the atmosphere utilising our methodology.

According to the invention, the gas is oxyhydrogen, which is hydroxy gas.

Preferably, the electronic ignition device may include a high voltage and high temperature spark plug, or glow plug but not excluding other designs. The electronic ignition device may be electrically connected to the or each heating tube to ignite the gas within said heating tube. In addition, a mechanical device is incorporated at the appropriate distance from the output of the injectors of the mixing cavity, required for the replacement of the electronic ignition device because of the carbon build-up over time or ultrasonic removal of the carbon black.

In some embodiments, the electronic ignition device includes:.

The mechanised delivery system may include a magazine of replacement spark plugs. The mechanised delivery system may include an ultrasonic cleaning device for cleaning dirty spark plugs.

Preferably, the or each heating tube is adapted to generate and/or support temperatures across the range of <NUM> degrees Celsius to <NUM>,<NUM> degrees Celsius during pyrolysis and combustion of the byproduct(s). Preferably, the temperature generated within the or each heating tube during pyrolysis and combustion of the by-product(s) is up to <NUM>,<NUM> degrees Celsius. This is caused by the mixture of the hydroxy gas and the by-products being pyrolysed and combusted. The hydroxy gas does not have the capacity to melt tungsten but make it white hot. The melting point of tungsten is <NUM>,<NUM> degrees Celsius and the boiling point is <NUM>,<NUM> degrees Celsius. The temperatures are kept in a controlled environment within the heating tubes up to <NUM> degrees Celsius. In some embodiments, the heating tubes may be adapted to support pyrolysis and combustion in ranges such as <NUM> to <NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius or any range or sub range therebetween.

Preferably, the temperature generated within the chamber and the crucible can extend up to <NUM>,<NUM> degrees Celsius. In some embodiments, the crucibles may be adapted to support pyrolysis and combustion in ranges such as <NUM> to <NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius, <NUM>-<NUM> degrees Celsius or any range or sub range therebetween.

Preferably, the apparatus further comprises a housing with an opening configured to receive and mount the agitating crucible there within the cavity/cham ber.

Preferably, the or each heating tube is mounted within a housing cavity of the housing. Suitably, the or each heating tube is mounted within the internal and external wall of the housing. The outside wall of the housing , the lid and the seals on the internal wall of the housing. In some embodiments, the chamber includes refractory brick insulation to maintain the heat internally.

In one embodiment, the one or more heating tubes comprise a plurality of heating tubes mounted within the housing. Preferably, the apparatus comprises an array of heating tubes disposed around the one or more crucibles Preferably, the heating tubes are spaced apart arranged around the perimeter of the crucible. The heating tubes may be configured in multiple arrays and placed within housing cavity. In some embodiments, the one or more heating tubes comprise a plurality of heating tubes mounted within the housing and disposed in spaced apart arrangement within the housing around a chamber conducting the heat to the crucible.

Preferably, the apparatus further comprises a lid that is configured to seal, to engage the opening of the housing, to enclose the chamber. The lid preferably seals the chamber and the crucible. Preferably, there is a clearance between the crucible and the lid so that the crucible can be agitated within the chamber.

Preferably, the apparatus further comprises a conduit that extends substantially through the lid. The conduit may also extend through the refractory brick work insulation and the opening of the chamber. Preferably, each heating tube has a corresponding mixing cavity. The gases are mixed with hydroxy gas and are injected into the heating tubes via injectors. The number of heating tubes is not restricted by this design. The number of injectors in the system is preferably the same number of heating tubes in the system. In some embodiments, the conduit comprises one or more holes to allow gases to escape upwards.

Preferably, the conduit facilitates the flow of gases and vaporised hydrocarbons to the mixing cavities of the heating tubes. In some embodiments, the apparatus further comprises an overflow reservoir in communication with the conduit to regulate the flow of flue gases from the crucible. Any overflow liquids and gases may redirected via PLC ultrasonic control flow meters/sensor to the reservoir with electrical vaporiser, via the conduit. This redirection facilitates overflow when necessary to one or more of the mixing cavities. If no overflow, the gases go directly to all the mixing cavities. The number of heating tubes is not restricted by this design.

Preferably, the apparatus further comprises a magnetic drive mechanism that is configured to agitate the crucible. Preferably the magnetic drive mechanism is located within the housing.

In one embodiment, the or each heating tube is manufactured from tungsten or tungsten-molybdenum alloy, or a graphite tungsten or aluminium alloy or ceramic tungsten or any other tungsten compound for high temperature application, up to <NUM> degrees Celsius.

In one embodiment, the material processed by the system is a hydrocarbon containing material or coal or natural gas and all waste material or silica and calcium carbonate for the manufacture of cement.

In one embodiment the material processed by the system is waste material, or coal or natural gas or silica and calcium carbonate with coal for the manufacture of cement.

Preferably, the hydrocarbon containing material is selected from the group consisting of biomass, natural or synthetic rubber-based products, natural gas, town gas, domestic waste, medical waste, industrial waste, and any mixture thereof.

Preferably, these by-product(s) are produced via pyrolysis and combustion within the pyrolysis within the crucibles. It is expected a minuscule level of oxygen within the material within the crucibles. These are hydrocarbon containing material selected from the group consisting of vaporized hydrocarbon(s), water, coal, town gas, propane (CsHs), natural gas (methane), ethane (C<NUM>H<NUM>), carbon char, hydrogen, carbon monoxide, carbon dioxide, oxygen, nitrogen, nitrous oxide, ash, and any mixture thereof.

Suitably, the gas is supplied from a gas supply device to the or each heating tube. Preferably the gas is supplied at a pressure that this up to <NUM> kPa or <NUM> PSI.

In one embodiment, the or each heating tube is manufactured from tungsten, tungsten-molybdenum alloy, or a graphite tungsten aluminium alloy.

In one embodiment, the materials are hydrocarbon containing materials.

Preferably, the hydrocarbon containing material is selected from the group consisting of biomass, natural or synthetic rubber-based products, natural gas, town gas, domestic waste, medical waste, industrial waste, sewage, and any mixture thereof.

Preferably, the by-product(s) produced via combustion of the hydrocarbon containing material within the crucibles selected from the group consisting of vaporized hydrocarbon(s), water, carbon char, hydrogen, carbon monoxide, carbon dioxide, oxygen, nitrogen, nitrous oxide, ash and any mixture thereof.

Preferably, the material received within the crucibles is pyrolysed and combusted using the heat generated by the or each heating tube during the ongoing pyrolysis and combustion of the by-products in gaseous form or vaporised form premixed with the hydroxy gas. This is preferably achieved within the mixing chamber and the mixing cavity enclosure.

Preferably, the temperature generated within crucibles is up to <NUM> degrees Celsius.

The hydroxy gas safely produces high temperatures, that may go up to <NUM>,<NUM> degrees. During the pyrolysis process, the hydroxy gas is acting like a plasma stream. The generated hydroxy gas is able to penetrate through any refractory material in a matter of seconds. The generation of such high temperatures is due to the phenomenon that hydroxy has a surplus number of electrons. The mix of HHO, on the flame front, is stoichiometry of the ratio <NUM>:<NUM> Hydrogen to Oxygen. On combustion, HHO produces high temperatures and H<NUM>O (steam). H<NUM>O can be recycled within the system. See reference <NUM> below.

The gas is preferably supplied from the hydroxy gas supply device <NUM> to the or each heating tubes, at a pressure that falls within a range of <NUM> kPa up to <NUM> kPa.

The gas supply device preferably comprises a hydroxy electrolytic tube for electrolytically generating said oxyhydrogen, hydroxy gas. This tube is preferably self-pressurised. Preferably, the hydroxy electrolytic tube utilises water and produces hydroxy gas which is oxygen and hydrogen together. In some embodiments, within the hydroxy electrolytic tube, one litre of water produces <NUM>,<NUM> litres of hydroxy gas which becomes self-pressurising. Preferably the hydroxy gas has an operating pressure of up to <NUM> kpa. In some embodiments, the hydroxy electrolytic tube consumes about <NUM> kWh to produce <NUM>,<NUM> litres of hydroxy gas at NTP.

Suitably, the hydroxy electrolytic cell within the hydroxy electrolytic tube, comprises of multiple pairs of plate electrodes, fully immersed in an electrolyte solution in a spaced apart arrangement. In some embodiments, the electrolytic tube comprises one or more electrolytic cells that each comprise a pair of plate electrodes fully immersed in an electrolyte solution in spaced apart arrangement.

Suitably, the multiple pairs of plate electrodes are electrically connected to a corresponding pair of terminals of an electrical power supply.

In one embodiment, the electrolyte solution is in the form of an aqueous solution of a metal hydroxide. The electrolyte solution may be sodium hydroxide or potassium hydroxide. This is required to increase the conductivity of water and consequently generate hydroxy gas.

Suitably, the metal hydroxide is selected from the group consisting of sodium hydroxide or/and potassium hydroxide.

In one embodiment, the material received within the crucible is a hydrocarbon containing material.

Preferably, the hydrocarbon containing material is selected from the group consisting of biomass, natural or synthetic rubber-based products, natural gas, town gas, domestic waste, medical waste, industrial waste, sewage and any mixture thereof.

Preferably, the byproduct(s) produced via combustion of the hydrocarbon containing material within the crucibles is selected from the group consisting of vaporized hydrocarbon(s), water, carbon char, hydrogen, carbon monoxide, carbon dioxide, oxygen, nitrogen, nitrous oxide, ash, and any mixture thereof.

Preferably, the system further comprises an electrical power supply, electrically connected to each of the apparatus and system and the gas supply device for supplying electrical power thereto.

In some embodiments, the system further comprises one or more air cooled heat exchangers configured to receive flue gas from one or more of the heating tubes. The system preferably further comprises one or more flue gas pumps for receiving flue gas from the one or more air cooled heat exchangers. The system preferably further comprises one or more cyclonic separators configured to receive flue gas from the one or more flue gas pumps to separate particles from the flue gas.

In some embodiments, the system comprises an array of heating tubes disposed circumferentially around the crucible(s).

In one embodiment, the system comprises:.

In some embodiments, the system comprises <NUM> vertically disposed stacks of arrays of <NUM> circumferentially disposed heating tubes. In other embodiments, the system or apparatus includes other combinations of vertically stacked arrays of heating tubes. Each array may include between <NUM> and <NUM> heating tubes.

The system may further comprise a density separation scraper module to perform a density separation process on flue gasses with the housing.

Preferably, during the pyrolysis and combustion in the one or more heating tubes, an amount of hydrogen, CO<NUM> and CO is reduced, and an amount of N<NUM>O and O<NUM> is increased.

It is to be understood that the following description is for the purpose of describing particular embodiments only and is not intended to be limiting with respect to the above description.

