Patent Description:
Plastics play an important role in modern industrial society. Plastics can be found in packaging materials, heat-insulating materials, components of electrical and electronic devices, automobile parts, automobile interiors, and the like. In <NUM>, a study by the National Geographic Society estimated that humans had produced <NUM> billion metric tons of plastic waste since the early <NUM>'s. Only <NUM>% of this plastic waste had been recycled. The amount of plastic waste production has only continued to increase, as the consumption of plastics continues to increase.

Plastics have excellent corrosion resistance, chemical resistance, durability, and the like. While this makes them very useful for parts and products, it also means that plastics do not easily decompose in their natural state. This has a devastating effect on the environment. For example, marine life has been adversely affected by plastic waste, and especially by the micro-plastics that are generated from larger plastics. For example, plastic waste has decreased the number of plankton. However, not only does plastic waste affect marine life, it also affects human and other animal life, since a large amount of food is sourced from the ocean.

Because of the toxic nature of plastic waste and polymers, much effort has been directed to the problem of recycling plastics and using recycled plastics. One method of disposing of plastic waste uses fuel, such as natural gas, to burn the plastic waste. However, this method produces excessive pollutants, is not cost-effective, and requires high temperatures in order to consume the plastic waste. Another method involves complicated and expensive chemical processes.

Prior art publications <CIT>, <CIT>, <CIT>, and <CIT> each disclose apparatus and processes for combusting waste plastics. These known apparatus differ from the invention as claimed herein at least in that they are not provided with the particular configuration of a primary reactor ejecting into the side of a secondary reactor.

Accordingly, a plastic-powered power generator is disclosed that utilizes plastic waste as fuel to generate power. The plastic-powered power generator may comprise an electrochemical, thermal, and/or mechanical system that conveys heat from processed plastic waste to an inline heat exchanger. The plastic power generator may utilize micro-pulverized plastic to create thermal energy, and extract that thermal energy to turn a steam turbine that produces electricity.

According to a first aspect, the invention provides a plastic-powered power generator according to claim <NUM>. The plastic-powered power generator may further comprise a reducer positioned between the blower and the secondary reactor, wherein the reducer is configured to speed up the air flow into the secondary reactor.

The second opening of the primary reactor chamber may be angled with respect to a longitudinal axis of the primary reactor chamber, such that the second end of the primary reactor chamber extends farther into the secondary reactor at a side nearer the blower than at a side farther from the blower. The second end of the primary reactor chamber may comprise a lip which extends over a portion of the second opening of the primary reactor chamber.

The air-fuel distribution assembly may comprise an air-oxidizer manifold that comprises: a dispersal port comprising a channel from a rear surface of the air-oxidizer manifold to a front surface of the air-oxidizer manifold, wherein the front surface of the air-oxidizer manifold faces the first opening in the primary reactor chamber; at least one concentric channel, surrounding the dispersal port, recessed into the rear surface of the air-oxidizer manifold; at least one inlet port through a side surface of the air-oxidizer manifold and connected to the at least one concentric channel; and one or more jet holes extending through the air-oxidizer manifold from a recessed surface of the at least one concentric channel to the front surface of the air-oxidizer manifold. The one or more jet holes may be angled with respect to a longitudinal axis of the air-oxidizer manifold. The at least one concentric channel may comprise two or more concentric channels, wherein the at least one inlet port comprises two or more inlet ports that are each connected to one of the two or more concentric channels, and wherein the one or more jet holes comprise a plurality of jet holes. One of the two or more concentric channels may be recessed deeper into the rear surface of the air-oxidizer manifold than a second one of the two or more concentric channels.

The plastic-powered power generator may further comprise a pneumatic system that is configured to supply air through a first one of the two or more inlet ports, and supply an oxidizing agent through a second one of the two or more inlet ports. The pneumatic system may be further configured to supply the air through the second inlet port. The pneumatic system may be configured to: monitor a temperature in the primary reactor chamber; while the temperature remains below a predetermined threshold, supply the air through the first inlet port, and supply the oxidizing agent through the second inlet port; and, when the temperature exceeds the predetermined threshold, supply the air through both the first inlet port and the second inlet port, and reduce or stop the supply of the oxidizing agent through the second inlet port.