The present invention relates to an apparatus and a method for pyrolysing and combusting a material. By way of example, the material may be a hydrocarbon-based waste material. A range of different materials that can be pyrolysed and combusted by the invention are described herein. However, it will be appreciated that the invention is suitable for pyrolysing and combusting various other materials. The invention is capable of pyrolysing and combusting the material at high temperatures to the point whereby the resulting flue gases produced can be subject to cryogenic or membrane separation methods to yield products that can be utilised as commodities for mitigating some of the costs associated with the pyrolysis method. At the same time, some or all of the remainder of the flue gases are rendered carbon neutral and inert and can be vented to the atmosphere without fear of polluting the environment.

<FIG> and <FIG> show schematic representations of an apparatus <NUM> according to preferred embodiments of the present invention. <FIG> illustrate a first embodiment apparatus 10A, while <FIG> illustrate further embodiments 10B-E. <FIG> illustrate overall systems 300A-F which incorporate the embodiments of apparatus <NUM>.

Specifically, as shown in <FIG> and <FIG>, the apparatus <NUM> comprises a housing <NUM> defined by a generally circular base <NUM> and a double-wall, as defined by an external wall <NUM> and an internal wall <NUM>, upstanding from the base <NUM> to define a cavity <NUM>. As shown in <FIG>, the top of this cavity <NUM> can be sealed by a generally circular lid <NUM> such that argon gas is contained within the cavity. Argon is a thermal working gas that can be recycled, and it protects all components from corrosion. Housing <NUM> and lid <NUM> collectively define a chamber <NUM> in which pyrolysation and combustion can occur. Mounted within the chamber <NUM> is a heating crucible <NUM>. Crucible <NUM> is defined by a generally circular base <NUM>, which includes or is formed of a magnetic material, and a wall <NUM> upstanding from the base <NUM> to define an open-topped crucible <NUM> within the chamber cavity <NUM>. The crucible <NUM> is rotatable <NUM> degrees about a central vertically disposed axis in both a forward and backward direction during an agitation process within the chamber <NUM>. The crucible is mounted within chamber <NUM> and has a diameter smaller than that of internal wall <NUM> of housing <NUM> so as to define a gap <NUM>, as best shown in <FIG>.

Crucible <NUM> is preferably formed of a material capable of maintaining strength at temperatures at or above <NUM> degrees Celsius. Suitable materials include tungsten, tungsten carbide or <NUM> stainless steel. The material used to form crucible <NUM>, or at least base <NUM>, should be magnetic so as to facilitate magnetic agitation as described below.

Within gap <NUM>, a series of side rollers <NUM>-<NUM> and a series of bottom rollers 90A-95A are disposed to allow the crucible <NUM> to be rotate relative to housing <NUM> and be agitated about a longitudinal axis of the housing <NUM> in use. Side rollers <NUM>-<NUM> are rotatably mounted to internal wall <NUM> of housing <NUM> while bottom rollers 90A-95A are rotatably mounted to base <NUM>. In the illustrated embodiments, apparatus <NUM> includes six circumferentially disposed side rollers <NUM>-<NUM> and six bottom rollers 90A-95A. However, it will be appreciated that different numbers and configurations of side and bottom rollers may be implemented in different embodiments. A magnetic plate <NUM> is attached to or embedded within the base <NUM> of cavity <NUM> inside the housing <NUM> to facilitate magnetic agitation as described below.

<FIG> illustrate alternate embodiments of apparatus <NUM> and apparatus 10C of <FIG> incorporates two crucibles <NUM> and <NUM>. The apparatus 10D illustrated in <FIG> includes no heating crucible.

It will be appreciated that the housing <NUM> and the crucible(s) <NUM>-<NUM> are both manufactured from a suitable material that can withstand high temperatures such as tungsten, tungsten carbide or <NUM> stainless steel.

As will be described in further detail later in the description, the crucibles <NUM>-<NUM> are configured for receiving a range of different materials to be pyrolysed and combusted and the design of apparatus <NUM> may vary depending on the intended material(s) to be processed. By way of example, embodiments of apparatus <NUM> may be adapted to process a waste material or coal or silica and calcium carbonate (for the manufacture of cement), or contaminated soil/toxic waste or natural gas, to be pyrolysed and combusted therein. The different processes involved in the processing of these different materials are illustrated schematically in <FIG>. <FIG> illustrates a system for the treatment of cement, while <FIG> illustrates a system for the treatment of sewage. Only cement, sewage, toxic waste treatments require, in the current embodiments, two crucibles. A single crucible is required for the treatment of waste and for the treatment of coal, such as in a coal fire power station. An apparatus having no crucible may be used for the processing of natural gas.

To seal chamber <NUM>, lid <NUM> engages an upper portion of housing <NUM>, so as to enclose the crucibles <NUM>-<NUM> and sealing gap <NUM> using housing <NUM>. A suitable sealing mechanism (not illustrated) such as clamps or locking mechanisms may be employed in the sealing process. In a preferred embodiment, lid <NUM> is manufactured from a high temperature material such as tungsten, tungsten-molybdenum alloy or similar materials able to withstand high temperatures. For improved thermal insulation, lid <NUM> may be insulated with refractory brick work as shown in <FIG> and <FIG>. Lid <NUM> should be designed so to seal tightly and not allow waste, liquids, and flue gases to escape or enter gap <NUM>, which may cause damage to or clog rollers <NUM>-<NUM> and 90A-95A. At the same time, lid <NUM> should maintain clearance to allow the crucible(s) <NUM> and <NUM> to be agitated. With more efficient agitation and sealing within the apparatus, the gases will be formed faster and will flow upwards so that the waste material is pyrolysed quicker.

The apparatus <NUM> further comprises a plurality of circumferentially positioned heating tubes <NUM>-<NUM> located inside housing <NUM> and within cavity <NUM>. As shown in apparatus 10B and 10C of <FIG> and <FIG>, this circumferential configuration may be repeated up to fifteen times <NUM>-<NUM>/<NUM>-<NUM> with up to fifteen vertically disposed arrays or stacks of circumferential heating tubes. In other embodiments not described herein, more than <NUM> circumferential arrays of heating tubes may be used.

As best shown in <FIG>, the heating tubes <NUM>-<NUM> of each array are disposed circumferentially inside the housing <NUM> in a spaced apart arrangement between external wall <NUM> and internal wall <NUM>. As will become apparent from the description below, the spaced apart arrangement of heating tubes <NUM>-<NUM> ensures that the waste material received within the crucibles <NUM>-<NUM> can be heated by the heating tubes <NUM>-<NUM> in a uniform manner. The space enclosed by the external wall <NUM> and the internal wall <NUM>, and thus surrounding each of the heating tubes <NUM>-<NUM>, is shrouded in an inert gas such as argon <NUM>. The argon <NUM> serves to protect the heating tubes <NUM>-<NUM> from undergoing oxidation as a result of the high temperatures that may be produced during the pyrolysis and combustion process described in more detail below.

<FIG> illustrates the inside of cavity <NUM> and gap <NUM> showing example positioning of heating tubes <NUM>-<NUM> and side rollers <NUM>-<NUM>. A similar layout occurs for crucible <NUM> illustrated in <FIG>. Within cavity <NUM>, the twelve heating tubes <NUM>-<NUM> are positioned, spaced at substantially equal circumferential intervals. Within gap <NUM>, six rollers <NUM>-<NUM> are spaced at substantially equal intervals inside this cavity. As mentioned above, in some configurations of the apparatus <NUM>, such as apparatus 10B and 10C illustrated in <FIG> and <FIG>, fifteen levels/arrays of heating tubes are provided, each having twelve tubes per level. In this configuration of the apparatus <NUM>, three levels/arrays of side rollers are utilised, each having six side rollers per level.

It will be appreciated by persons skilled in the relevant art, that the number of heating tubes <NUM>-<NUM> is not limited to the twelve heating tubes <NUM>-<NUM> shown in the figures, but may include a greater or lesser number of heating tubes depending on the system requirements. Furthermore, it will be appreciated that other combinations of rollers and other components are possible.

In a preferred embodiment, the heating tubes <NUM>-<NUM> are manufactured from tungsten. In other embodiments, the heating tubes <NUM>-<NUM> may be manufactured from other materials such as tungsten-molybdenum alloy or ceramic tungsten or a graphite tungsten aluminum alloy or any other tungsten alloy.

Located at the base of each of the plurality of heating tubes <NUM>-<NUM> is a corresponding mixing chamber, as indicated by the reference numerals 100A -210A in <FIG>, <FIG>, and <FIG> in respect of corresponding heating tubes <NUM>-<NUM>. Although only two mixing chambers are illustrated, it will be appreciated that each of the twelve heating tubes include a corresponding mixing chamber. The number of heating tubes is not restricted by this design. Mixing chambers 100A-210A are preferably connected to their corresponding heating tubes by way of compression fitting and formed of similar materials to that of the heating tubes.

As illustrated in <FIG>, each of the mixing chamber enclosures define a respective corresponding internal mixing cavity, designated by numerals 100B-210B. These mixing cavities provide space for the gases to be mixed before progressing to the respective heating tubes <NUM>-<NUM>. Each mixing chamber includes a corresponding injector <NUM> having a nozzle and injector magazine <NUM> for injecting mixed gasses into heating tubes <NUM>-<NUM>.

In addition to generating heat for pyrolysing or combusting material within the crucibles <NUM> and <NUM>, the plurality of heating tubes <NUM>-<NUM> are also configured for receiving, via one or both of conduits <NUM> and <NUM>, from an overflow reservoir <NUM>, one or more byproduct(s) produced as a result of the pyrolysis and combustion of the material. In operation, the heating tubes <NUM>-<NUM> are capable of pyrolysing and combusting the one or more byproduct(s) in conjunction with the primary pyrolysis and combustion of the material in the crucibles <NUM> and <NUM>. <FIG> illustrate systems in which a range of materials that can be processed by the crucibles and in turn the heating tubes. These include waste products as shown in <FIG>, coal as shown in <FIG>, natural gas as shown in <FIG>, cement manufacture as shown in <FIG>, sewage treatment as shown in <FIG> and contaminated soils/toxic waste as shown in <FIG>.

The apparatus <NUM> illustrated in <FIG>,<FIG> <FIG>, <FIG> and <FIG> include a pair of horizontally disposed but vertically separated magnetic drive plates <NUM> and <NUM> attached to or embedded within the base <NUM> of cavity <NUM>. Both plates <NUM> and <NUM> are disposed inside the cavity <NUM> and are connected via a vertically extending shaft <NUM>. Refractory bricks <NUM> are placed between plates <NUM> and <NUM>. Magnetic drive plates <NUM> and <NUM> may be formed of tungsten or any other magnetic material that can withstand high temperatures.

The apparatus <NUM> further comprises a magnetic drive mechanism <NUM>. The magnetic drive mechanism <NUM> activates magnetic plate <NUM> and shaft <NUM> and connects them with the magnetic plate <NUM> that activates the agitating crucibles <NUM>-<NUM>. Under agitation, magnetic drive mechanism <NUM> rotates crucible <NUM> about a central vertical axis in a back and forth motion. The reciprocating rotational motion is preferably at angles less than a full <NUM> degree rotation.

Preferably, magnetic drive mechanism <NUM> is located outside of chamber <NUM> and is directly or indirectly mounted to base <NUM> of housing <NUM>. This arrangement facilitates sealing between the housing <NUM> and crucible <NUM> such that no leakage occurs between the crucible <NUM> and housing <NUM>. Below the six bottom rollers 90A-95A, refractory brick <NUM> is installed for thermal insulation. The bottom rollers 90A-95A are preferably positioned in a distributed manner to bear the weight of the whole crucible <NUM>.

As is apparent from <FIG> and <FIG>, lid <NUM> includes an aperture that extends substantially through lid <NUM> and through which a conduit <NUM> is received. The conduit <NUM> is of a sufficient length to extend through the aperture into the crucible <NUM> when the lid <NUM> is engaged with the housing <NUM>, corresponding to the apparatus <NUM> being in a closed configuration, as shown in <FIG>. Conduit <NUM> may also extend through the refractory brick work insulation <NUM> and the opening of the chamber <NUM>, to facilitate the gaseous flow of flue gases from the crucible <NUM> to corresponding mixing cavities 100A-210A.

Conduit <NUM> may comprise a single continuous element such as a tube or pipe, or may be formed of a plurality of segments joined together. The individual segments may be formed of different materials and/or have different diameters or wall thicknesses.

Within chamber <NUM>, conduit <NUM> extends substantially vertically into an upper, central or lower region of crucible <NUM>. Extending radially outwardly from a wall of the conduit <NUM> are a plurality of stirring rods, collectively given the general reference numeral <NUM>. The stirring rods <NUM> are oriented generally orthogonal to the vertical longitudinal axis of the housing <NUM>. The rods <NUM> are configured for use in agitating and breaking up the waste material or coal or silica and calcium carbonate within the crucible <NUM>. Under agitation, crucible <NUM> is rotated by magnetic drive mechanism <NUM> relative to stirring rods <NUM>, which act to stir the material within crucible <NUM>. Agitation of the crucible helps to facilitate the removal of any oils or toxins from the waste material or coal or silica and calcium carbonate for the manufacture of cement during pyrolysis and combustion. Conduit <NUM> and/or stirring rods <NUM> include one or more apertures for receiving ingress of flue gases into conduit <NUM>.

In apparatus 10C of <FIG>, the second crucible item <NUM> is agitated by a high strength shaft <NUM> and it is agitated by a high temperature high strength gear box <NUM>. Gear box <NUM> is powered by a motor (not shown) to rotationally drive shaft <NUM> to rotate agitating crucible <NUM>. Shaft <NUM> includes one or more radially extending stirring rods to facilitate the agitation and stirring of material within crucible <NUM>.

In a preferred embodiment, the conduit <NUM>, the stirring rods <NUM>, shaft <NUM> and gearbox <NUM> are all manufactured from a high temperature and high tensile strength material. The type of material that may be used are tungsten-based materials and or molybdenum-based materials and or rhenium-based materials that can withstand high temperatures up to <NUM>,<NUM> degrees Celsius and also have high tensile strength. These materials are used in the turbine industry and jet engine design and it will be appreciated that other materials used in those industries may be appropriate to use in the present invention.

While tungsten can maintain high temperatures, up to <NUM>,<NUM> degrees Celsius, it is also a brittle material. As such, components within the apparatus which are required to maintain very high temperatures, such us the rollers, heating tubes, the crucible(s), the stirring rods or other components within the housing, should preferably utilise a tungsten alloy material that has a high strength at high temperatures. One possible base material for forming such an alloy is a high temperature stainless steel that may not distort or change shape.

As shown in <FIG> and <FIG>, the apparatus <NUM> further comprises an overflow reservoir <NUM> with an electrical vaporiser that is in fluid communication with conduit <NUM> by virtue of input sensors <NUM> and with an additional overflow conduit <NUM>. Input sensors <NUM> regulate the flue gases that are directed into the mixing cavity 100A - 210A either with or without the use of reservoir/vaporiser <NUM>. By way of example, sensors <NUM> may include one or more of optical sensors to monitor the flow rates and temperature of input gases, or ultrasound flow control sensors to monitor gas flow rates, temperature sensors to monitor temperatures of gases, as well as other sensors such as fluid sensors and spectrum analysis sensors to monitor output gas composition.

Reservoir/vaporiser <NUM> is used to regulate the flow of flue gases from crucibles <NUM>-<NUM> when necessary. During pyrolysis and combustion, flue gases from crucibles <NUM> and <NUM> are output through conduit <NUM> and may condense during passage of conduit <NUM>. Sensors <NUM> are disposed within conduit <NUM> and are configured to sense the output flue gases. Depending on the volume, flow rate and/or temperature of the flue gases, sensors <NUM> send signals to trigger corresponding valves (not shown) to direct the gases either directly to mixing chambers 110A-210A or into overflow conduit <NUM> and reservoir/vaporiser <NUM>. If the temperature and flow rate of the flue gases are sensed by sensors <NUM> to be sufficiently high, then they may be directed straight to the heating tubes. If, however, the temperature of the flue gases are sensed to be low and/or the heating tubes do not require filling, the flue gases may be directed into overflow reservoir/vaporiser <NUM>.

Within, reservoir/vaporiser <NUM> the flue gases can be stored temporarily and re-vaporised and heated for subsequent supply to the heating tubes.

The gases in reservoir/vaporiser <NUM> are again redirected via sensors <NUM> into the mixing chambers 100A/<NUM>-<NUM>, via an output conduit <NUM>. In other embodiments of the design, conduit <NUM> may also be used to redirect hot unprocessed gases to mixing chambers 110A-210A/<NUM>-<NUM>, depending on the decision tables controlled by the sensors and a PLC control system (described below) and the overall flow of the system.

In a preferred embodiment, the overflow reservoir <NUM> and the conduits <NUM>, <NUM> and <NUM> are all manufactured from a high temperature and high tensile strength material. The type of material that may be used are tungsten-based materials and or molybdenum-based materials and or rhenium-based materials that can withstand high temperatures up to <NUM>,<NUM> degrees Celsius and also have high tensile strength.

In addition to sensors <NUM> described above, similar sensors may be positioned at various locations within the entire system, such as within the conduits and, heating tubes and crucible(s), to measure temperatures that may be over <NUM>,<NUM> degrees Celsius and all other inputs or outputs or system failures. The sensors must be designed so as to withstand high temperatures, up to <NUM>,<NUM> degrees Celsius. Signals from sensors <NUM> may be fed to a PLC control system (described below). The PLC control system is responsive to the sensor signals to make system decisions for shut downs or redirection of inputs or outputs to other part of this system or to slow the flow of material or request immediate or scheduled maintenance of system components and so on. Sensors <NUM> and the PLC control system may communicate with a system of actuators for controlling flow of flue gas and other system components.

As shown in <FIG> and <FIG> the overflow reservoir/vaporiser <NUM> is in communication with the mixing cavity 100A via conduit <NUM>, to allow byproduct(s) resulting from the pyrolysed and combusted material to flow from the crucible <NUM> to the respective heating tubes <NUM>-<NUM> to be pyrolysed and combusted therein in the presence of hydroxy gas, when ignited. Preferably, each apparatus <NUM> includes a single overflow reservoir <NUM>. If multiple interconnected arrays of heating tubes are present in an apparatus, only the first heating tubes <NUM>/<NUM>-<NUM> of each array receive the output of reservoir <NUM>. If a number of apparatus <NUM> are included in a system design <NUM>, one or more active reservoirs <NUM> for the entire system <NUM> may be provided that service several apparatuses <NUM>.

Apparatus 10B illustrated in <FIG> includes a single crucible <NUM> and shows the representation of multiple arrays of heating tubes. This configuration incorporates twelve heating tube arrays <NUM>-<NUM>. These heating tubes are located inside the housing <NUM> and within and housing cavity <NUM>. The apparatus 10B of <FIG> also includes three vertically separated arrays of six circumferentially disposed side rollers <NUM>-<NUM>, which are secured across the perimeter of the chamber <NUM>, attached to the internal wall of the housing <NUM>. These side rollers are secured within the chamber item on a gap that exists between the internal wall of the housing <NUM> and the crucible <NUM>. The crucible <NUM> is preferably removable to more easily facilitate the emptying and refilling of the crucible with the required material for the purpose of pyrolysis and combustion. The rollers <NUM>-<NUM> are preferably rotatably mounted at a fixed position.

Apparatus 10C of <FIG> includes two crucibles <NUM> and <NUM> and shows the representation of multiple arrays of heating tubes. A two-crucibles design is proposed for the production of cement by utilising coal in crucible <NUM> and mainly silica and calcium carbonate in crucible <NUM>. This configuration incorporates a twelve-heating tube array, items <NUM>-<NUM>. These heating tubes are located inside the housing <NUM> and within and housing cavity <NUM>. Apparatus 10C also includes three vertically separated arrays of six circumferentially disposed side rollers <NUM>-<NUM>. The rollers are secured across the perimeter of the chamber and attached to the internal wall of the housing <NUM>. These rollers are secured within the chamber <NUM> in a gap <NUM> that exists between the internal wall of the housing <NUM> and the crucibles items <NUM> and <NUM>. The crucibles <NUM> and <NUM> are preferably removable because they need to be emptied and refilled with the required materials for the purpose of pyrolysis and combustion. The rollers <NUM>-<NUM> are preferably rotatably mounted in fixed positions to housing <NUM>.

For the purpose of cement manufacture, upper crucible <NUM> is filled with a required amount of calcium carbonate and a required amount of silica and any other required material, while the lower crucible <NUM> is filled with a required amount of coal to produce the town gas mixed with hydroxy gas that generates the required temperatures and energy to create cement.

In the preferred embodiments of apparatus <NUM>, the height of the single crucible design is approx. <NUM> meters. The diameter of the crucible is about <NUM> and the circumference of the crucible is around <NUM>. The volume is estimated to be <NUM>,<NUM><NUM>. The volume of the single crucible design is around <NUM> litres. The weight of the content is estimated to be around <NUM>- <NUM> of waste per processing cycle. Each processing cycle takes approximately one hour to be completed. Per year the approximate processing of waste is around <NUM> x <NUM> hours x <NUM> days = <NUM>,<NUM> of waste per year. This design requires twelve heating tubes around the crucible in the housing cavity. The approximate heating tube diameter in this design is about <NUM> with a <NUM> hole and being spaced apart by around <NUM> apart.