The air-fuel distribution assembly may further comprise an air-fuel mixer that is attached to the rear surface of the air-oxidizer manifold, wherein the air-fuel mixer comprises: an internal chamber; a fluidized polymer outlet port connecting the internal chamber to the dispersal port in the air-oxidizer manifold; an air inlet port configured to supply air flow through the internal chamber; and a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber.

The plastic-powered power generator may further comprise a fluidizer that comprises: a body comprising a first opening in a first end and a second opening in a second end, wherein the body is configured to house one or more layers of polymer; a base that covers the first opening in the body, wherein the base comprises an internal cavity, an air inlet port configured to receive air, and a porous membrane between the internal cavity and the first opening in the body; and a lid that covers the second opening in the body, wherein the lid comprises a fluidized polymer outlet port that is connected to the fluidized polymer inlet port of the air-fuel mixer, so as to provide fluidized polymer to the air-fuel mixer through the connected fluidized polymer outlet and inlet ports.

The ignition system may comprise one or more electrode pairs, wherein each of the one or more electrode pairs comprises a positive electrode aligned, through the primary reactor chamber, with a ground electrode. The one or more electrode pairs comprise a plurality of electrode pairs, wherein the plurality of electrode pairs alternate in orientation, such that no positive electrode is adjacent to another positive electrode and no ground electrode is adjacent to another ground electrode. The plurality of electrode pairs may comprise two or more electrode pairs that are oriented in a plane that is orthogonal to a plane in which two or more other electrode pairs are oriented.

The plastic-powered power generator may further comprise a distributor system that comprises: a high-spark energy generator and a ground distributor, wherein each of the high-spark energy generator and the ground distributor comprises a distributor cap comprising a plurality of towers arranged around a circumference of the distributor cap, wherein each of the plurality of towers on the distributor cap of the high-spark energy generator is electrically connected to a positive electrode in one of the plurality of electrode pairs, and wherein each of the plurality of towers on the distributor cap of the ground distributor is electrically connected to a ground electrode in one of the plurality of electrode pairs, and a pulley connected to a rotor by a shaft, such that, when the pulley rotates, the rotor passes underneath each of the plurality of towers in a sequence; and a motor that drives a timing belt to rotate the pulleys of the high-spark energy generator and the ground distributor, such that, as the rotor of the high-spark energy generator passes underneath a tower on the distributor cap of the high-spark energy generator, the rotor of the ground distributor simultaneously passes underneath a corresponding tower on the distributor cap of the ground distributor, so as to create a spark from the positive electrode that is electrically connected to the tower on the distributor cap of the high-spark energy generator to the ground electrode that is electrically connected to the corresponding tower on the distributor cap of the ground distributor.

The heat exchanger may be configured to receive an aqueous fluid into the coil and output steam, resulting from heating the coil, through a steam line connected to the coil, and wherein the plastic-powered power generator further comprises: an electrical generator; and a turbine configured to spin the electrical generator as the steam passes through the turbine, so as to produce electrical power from the electrical generator.

According to a second aspect, the invention provides a method according to claim <NUM>. Pulverizing the plastic waste may comprise: shredding the plastic waste into micron-scale plastic waste; and pelletizing the shredded micron-scale plastic waste into the sub-micron-scale polymer.

The details of the present invention, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:.

Embodiments of a plastic-powered power generator according to the invention are disclosed. The plastic-powered power generator uses plastic waste, which is a clean and energy-rich material derived from crude oils, as fuel. Advantageously, this conversion of plastic waste to fuel not only provides power, but also reduces plastic waste.

After reading this description, it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example and illustration only, and not limitation. As such, this detailed description of various embodiments should not be construed to limit the scope or breadth of the present invention as set forth in the appended claims.