<FIG> includes several modules of a complete system design. These are as follows: the apparatus <NUM>, an electrical power supply <NUM> providing electricity to all modules, hydroxy cell <NUM>, an emptying and refilling module <NUM> of the crucible, a separation of waste module <NUM>, and an electrostatic removal of ash and other commodities module <NUM> with outputs of carbon, ash steel and cement.

<FIG> also include an air cooler heat exchanger <NUM>, which is connected to the apparatus for pyrolysis and combustion system <NUM>, a flue gas pump <NUM>, a cyclone separation module <NUM>, a heat exchanger <NUM>, a conversion to electricity module <NUM>, and a cryogenic separator <NUM> having as its outputs N<NUM>, CO, CO<NUM>, O<NUM>, NO<NUM>, H<NUM>.

The cyclone separation module <NUM> separates flue gases from particles (such as Carbon, ash, cement) to allow the separation of any particles from the gases which are: HC, CO, CO<NUM>, <NUM>, N<NUM>O, H2The cryogenic or molecular sieve separator <NUM> is adapted to separate gases such as CO, CO<NUM>, O<NUM>, N<NUM>, NO<NUM> and H<NUM>. The hydrocarbon was removed by the previous processes and by the <NUM>-heating tube design configuration that works in stages. Current experimentation illustrated in examples <NUM>-<NUM> below indicates that just two heating tubes eliminated essentially all of the hydrocarbons and significantly reduced the levels of CO and CO<NUM>. Therefore a <NUM>-tube configuration design with a <NUM> deep array structure with PLC monitoring and control module is estimated to eliminate the hydrocarbons and will minimise and adjust the pollutants to the required configuration levels to produce commodities, that includes green electricity.

Furthermore, the significant number of heating tubes arranged in a loop design allows for partial pyrolysation and combustion of hydrocarbons to be performed at each stage. This allows reduction of the required input power levels to decompose the CO<NUM> at an overall reduced energy input compared to that of existing methods. This is illustrated in examples <NUM> and <NUM> below when compared to references <NUM>-<NUM>.

<FIG> include a heat exchanger <NUM> for temperature reduction, an argon gas density separator <NUM> and a temperature reduction heat exchanger <NUM>. Finally <FIG> include a PLC computer system <NUM> that controls operations and computer-generated actions on each of the above modules via sensors and monitoring.

Hot and polluted argon with flue gases is directed by the system, from apparatus <NUM> to the heat exchanger <NUM> to reduce its temperature. The cooled gases are then redirected to the separation scrubber <NUM> for the purification of the argon gas from the flue gases. After that, the clean argon is redirected back to apparatus <NUM>. The cleaned argon goes back into the housing cavity and the hydrocarbons are passed back into the heating tubes for further treatment.

Polluted argon from apparatus <NUM> arrives at the heat exchanger <NUM> in a heated state, up to <NUM>,<NUM> degrees Celsius. Hot polluted argon moves to a primary chamber of heat exchanger <NUM>. The primary chamber of heat exchanger <NUM>, which has argon and other mixture of gases contained therein, is designed to expand the volumes of argon and helium mix (separate area and separate gases) which are in a secondary chamber of heat exchanger <NUM>. The argon and helium mix are supplied as input to the heat exchanger <NUM> and subsequently to turbine electricity generators <NUM> for the creation of electricity via the turbines.

The cooled and polluted argon in the primary chamber of heat exchanger <NUM>, which is isolated from the secondary chamber, is then redirected to the flue gas separation scrubber <NUM>. The argon and helium gas mix from the secondary chamber is not connected or mixed with polluted argon with hydrocarbon in the primary chamber. These two sets of gases have different functions in the invention. Helium and argon mix from the secondary chamber, of the heat exchanger <NUM> for the reduction of temperature, and is used to create electricity via the heat exchanger and via turbine electricity generators <NUM>. These two gases mix, and pure argon and helium remains permanently within that loop.

These two technologies for Heat exchanger for reduction of temperature and for heat exchanger and turbine electricity generation are known and established technologies and are used by our system as required to take advantage of the heat generation of the apparatus of pyrolysis and combustion and generate efficiency and cheaply green electricity.

Sensors <NUM> located on components such as the heating tubes, condenser, flue gas pump and cyclonic separator may be implemented to provide information online and/or in real time. The sensors <NUM> feed the data collected into the PLC computer system <NUM> integrated monitoring and control, module. System <NUM> is responsive to the sensor signals to control various actuators such as valves and pumps across the system to control system parameters. Actions will be taken and relayed to the appropriate module to allow the system operators and system control software to control the entire system in milliseconds, most likely from a remote location. These tight monitoring and control processes are required in case of any system emergency, to avoid mishaps or any system disasters, to address possible inefficiencies or component failures. The number of active heating tubes per array to be used may be reduced or increased for system use depending on these measurements. In some embodiments, the number of arrays of heating tubes currently <NUM>, positioned one on top of each other, can be changed.

A primary role of the sensors and the PLC system <NUM> is to measure in all detail input gases, output gases, particles such as ash, carbon and cement and all waste material and gases for each of these components or modules and report the data in real time back to the PLC for processing.

The configuration of the PLC computer integrated monitoring and control system <NUM> requires integrated logic that embraces all aspects of the overall design for all modules and all components of this system, including mechanical, electronic, pneumatic and hydraulic. The PLC logic is adapted for sending and receiving data and commands to these modules and these components online in real-time taking all data into consideration and adjusting all flows appropriately to ensure the safety of the overall system 24x7.

In some embodiments, the PLC computer integrated monitoring and control system <NUM> will execute workarounds, diagnostics and set maintenance protocols when and if these changes are demanded. The PLC module <NUM> may also schedule engineering actions. One purpose of the overall PLC system command structure design, module is to ensure efficiency, safety and to regulate the inputs, outputs in every form so that waste material elimination, cement production, green electricity production, carbon and all other commodities production is executed is the most cost effective way ensuring at all times safety, integrity of the system and the employee.

The PLC system design is preferably internet connected to a head office for monitoring, control and overwriting of decisions when this is required. The PLC system command structure design module will impact the operations and configuration of all proposed designs, waste management, Coal, natural gas treatment, cement manufacture, sewerage treatment, contaminated soil and toxic waste treatment.

The configuration of the PLC, computer integrated monitoring and control system <NUM> may regulate and adjust the input components output components of apparatus <NUM>.

The configuration of the PLC, computer integrated monitoring and control system <NUM> may also allow for regulating all material in the emptying and re-filling the agitating crucible(s). This material may be waste material for waste to energy production or coal for the coal fire power station to produce electricity or silica and calcium carbonate with coal required to produce cement. This material may be natural gas, sewerage treatment material, contaminated soil, and toxic waste treatment material.

According to the invention, the gas for use in pyrolysing and combusting the byproduct(s) is oxyhydrogen gas, often referred to under alternative names such as "hydroxy gas", "Brown's gas", or even "HHO" gas on account of the <NUM>:<NUM> ratio of the hydrogen (H<NUM>) to oxygen (O) components associated with oxyhydrogen gas.

As shown in <FIG>, it will be appreciated that the oxyhydrogen (HHO) gas may be generated by a gas supply device <NUM> that forms part of the overall system <NUM>, and which is operably connected to each of the plurality of heating tubes <NUM>-<NUM> in multiple consecutive arrays <NUM>-<NUM> for supplying oxyhydrogen (HHO) gas thereto by way of the corresponding mixing chambers, such as mixing chamber enclosure 100A-210A.

In a preferred embodiment, the oxyhydrogen (HHO) gas is supplied to the heating tubes <NUM>-<NUM> at a pressure from <NUM> kPa to <NUM> kPa via the hydroxy electrolytic cell <NUM>.

In a preferred embodiment, the gas supply device takes the form of an electrolytic cell <NUM>, as shown in <FIG>, that comprises a pair of plate electrodes, each having one end electrically connected to a corresponding one of a pair of terminals of an electrical power supply <NUM> and the opposing end immersed in spaced arrangement in an electrolyte solution in the form of an aqueous solution of a suitable metal hydroxide such as sodium hydroxide or potassium hydroxide.

In a preferred embodiment, the plate electrodes are manufactured from base metals.

As shown in <FIG>, the electrical power supply <NUM> is also electrically connected to the apparatus <NUM> for use in powering the magnetic drive mechanism <NUM> to agitate the crucibles <NUM>-<NUM> in use. Only one magnetic drive <NUM> is required for up to two crucibles <NUM>-<NUM> and one lid <NUM>. Further, one conduit <NUM> and rods <NUM> are required per apparatus. For the two-crucible apparatus 10C of <FIG>, a high strength shaft <NUM> and a high strength gear box <NUM> are required to control agitating crucible <NUM> sitting below crucible <NUM>. However, multiple interconnected arrays of heating tubes <NUM>-<NUM>/<NUM>-<NUM> are needed, which are stacked within each apparatus <NUM> design.

According to another aspect of the present invention, there is provided a method for pyrolysing and combusting a material using an apparatus <NUM> as described above. The crucibles <NUM>-<NUM> facilitate the process of pyrolysing and combustion using heat generated in the heating tubes <NUM>-<NUM>/<NUM>-<NUM>.

In particular, the method is directed to pyrolysing and combusting a hydrocarbon-based waste material such as those described above or coal or silica and calcium carbonate for the manufacture for cement, with a view to producing byproduct(s) that are either useful as commodities to offset the costs associated with the pyrolysis method, or are sufficiently pyrolysed and combusted to the point that they are inert and thus capable of being disposed of in a safe and environmentally friendly manner. See <FIG> for the treatment of various materials by the combustion and pyrolysis process.

Prior to adding the material to the crucible(s) to be pyrolised, some materials require a degree of pre-processing. All input materials that are not combustible should be removed in a sorting process. Example materials that should be removed include rocks, glass, bricks, tiles and ceramics. In each system designed to pyrolise different materials, the sorting process will have variations. As part of waste management, certain toxins and contaminated soil should be removed from what is considered acceptable household waste. Actions such as shredding of materials to an appropriate size and mixing should also take place before any acceptable material is placed into the crucible(s) for combustion and pyrolysis. A system designed to process natural gas does not require sorting of solid materials but requires a regulated supply of natural gas. These different configurations are adjusted and regulated by the PLC monitoring and control module.

The method comprises as initial pre-processing steps of separation and shredding of waste (as per module <NUM> of <FIG>) or coal crushing (as per module <NUM> of <FIG>). In the gas supply system 300C of <FIG>, natural gas is supplied to the apparatus by module <NUM>. In the cement manufacture system 300D of <FIG>, calcium carbonate, silica and coal is supplied to the apparatus at module <NUM>. In the sewerage treatment system 300E of <FIG>, sewerage sludge and coal is supplied to the apparatus at module <NUM> and the agitating crucibles are emptied and refilled at module <NUM>. These initial steps are required in receiving waste material or coal or silica and calcium carbonate for the manufacture of cement or sewage or contaminated soil and toxic waste and cement manufacture. No sorting of material is required for the treatment of NG. These initial steps provide inputs to apparatus <NUM>.

To kick-start the combustion process within apparatus <NUM>, these steps need to happen first. Once the material within the crucible is received, the lid <NUM> is used to seal the loaded crucibles <NUM>-<NUM> within the housing <NUM> of the apparatus <NUM>. Then, the material is heated to temperatures of up to <NUM>,<NUM> degrees Celsius by feeding a mixture of oxygen and liquefied petroleum gas (LPG) or natural gas into the plurality of tungsten heating tubes <NUM>-<NUM> via the corresponding mixing chambers, such as mixing cavity 100A -210A in respect of tungsten heating tubes <NUM>-<NUM>. The number of heating tubes <NUM>-<NUM> is not restricted by this design also the number of arrays of stacked heating tubes <NUM>-<NUM> is not restricted by this design.

Once the temperature within the crucibles <NUM>-<NUM> reaches up to <NUM> degrees Celsius, pyrolysis with combustion starts to occur, and the waste hydrocarbon-based material starts to thermally decompose or dissociate, resulting in the formation of byproduct(s) in the form of vaporized hydrocarbons, collectively referred to as HC (g), and vaporized oil.

In a further step, the vaporised hydrocarbon (HC (g)) byproduct and the vaporised oil by-products produced during pyrolysis and combustion, flows either through the conduit <NUM> or via the reservoir <NUM> as shown in <FIG>, toward the mixing chamber enclosures 100A associated with the tungsten heating tubes <NUM>, by the mixing cavities 100B. The first in line heating tubes push the subsequent partially processed gases to the next heating tube <NUM> and so forth in a sequence until these gases reach final heating tube <NUM>. As per <FIG>, before the partially processed gases are progressed to the next heating tube, they are moved into an air cooler <NUM>/<NUM>-<NUM> to a flue gas pump <NUM>/<NUM>-<NUM> and to a cyclonic separator <NUM>/<NUM>-<NUM>. This process is repeated twelve times for each heating tube.

This process in the illustrated embodiments, passes between apparatus <NUM> and cyclonic separator <NUM> twelve times, before the cyclone separation of carbon and cement step is fully completed and progresses to heat exchanger <NUM>. Conduit <NUM> transfers the gasses from crucibles <NUM>-<NUM> to the mixing chambers 100A/<NUM>-<NUM> via the process explained above and as shown in <FIG>.

Here, the by-products(s) are mixed with oxyhydrogen (HHO) gas in the mixing cavity 100B-210B, and the byproduct(s)/gas mixture then enters the tungsten heating tubes <NUM>-<NUM>, as shown in <FIG>.

<FIG> shows the two first mixing chambers, items 100A and 110A and the mixing cavities 100B and 110B, where the hydroxy gas is mixed with vaporised polarised and combusted gases, from the crucibles <NUM>-<NUM>. The diagram includes an electronic ignition device <NUM> and ignition magazine <NUM>, and an injector <NUM> and injector magazine <NUM>. <FIG> includes indicative input and output temperatures of these two heating tubes, with temperatures of the gas starting at zero degrees Celsius within cavity 100B advancing up to <NUM>,<NUM> degrees Celsius and gradually reducing back to <NUM> degrees Celsius upon exit to an air cooler heat exchanger <NUM>/<NUM>. The gases are then passed to a flue pump <NUM>/<NUM> and cyclone separator <NUM>/<NUM> before they renter the heating chamber 110A/<NUM>. This process is repeated twelve times for each subsequent heating tube in the preferred configuration and for each of the fifteen levels for each chamber <NUM> within the housing item <NUM>. The number of electronic ignition devices <NUM>, ignition magazines <NUM>, injectors <NUM> and injector magazines <NUM> is proportional to the number of heating tubes in the apparatus.

Once the byproduct(s)/gas mixture has entered the tungsten heating tubes <NUM>-<NUM> the method comprises, as a next step, igniting the oxyhydrogen (HHO) gas component of the mixture by use of an electronic ignition device <NUM> and associated ignition magazine <NUM>. These devices, which are illustrated in <FIG>,<FIG>, are electrically connected to each of the plurality of heating tubes <NUM>-<NUM>, where the heat generated as a result is sufficient for use in pyrolysing and combusting the byproduct(s) within the tungsten heating tubes <NUM>-<NUM>. The hydroxy gas is gradually produced sufficiently and the LPG/natural gas with oxygen are gradually reduced. In turn, power is generated by the system, (starting with the LPG/natural gas) to self-sustain the ongoing production of hydroxy gas required for the heating tubes.

As shown in <FIG>, the heat generated as a result of igniting the oxyhydrogen (HHO) gas component of the mixture within the exemplary heating tube <NUM>/<NUM>-<NUM>/<NUM> (as representative of the plurality of tungsten heating tubes <NUM>/<NUM>-<NUM>, <NUM>/<NUM>-<NUM>) reaches a temperature up to <NUM>,<NUM> degrees Celsius as pyrolysis and combustion of the byproduct(s) occurs within the heating tubes.

During pyrolysis and combustion, in the heating tubes <NUM>-<NUM>, the byproduct(s) from the combusted hydrocarbon based material, namely vaporized hydrocarbon (HC (g)) and vaporized oil, are thermally degraded or dissociated over time into a mixture of pyrolysis products that exit the exemplary/typical tungsten heating tube <NUM> from the upper to lower portion thereof as a flue gas mixture. Upon exit from each heating tube, the byproduct(s) are passed to the heat exchanger <NUM>, the flue gas pump <NUM> and the cyclonic separator <NUM> as they move from the first heating tube to the final heating tube in the array. Hence, for the embodiments illustrated in <FIG>,<FIG>,<FIG> and <FIG>, the process is repeated twelve times.

According to a fourth step, the method comprises the step of utilising the heat up to <NUM>,<NUM> degrees Celsius generated within the tungsten heating tubes <NUM>-<NUM> during the pyrolysis and combustion step to combust the hydrocarbon-based material within the heating tubes. At this point, the oxygen/(LPG) or natural gas mixture used to kick-start the combustion process according to the first step is no longer required and can be stopped, so that any further pyrolysis and combustion of the hydrocarbon-based material within the crucibles <NUM>-<NUM> can be achieved through the use of the heat generated within the tungsten heating tubes <NUM>-<NUM> during the pyrolysis and combustion step.

In fact, the heat generated within the tungsten heating tubes <NUM>-<NUM> amount is sufficient to raise the temperature within the crucibles <NUM>-<NUM> up to <NUM>,<NUM> degrees Celsius. The inventor has found that this temperature is sufficient to combust a wide variety of hydrocarbon-based waste materials including, for example, biomass, natural or synthetic rubber based products, silica and silica carbonate for the manufacture of cement, town gas/coal, domestic waste, medical waste, toxic waste, sewage, contaminated soil, NG, industrial waste or any mixture thereof, to the point where the resultant byproduct(s) comprise vaporised hydrocarbon (HC (g)) and vaporized oil. See <FIG> for a non-exhaustive variety of products that can be processed by, item <NUM>.

The temperature produced within the crucibles <NUM>-<NUM> can be controlled by virtue of the presence of the inert gas(es) such as argon, being circulated around the tungsten heating tubes <NUM>-<NUM>. The argon and/or other inert gas(es) is contained within the housing cavity <NUM>.

The inventor's research indicates that the pyrolysis and combustion of the hydrocarbon based waste material in the presence of the oxyhydrogen (HHO) may yield, amongst others, the following important pyrolysis and combustion products: water, carbon char, carbon dioxide, carbon monoxide, oxygen, nitrogen, nitrous oxide and high volumes of hydrogen. This phenomenon is a result of the affinity or attraction of the hydrocarbons to the oxygen and thus the production of carbon dioxide and carbon monoxide as a first reaction. The secondary reaction is the combustion of hydrogen to produce water. The overall reaction produces high volumes of hydrogen because of the hydrogen content in the vaporised hydrocarbon (HC (g)) when mixed with the oxyhydrogen (HHO) gas.

The carbon char and ash can be disposed of without the need for chemical means using, for example, a simple separation method such as electrostatic separation of ash, steel, carbon and cement. This is illustrated in module <NUM> of <FIG>, <FIG>. For instance, when the pyrolysis and minimal combustion process has been completed, the carbon char and ash that remains is substantially sealed within the crucibles <NUM>-<NUM> by capping the crucibles <NUM> with lid <NUM> and then removing the sealed crucibles <NUM>-<NUM> from the gap <NUM> of the chamber <NUM>. The carbon char and ash can then be either disposed of in a safe and environmentally friendly manner or used for other purposes.

Once the crucibles <NUM>-<NUM> have been emptied, these can be filled with further material(s), during a refilling step performed at module <NUM>, and loaded back into the apparatus <NUM> for pyrolysis and combustion.

It will be appreciated by persons skilled in the relevant art, that the apparatus <NUM> is thus basically equipped to receive a succession of crucibles <NUM>-<NUM> in turn, thereby rendering this a continual process for pyrolysing with combustion waste material or coal or silica and calcium carbonate required for the manufacture of cement and for the variety of materials used.

As shown in <FIG>, the temperature within the heating tube <NUM> reaches up to <NUM>,<NUM> degrees Celsius to allow pyrolysis and combustion at high temperatures. However, gradually as the flue gases travel toward the outlet, the temperature within the heating tube is lowered and the flue gases eventually exit the heating tube at temperatures of around <NUM> degrees Celsius in the preferred embodiments. Pressure of around <NUM> PSA moves the gases from one tube to the next utilising first a condenser <NUM>, then a gas pump <NUM> and subsequently a cyclonic separator system <NUM>. Each tube fitting requires a condenser and a pump mounted outside the refractory brick work <NUM>.

It will be appreciated by persons skilled in the relevant art that the cooling of the flue gases within the tungsten heating tubes <NUM>-<NUM> can be achieved by any one of several means. For instance, in a preferred embodiment, the cooling is achieved by argon <NUM> as cooling agent, within cavity <NUM>. See <FIG>,<FIG>.

As shown in <FIG>, it may be possible to use a cryogenic or molecular sieve separator <NUM> to separate the flue gases generated following the pyrolysis and combustion step to produce such commodities as carbon dioxide and carbon monoxide to produce dry ice, liquid oxygen, liquid nitrous oxide and gaseous hydrogen to produce either electricity or methanol.

Moreover, the high percentages of hydrogen, carbon dioxide and carbon monoxide separated from the flue gases make them suitable for application as syngas for the catalytic conversion to useful alcohols such as methanol or combusted with air/oxygen to produce electricity as per step <NUM> of <FIG>.

Any nitrogen present within the flue gases, will have little or no effect on the catalyst conversion process, and can simply be vented into the atmosphere, as per process <NUM> in <FIG>.

Alternatively, or in addition to any H<NUM>,N<NUM>, CO or CO<NUM> separated out from the flue gases in process <NUM>, these gases may be looped back via an appropriate conduit and used as refrigerants to assist the incoming flue gases for the cryogenic separation of the flue gases. This, in turn improves the heat exchange and conversion to electricity or conversion to methanol in steps <NUM> and <NUM>. Further, this process may be achieved without generating of any pollutants.

Similarly, by attaching an air cooled heat exchanger condenser <NUM> to extract the water from the flue gases by condensation and thereafter a flue gas pump <NUM> and cyclonic separator <NUM> to the output of each of the tungsten heating tubes <NUM>-<NUM>, it becomes possible to use centrifugal force to isolate any carbon powder that may have been produced or cement particles in separator <NUM>. The extracted water from the air-cooled heat exchanger condenser <NUM> can be recycled and placed back in the hydroxy electrolytic cell <NUM> after it is filtered by reversed osmosis or filtration principles in reverse osmosis module <NUM>.

The carbon powder is generally of a purity that renders it suitable for use in several applications, such as a pigment for use in the paint and/or ink industry or for graphite manufacture. The cement is part of the cement manufacturing process. The electrostatic separation process removes these materials from the valuable carbon. This is achieved in the electrostatic separation process <NUM>. <FIG> illustrate the differences in treatment of various materials. In all treatments, in step <NUM>, the cyclone separation of particles from flue gases is used for the removal of all particles from the gases.

As shown in <FIG>, <FIG> the inert gas, argon <NUM> is used to prevent oxidation of the arrays of tungsten heating tubes <NUM>-<NUM> in apparatus <NUM>. The inert gas argon <NUM> controls the temperature within the housing <NUM> within the chamber <NUM> and within the crucibles <NUM>-<NUM>. These items are heated by the heat generated within the arrays of tungsten heating tubes <NUM>-<NUM> during pyrolysis and combustion. The inert gas(es) expands within the confines of the double wall <NUM>, <NUM> of the housing <NUM>.

As show in <FIG>,<FIG> as a result, it may be possible to exploit this expansion after the increase in pressure and temperature and transfer hot argon gases from apparatus <NUM> to the heat exchanger <NUM> for reduction of temperature and use the heat as the required energy at a lower temperature to power the turbine electricity generation at step <NUM>. The hot inert gases, argon <NUM> and the leaked flue gases are moved to the argon and flue gases recycling and separation scrubber <NUM>. The leaked gases are redirected from scrubber <NUM> back to the heating tubes <NUM>-<NUM> and the cleaned argon <NUM> is transmitted back to the housing <NUM> of apparatus <NUM>. It also follows that electricity is redirected back to electrical power supply <NUM> from the turbine electricity generation <NUM> to generate electrical power that can be used to supply additional electricity to the apparatus <NUM>, to the hydroxy electrolytic tube <NUM>, which is the hydroxy gas supply device and all other modules of system <NUM>.

To achieve this, the inert argon gases <NUM> exiting the apparatus <NUM> up to <NUM>,<NUM> Celsius must be cooled using heat exchanger <NUM> to a temperature of around <NUM> degrees Celsius or less, thereby enabling the inert gases to be used to drive the blades of the turbine <NUM> without causing heat damage to the blades, see <FIG>.

Inside the hydroxy electrolytic tube <NUM>, polymers may be used for the purpose of insulation. The hydroxy electrolytic tube <NUM> should be earthed to remove static electricity as it is a safety and reliability concern. Elsewhere in apparatus <NUM>, instead of polymers outside the device, materials such as stainless steel or steel that can be earthed may be used to avoid issues associated with build-up of static electricity.

The AC/DC electrode design inside of the hydroxy electrolytic tube <NUM> may be sealed with fire choke and Teflon packing. This action will maintain the hydroxy pressure around <NUM> PSI (<NUM> kPA). It will also seal the electrolyte and it will maintain the electrical insulation. This design configuration should be resistant to break down as it is inert and is a ceramic. Further, the solutions within the hydroxy electrolytic tube which include NaOH or KOH will not react with the proposed sealing compounds.

The water configuration used for the hydroxy electrolytic tube <NUM> may preferably be protium water, having one electron and one proton. This water will increase the efficiency in the production of hydroxy gas.

Using the operation of the heat exchanger <NUM> and turbine electricity generation module <NUM> in the presently described embodiments can provide an improved Carnot cycle. The apparatus <NUM> can improve the efficiency of the turbines, in the turbine electricity generation module <NUM> because of the extensive and ongoing heat produced by the apparatus, up to <NUM>,<NUM> degrees Celsius. The current efficiency of the turbine electricity generation module <NUM> is <NUM>%. The improvement in efficiency provided by embodiments of the present invention is estimated to be up to <NUM>% because of the high temperatures achieved.

In apparatus 10D of <FIG> for the processing of natural gas, the process will gradually reduce within the system via the heating tubes and effectively eliminate the CO<NUM> gases. Due to the high efficiencies of the Carnot cycle, the higher levels of electricity produced will be redirected back into the system for the additional production of hydroxy gas.

The apparatus 10D for treatment of natural gas CO and CO<NUM> described above can also be used for methanol production. This also eliminates CO and CO<NUM> emissions from these pollutants.

As shown in <FIG>, electricity from the electrical power supply <NUM> will be directed to the magnetic drive mechanism <NUM> to supplement the electrical power provided to these devices. In addition, electricity supply <NUM> provides ongoing electricity to the PLC computer integrated monitoring and control system <NUM>. Preferably, all modules of system <NUM> are connected to the electricity power supply <NUM>. Preferably all modules of system <NUM> are bidirectionally connected to the PLC system <NUM>, which acts as the command and control module of the entire system <NUM>.

As illustrated in <FIG>, any excess electricity can simply be transferred back to the electricity grid <NUM> as a further means by which to offset the costs associated with the pyrolysis and combustion method.

In one preferred device configuration illustrated in <FIG>,<FIG>, electronic ignition device <NUM> is a replaceable electronic ignition device such as a high temperature spark plug. Magazine <NUM> is a magazine design delivery mechanism with multiple clean spark plugs stored therein. The magazine <NUM> is adapted for delivering replacement high temperature spark plugs <NUM>, when the active spark plug becomes clogged up due to carbon built-up. Magazine <NUM> may also include or be associated with an ultrasonic mechanism that is used for the removal of carbon buildup on the active spark plug <NUM>.

In apparatus 10A illustrated in <FIG>, nozzle <NUM> is a replaceable injector nozzle that is required to inject the mixed gasses into the tungsten reaction tube <NUM>-<NUM>. Magazine <NUM> is a magazine design mechanism with multiple clean injectors that is used for the automatic removal or an active injector with a new clean injector when the active injector is clogged up due to carbon built-up. Magazine <NUM> will remove the active injector and replace it with a new one. Magazine <NUM> may also be an ultrasonic mechanism that is used for removal of carbon buildup on the active injector.

The above described mechanised delivery system including the magazines <NUM> and <NUM> may be adapted to shield the injectors and spark plugs from exposure to high temperatures. At the flame front, the hydroxy gas is injected at relatively low temperatures. Further down from the flame front, the pyrolysis and combustion are activated and that achieves high temperatures that may go up to <NUM>,<NUM> degrees Celsius.

In a further preferred device configuration illustrated in <FIG>, the system <NUM> includes heat exchanger/condenser <NUM> is an air cooled heat exchanger condenser and reservoir for the removal of heat and water from flue gases that are produced from the heating tubes items <NUM>-<NUM> and from the crucibles <NUM>-<NUM>. The above described configuration includes twelve air cooled heat exchangers that are configured to service fifteen layers of heating tubes <NUM>-<NUM>/<NUM>-<NUM>, see <FIG>,<FIG>. In one embodiment system <NUM>, up to one hundred and sixty apparatuses <NUM> may be serviced concurrently. In turn, it follows that one hundred and sixty pairs of crucibles <NUM>-<NUM> may be serviced concurrently. For treatment of NG, no crucible is required (see <FIG>).

Each crucible communicates with <NUM> condensers and each of the condensers communicates with one of the <NUM> flue gas pumps. Each of the flue gas pumps communicates with one of the <NUM> cyclones. The ratio of air coolers, flue gas pumps and cyclones are preferably <NUM>:<NUM>. <NUM> crucible designs include <NUM> condensers. The ratios for crucible design within the chamber <NUM>, to condensers is preferably <NUM>:<NUM>. The ratio of condenser to pump is preferably <NUM>:<NUM>. The total number of crucibles included to condensers is <NUM> crucibles to <NUM> condensers. Note also that each row of tubes requires the use of all <NUM> condensers, <NUM> pumps and <NUM> cyclones according to the embodiments described above. Note that a crucible design includes one or two crucibles <NUM>-<NUM>, within the chamber <NUM>. However, it is envisaged that additional crucibles may be employed in future designs without departing from the scope of the invention.

In a further preferred device configuration, the system <NUM> includes pump <NUM> is configured to extract flue gases from the condenser <NUM> and pumping these into the cyclone <NUM>. The above described embodiments include twelve pumps that are configured to service fifteen layers of heating tubes <NUM>-<NUM>/<NUM>-<NUM>, as illustrated in <FIG>. However, in other embodiments, system <NUM> may service up to one hundred and sixty apparatus <NUM> with agitating crucibles <NUM>-<NUM>.

In the embodiments of <FIG>, the system <NUM> includes cyclone separation system <NUM> of flue gases and particles for the removal of particles from the flue gas. The ratio of the pump systems to cyclone separation system is preferably <NUM>:<NUM>, with twelve pumps connected to twelve cyclone separation modules via a separate conduit. For the overall design of the system of <NUM> agitating crucibles design, items <NUM>-<NUM>, within apparatus <NUM> the configuration includes twelve air coolers, twelve pumps, and twelve cyclones <NUM>. Particles such as carbon, graphite, ash and cement are extracted within cyclone <NUM>, collected and removed from the system, as valuable commodities.

In the embodiments of <FIG>, the system <NUM> includes the cryogenic and/or molecular sieve separation subsystem <NUM>. The ratio of the cyclone separation system <NUM> to the heat exchanger <NUM> and to the cryogenic separator <NUM> is preferably <NUM>:<NUM>. The flue gases from cryogenic separator <NUM> are redirected via a common conduit into the heat exchanger <NUM> and then to the cryogenic or molecular separator <NUM>. These commodities are produced within subsystem <NUM>, N<NUM>, CO, C0<NUM>, O<NUM>, N<NUM>O and H<NUM>. The commodities, such as N<NUM>, CO, CO<NUM> and H<NUM>, that the subsystem <NUM> outputs are redirected via a heat exchanger <NUM> to refrigerate the incoming flue gases from cyclone separation system <NUM> and then these gases are redirected into electricity conversion module <NUM> for the conversion to electricity or the manufacture of methanol.

In the embodiments illustrated in <FIG>, the system <NUM> includes a heat exchanger <NUM> for the gases N<NUM>, CO, CO<NUM>, H<NUM> for the treatment of hot gases arriving from the cyclone separation of flue gases from particles, cyclone separation system <NUM> prior for the gases directed into the cryogenic molecular sieve separator <NUM>. Heat exchanger <NUM> refrigerates the incoming flue gases utilising the N<NUM>, CO, CO<NUM>, H<NUM> as a refrigerant which is around <NUM> degrees below. The gases used in heat exchanger <NUM> are released in controlled amounts using the PLC module <NUM>.

In some embodiments, the system <NUM> requires conversion of gases N<NUM>, CO, CO<NUM>, H<NUM> into electricity or to methanol manufacture at step <NUM>. The inputs of this system are controlled amounts of output gases, these are, N<NUM>, CO, CO<NUM>, H<NUM> from heat exchanger <NUM> at room temperature. These are processed after the required treatment in cryogenic molecular sieve separator <NUM> and heat exchanger <NUM>. These modules are controlled by the PLC <NUM>.

Embodiments of the system <NUM> further includes electrical power supply <NUM>, which provides electricity to all module in system <NUM>.

Embodiments of the system <NUM> include the hydroxy electrolytic tube <NUM> that is providing hydroxy gas. The gas is redirected to heating tubes <NUM>-<NUM> of apparatus <NUM> at room temperature at around three atmospheres. However, it will be appreciated that the gas may be provided at higher or lower temperatures and pressures.

Embodiments of the system <NUM> include the step <NUM> of emptying and refiling the crucible in an enclosed environment. This may be an automated process where around <NUM>% of the material that is left over in the crucible, mostly carbon, is removed safely from the crucibles. The crucibles <NUM>-<NUM> are refilled and returned to apparatus <NUM>. During the emptying process all left over gases are returned to apparatus <NUM> and reprocessed via the heating tubes <NUM>-<NUM>. These gases must be first pumped via flue gas pump <NUM> in to the cyclone separation system <NUM> and then pushed pack into the heating tubes <NUM>-<NUM> of apparatus <NUM>. In the embodiment of <FIG>, the material used is waste products, in <FIG> the material is for the treatment of coal, in <FIG>, the material is NG/natural gas, in <FIG>, the material for the manufacture of cement which is silica, calcium carbonate with coal having two crucibles, in <FIG>, sewerage treatment material, and in <FIG> contaminated soil and toxic waste. The treatment of NG in the embodiment of <FIG> does not require a crucible, just the heating tubes.

In some embodiments, system <NUM> includes one hundred and sixty apparatuses <NUM> and includes <NUM>,<NUM> hydroxy electrolytic tubes <NUM>. That is, for the <NUM> apparatuses <NUM>, hydroxy is provided from <NUM>,<NUM> cells/tubes <NUM>. However, it will be appreciated that systems incorporating other numbers of apparatus <NUM> may be developed within the scope of the invention.

Embodiments of the system <NUM> include the module <NUM> for performing electrostatic removal of carbon from ash, steel, and cement. This process includes the magnetic separation of steel from the ash. In this process, the steel is first removed and then the carbon is removed from the ash and the cement. This may be implemented as an automated process. The outputs of this process are carbon, ash, steel, and cement. The NG treatment illustrated in <FIG> does not require module <NUM>. With the NG treatment, additional CO<NUM> and CO may be injected into apparatus <NUM>, via the heating tubes. These pollutants are mixed with NG and hydroxy gas and are pyrolysis combusted by the system. A separation of carbon and oxygen from the hydrocarbons CO and CO<NUM> is performed by the entire system.

Embodiments of the system <NUM> include heat exchanger <NUM> for the reduction of the temperature from the argon <NUM>, as per the embodiments of <FIG> and <FIG> heated from the heating tubes <NUM>-<NUM>, within the housing <NUM> of apparatus <NUM>. In addition, gases may be leaked from the heating tubes which are also present within the housing cavity <NUM>. These leaked flue gases are mixed with argon <NUM> and therefore must be extracted and removed from the cavity and directed to the heat exchanger <NUM> and the contaminated argon cleaned. The PLC module <NUM> and system sensor may be used to keep these flue gases in safe concentration.

In some embodiments, the system <NUM> includes turbine electricity generation <NUM>. The electricity is forwarded to an external system entity of the grid <NUM> or it is redirected back in the system <NUM> via the electrical power supply <NUM>.

Some embodiments of the system <NUM> includes an argon and leaked flue gas density separation scrubber <NUM>. Scrubber <NUM> performs a separation scrubber process in which the reduced temperature argon <NUM> and flue gases are taken from heat exchanger <NUM>. Example gases scrubbed from the heat exchanger <NUM> include Ar, HC, CO, CO<NUM>, N<NUM>, N<NUM>O, H<NUM> and O<NUM>. The uncontaminated argon gases are redirected back to apparatus <NUM> into cavity <NUM> and the leaked flue gases are redirected back into the heating tubes <NUM>-<NUM>, of apparatus <NUM> via the mixing chambers 100A-210A. This process is controlled and regulated by the PLC module <NUM>.

Some embodiments of the system <NUM> include the PLC computer integrated monitoring and control systems <NUM> with internet surveillance. PLC control system <NUM> is preferably connected to all modules in the system <NUM> of <FIG> via the appropriate monitoring system. The PCL control system makes decisions according to a decision table, written by the system architects.

One reason that the system includes a like number (e.g. <NUM>) of air cooled heat exchangers, pumps and cyclones is because gases of identical or similar makeup are being treated for each of the heat tube stages, depending on their stage of pyrolysis and combustion within the heating tube design.

Each heating tube on each of the <NUM> arrays, from /<NUM>-<NUM> depending on their position on the array from position <NUM>-<NUM> from /<NUM>-<NUM> will have similar or identical mixture of flue gases because of their position in the pyrolysis and combustion process. The <NUM>-<NUM> stages during the flue gas processing and therefore the <NUM> air coolers /<NUM>-<NUM> and <NUM> pumps /<NUM>-<NUM> and <NUM> cyclone from /<NUM>-<NUM> for flue gas separation of particles are positioned so that each of these pieces of equipment, starting with the air cooler heat exchange condensers accept input from all heating tubes that are in position one. Stage <NUM>, which is designated /<NUM> and air cooler heat exchange condenser two gets all gases from all <NUM> tube arrays on stage <NUM> /<NUM> in position <NUM> and so on until air cooler heat exchange condenser <NUM> gets all gases from all tubes that are in stage <NUM> which is position /<NUM>. In addition, the flue gases are extracted from the emptying and re-filling the crucibles <NUM>-<NUM> in an enclosed environment at module <NUM>. These gases from module <NUM> are pumped by the pump <NUM>/<NUM> into the cyclone separation <NUM>/<NUM>. From there they are directed back into tube <NUM>/<NUM>-<NUM> for apparatus <NUM>.

The above described embodiments may be adapted to process up to <NUM> kilos of waste per hour when using <NUM> arrays of <NUM> heating tubes. Using an embodiment having a single array of <NUM> heating tubes, between <NUM>-<NUM> kilos of waste per hour can be processed. As an example, the waste product combination may comprise: <NUM>% tyres, <NUM>% paper/carboard, <NUM>% plastic, <NUM>% food scrubs, <NUM>% toxic soup.

For the treatment of waste material, one crucible is required and it is expected that the outcomes from the crucible run are around <NUM>% ash, around <NUM>% carbon black.

For the creation of cement, two crucibles are required. In a top crucible, a mixture of <NUM>% calcium carbide and <NUM>% silica is input. This material on completion of the process will be fully transformed to cement. In a bottom crucible, a mixture of <NUM>% coal is input to be used as fuel to heat the top crucible. On the completion of this process the coal will be transformed <NUM>/<NUM> to coke and <NUM>/<NUM> to town gas. Therefore <NUM>% of the overall mixture on completion will be transformed into coke and the town gas will be mixed with hydroxy gas to generate high levels of heat inside the heating tubes.

For the creation of electricity with a coal fire power station design, one crucible is required. It is expected that the inputs of that crucible will be <NUM>% coal. The outputs of the crucible on completion will be <NUM>/<NUM> coke and <NUM>/<NUM> town gas. Therefore <NUM>% of the overall mixture on completion will be transformed into coke and the <NUM>. % will be mixed with hydroxy gas to generate high levels of heat within the heating tubes.

The overall system design may require the construction of sealed rooms for execution of these processes due to the creation of toxic fumes and pollutants within the overall system which will be captured and eliminated or processed within the overall system. Toxic fumes are looped safely back into the heating tubes, without any human hand intervention, only via automation and PLC control. For example, emptying and refilling of the agitating crucible(s) should be performed in an enclosed environment, as should be the sorting of waste material.

In some embodiments, the production of hydroxy gas may be done in situ as required. In these embodiments, no storage of hydroxy gas is required as the hydroxy gas may be generated and used immediately.

Some example measurements and experiments performed with the above described embodiments of the invention will now be described.

A single tungsten heating tube <NUM> was used for the purpose of combusting and pyrolysing a vaporised oil (produced as a byproduct from the pyrolysation and combustion of an afterlife vehicle tyre) in the presence of oxyhydrogen (HHO), hydroxy gas at temperature up to <NUM>,<NUM> degrees Celsius.

Note (*) these items were not measurable by the approved lab.

Note (**) these tests had no recorded measurements by the approved lab. The lab's written explanation was that the measurements were too small or outside their limitations. The tests <NUM>, <NUM> and <NUM> for the inputs and outputs will be repeated for completion in the future. The assumptions given in the written explanation of the lab is that the outputs of these tests, which are hydrocarbons and compounds, is zero.

The above results show that there was a marked increase in hydrogen production across all three measurements, each being considered an acceptable syngas amount for use in the production of methanol when reacted in the presence of carbon monoxide (CO) and carbon dioxide (CO<NUM>) via the catalytic compression conversion process. See <FIG>, item <NUM>. Therefore, if the results of test <NUM>-<NUM> are catalytically compressed they should produce methanol.

The most effective test is test <NUM> which has a balance/neutral blue flame, a of mix of hydroxy with the flue gases that were produced by <NUM>% chopped tyres.

These are the results of the above tests derived from the report provided from the approved lab on examination of the gas outputs:.

A single tungsten heating tube <NUM> was used for the purpose of pyrolysing and combusting a vaporized polymer oil (produced as a byproduct from the pyrolysis of plastic/polymers obtained from a sample of domestic waste) in the presence of oxyhydrogen (HHO) gas, hydroxy gas up to temperatures of <NUM>,<NUM> degrees Celsius.

These are the results of the above tests derived from the report provided from the approved lab, on examination of the gas outputs:.

Note (*) indicates that the measurements of this gas were not determined, or were not measurable by the approved lab.

The above results show that there was a marked reduction in carbon dioxide (CO<NUM>) from <NUM>% down to <NUM>% and carbon monoxide (CO) from <NUM>% down to <NUM>%. This equates to a <NUM> % reduction in CO<NUM> and a <NUM>% reduction in CO, with a total elimination of all hydrocarbons and toxins.

A single tungsten heating tube <NUM> was used for the purpose of pyrolysing and combusting bottled carbon dioxide (CO<NUM>). From the inputs presented for this test, some air was present. The pyrolysis and combustion of this mixture of gases was done in the presence of oxyhydrogen (HHO), hydroxy gas at temperature up to <NUM> degrees Celsius. That is, the hydrocarbons combined with the hydroxy when pyrolysed and combusted can increase the temperatures up to <NUM> degrees Celsius in the heating tubes. This process is supported by reference <NUM> below. In some embodiments, the pyrolysis and combustion at temperatures in the range of <NUM> to <NUM> degrees Celsius or within subranges thereof.

The above results show that there was a marked reduction in CO<NUM> from <NUM>% down to <NUM>%, which equates to a <NUM>% reduction in CO<NUM>.

A single tungsten heating tube <NUM> was used for the purpose of pyrolysing town gas/coal (produced as a byproduct from the pyrolysis and partial combustion of coal within the crucible). The combustion and pyrolysis were done within the heating tube <NUM> in the presence of oxyhydrogen (HHO), hydroxy gas up to temperatures of <NUM>,<NUM> degrees Celsius.

The above results show that there was a marked reduction in carbon dioxide (CO<NUM>) from <NUM>% down to <NUM>% and carbon monoxide (CO) from <NUM>% down to <NUM>%. This equates to a <NUM>% reduction in CO<NUM> and a <NUM>% reduction in CO, with a total elimination of all hydrocarbons and toxins.

A first tungsten heating tube <NUM> was used for the purpose of pyrolysing and combusting a mixture of the following products obtained from a combination of domestic and some industrial waste tyres (<NUM>%), general plastics (<NUM>%), paper cellulose (<NUM>%), food scraps(<NUM>%), toxic soup (<NUM>%), in the presence of hydroxy gas oxyhydrogen (HHO) gas at a temperature of up to <NUM> degrees Celsius. Other toxic products may be included in the waste mix such as toxic soil, PCBs for transformers, PFAS chemicals or any toxic chemical compound because we are breaking the bonding electrons by using high temperature pyrolysation and combustion within the tubes <NUM>, <NUM> and so forth.

The above results show that there was a marked reduction in carbon dioxide (CO<NUM>) from <NUM>% down to <NUM>% but a marked increase in carbon monoxide (CO) from <NUM>% up to <NUM>%. This equates to a <NUM>% reduction in CO<NUM> and a <NUM>% increase in CO, with a significant reduction in the number of hydrocarbons present, from <NUM>% down to <NUM>%, equating to a <NUM>% reduction of all hydrocarbons and toxins.

These are the results of the above tests derived from the report provided from the approved lab, on examination of the gas outputs:
Results after the tube <NUM>:.

Note (*) and note (**) explanations, nitrogen, and argon: inert gases, argon plus nitrogen, which is basically inert were measured. Nitrous oxide was not measured and a % range was introduced for completion. The composition of nitrous oxide in the gases will be measured in future experiments and configurations with the use of expensive, high precision, spectrum analysis sensors.

A second tungsten heating tube <NUM> was then used for the purpose of pyrolysing and combusting the resultant waste product flue gases in the presence of hydroxy gas (HHO) up to <NUM> degrees Celsius.

The above results show that there was a further reduction in CO<NUM> from <NUM>% down to <NUM>% and a subsequent reduction in CO from <NUM>% down to <NUM>%. This equates to an <NUM>% reduction in CO<NUM> and a <NUM>% reduction in CO, with a total elimination of all hydrocarbons and toxins.

These are the results of the above tests derived from the report provided from the approved lab, on examination of the gas outputs:
Results after tube02:.

The above results show that there was a reasonable increase in hydrogen production, across all three measurements, each being considered an acceptable amount for use in the production of methanol when reacted in the presence of carbon monoxide (CO) and carbon dioxide (CO<NUM>) via the catalytic conversion process suggested in system <NUM>, (see item <NUM> in <FIG>).

Note (*) and note (**) explanations, nitrogen, and argon: inert gases, argon plus nitrogen, which is basically inert, were measured. Nitrous oxide was not measured and a % range was introduced for completion. The composition of nitrous oxide in the gases will be measured in future experiments and configurations with the use of expensive, high precision, spectrum analysis sensors.

In test <NUM>, the above results show that there was a marked reduction in carbon dioxide (CO<NUM>) from <NUM>% down to <NUM>% and a decrease in carbon monoxide (CO) from <NUM>% down to. This equates to a <NUM>% reduction in CO<NUM> and a reduction of <NUM>% in CO. with a significant reduction in the number of hydrocarbons present, from <NUM>% down to zero, equating to a <NUM>% reduction of all hydrocarbons and toxins. For test <NUM> with the first heating tube <NUM>, there is a reduction of hydrogen from <NUM>% down to <NUM>% a <NUM>% reduction. For test <NUM> with the first heating tube <NUM>, there is an increase of oxygen from <NUM>% to <NUM>% a <NUM>% increase.

In test <NUM>, the above results show that there was an increase in carbon dioxide (CO<NUM>) from <NUM>% up to <NUM>% and a decrease in carbon monoxide (CO) from <NUM>% down to. This equates to a <NUM>% increase in CO<NUM> and a reduction of <NUM>% in CO, with a significant reduction in the number of hydrocarbons present, from (*) non measurable (methane, ethene, ethane) as outputs of previous heating tube <NUM>, reduced to zero, equating to a <NUM>% reduction of all hydrocarbons and toxins. For test <NUM> with the second heating tube <NUM>, there is a reduction of hydrogen from <NUM>% down to <NUM>%; an <NUM>% reduction. For test <NUM> with the second heating tube <NUM>, there is a decrease of oxygen from <NUM>% to <NUM>% a <NUM>% reduction.

The conclusion given that tests for heating tubes <NUM>-<NUM> for example <NUM> and example <NUM> have different outcomes is as follows: the temperatures and the volumes were not calibrated. Tubes <NUM>-<NUM> have not fully eliminated the introduction of air/nitrogen at this point on the apparatus, which is the intention of the inventor.

It is clear that the tests of heating tubes <NUM>-<NUM> for example <NUM> and example <NUM> have similar desirable outcomes in the following areas. Both tests indicate significant decrease of the CO<NUM> and HC elimination in these two tests process by the two heating tubes. This is achieved by the treatment of just two heating tubes and it is the intention to be done with an array of <NUM> heating tubes <NUM>-<NUM> connected in sequence. These outcomes are clearly demonstrated on all tests from example <NUM>-<NUM> utilises one heating tube, examples <NUM>-<NUM> utilises two heating tubes.

There is a clear correlation and a relationship between the directions of O<NUM> vs the directions of: CO, CO<NUM> and H<NUM>. That is when CO, CO<NUM> and H<NUM> go up, the O<NUM> goes down and when CO, CO<NUM> and H<NUM> go down, the O<NUM> levels goes up.

It is therefore apparent that the above described apparatus <NUM>, after the treatment of all inputs in the crucible <NUM>-<NUM> and the arrays of heating tubes <NUM>-<NUM>/<NUM>-<NUM> provides a significant reduction and elimination of HC, and reduction of CO and CO<NUM>, to produce methanol or dry ice. The levels of reduction of H<NUM> after the complete treatment by the apparatus <NUM> will depend on the reduction of CO and CO<NUM>. It is predicted that the levels of O<NUM> should increase, the level of NO<NUM> should decrease and the level of N<NUM> (nitrogen) once the whole system is sealed (no air) would be stabilised and decrease.

In essence, the apparatus <NUM> and method as described above presents a unique and environmentally safe means by which to dispose of hydrocarbon based waste materials that may otherwise simply pollute the atmosphere and groundwater during their disposal via conventional methods.

The apparatus <NUM> and method as described above also present a unique and environmentally safe means by which coal can be processed, via pyrolysis and combustion, in a coal fire power station and coal with silica with calcium carbonate, for manufacture of cement.

This apparatus <NUM> could prove invaluable to industry particularly the energy industry, whereby the need for chimney stacks to ventilate highly toxic flue gases into the upper atmosphere becomes a thing of the past.

Similarly, the high calorific value associated with the pyrolysis and combustion of hydrocarbon based waste materials or coal may be exploited by converting them to electrical energy that will be utilised by the apparatus <NUM>, while the remainder may be sold back to the grid <NUM>.

With some straightforward system design amendments to the overall apparatus10, the presently described configurations can be adopted for processing a wide range of waste products, including coal fire power stations (coke), cement manufacture, gas fire power stations, sewerage treatment, contaminated soil and toxic waste and all engineering systems that serve the industrial heat industry that may require high temperatures or crucible(s) or just heating tubes, without a crucible. Adjustments to the electronics can be made to the PLC computer integrated monitoring and control system to accommodate the various inputs for each system application of the apparatus of polarisation and combustion.

While the invention has been described in conjunction with a limited number of embodiments, it will be appreciated by those skilled in the art that many alternatives, modifications, and variations in light of the scope of the invention as defined in the appended claims.

Claim 1:
An apparatus (<NUM>) for pyrolysing and combusting a material, the apparatus (<NUM>) comprising:
one or more crucibles (<NUM>, <NUM>) for receiving a material to be pyrolysed and combusted therein; and
one or more heating tubes (<NUM>-<NUM>) disposed around the crucible(s) (<NUM>, <NUM>),
wherein the or each heating tube (<NUM>-<NUM>) is configured for:
receiving byproduct(s) via a conduit ( <NUM>) produced during pyrolysis and combustion of the material within the crucible(s);
mixing, in a mixing chamber (110A-210A) a hydroxy gas comprising a mix of hydrogen and oxygen with the byproduct(s); and
igniting the hydroxy gas, via an electronic ignition device (<NUM>) that is electrically connected to the or each heating tube (<NUM>-<NUM>) to pyrolyse and combust the mixture of the byproduct(s) and the hydroxy gas to produce processed gas from the byproduct(s).