<FIG> and <FIG> illustrate a plastic-powered power generator <NUM> in different perspective views, and <FIG> illustrates plastic-powered power generator <NUM> in an exploded perspective view, according to an embodiment. In the illustrated embodiment, plastic-powered power generator <NUM> comprises a blower <NUM>, which may utilize a motor to blow air into an adaptor or reducer <NUM>. Reducer <NUM> increases the velocity of the blown air as the air is fed into a secondary reactor <NUM>. Secondary reactor <NUM> heats the air and outputs the heated air into heat exchanger <NUM>, which may heat water to produce steam. In addition, a primary reactor <NUM> is connected to secondary reactor <NUM> at a perpendicular angle with respect to a longitudinal axis through secondary reactor <NUM>.

Plastic-powered power generator <NUM> may be manufactured from one or more materials, including pure ceramic, ferrous, or non-ferrous metal that is ceramic-coated or anodized. Anodization is an electrolytic passivation process, used to increase the thickness of the natural oxide layer on the surface of non-ferrous metal parts. Advantageously, ceramic-coated or anodized ferrous metal creates a dielectric state to protect against the dangers of static electricity, including grounding.

Plastic-powered power generator <NUM> may be manufactured to any scale. For example, plastic-powered power generator <NUM> may be manufactured as a small-scale, portable generator. Alternatively, plastic-powered power generator <NUM> may be manufactured as a large-scale regional power plant. As another alternative, a system, comprising any quantity of plastic-powered power generators <NUM>, may be constructed to provide any desired amount of electrical power.

<FIG> illustrate blower <NUM> in perspective and side views, respectively, according to an embodiment. In the illustrated embodiment, blower <NUM> comprises a main body <NUM> and a flange <NUM>.

Main body <NUM> may house a blower motor that spins to generate air flow out of opening <NUM> in main body <NUM>. Alternatively, another motor or mechanism may be used to generate the air flow out of opening <NUM>.

Flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough.

<FIG> illustrate reducer <NUM> in perspective and side views, and <FIG> illustrate individual components of reducer <NUM>, according to an embodiment. In the illustrated embodiment, reducer <NUM> comprises an adapter cone <NUM> that is open on both ends, with a flange <NUM> on the larger end (i.e., the end with the larger diameter) and a flange <NUM> on the smaller end (i.e., the end with the smaller diameter).

Adapter cone <NUM> has a substantially conical shape, with openings on both ends. However, adapter cone <NUM> may have substantially cylindrical portions <NUM> and <NUM> on both ends. Flanges <NUM> and <NUM> may be seated on or integrated with these substantially cylindrical portions <NUM> and <NUM>, respectively.

Flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough. Specifically, flange <NUM> may be adjoined to flange <NUM> of blower <NUM>, with each hole <NUM> aligned to a corresponding hole <NUM>. Flange <NUM> may then be fixed to flange <NUM> by inserting bolts through the aligned holes <NUM>/<NUM>, and threading and tightening the bolts through corresponding nuts, to thereby fix reducer <NUM> to blower <NUM>. Alternatively or additionally, other mechanisms may be used to fix flanges <NUM> and <NUM> to each other and/or to fix reducer <NUM> and blower <NUM> to each other.

Flange <NUM> may be substantially similar to flange <NUM>, but with a smaller inner diameter than flange <NUM>, and optionally a smaller outer diameter as well. Similarly to flange <NUM>, flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM> configured to receive a bolt therethrough.

As air flows through the conical reducer, from the larger diameter end, defined by end portion <NUM> and flange <NUM>, to the smaller diameter end, defined by end portion <NUM> and flange <NUM>, the speed of the air will increase. Thus, reducer <NUM> increases the speed of the air flowing out of opening <NUM> of blower <NUM> and into the proximal end of secondary reactor <NUM>.

<FIG> illustrates secondary reactor <NUM> in a perspective view, and <FIG> illustrate secondary reactor <NUM> in different side views, according to an embodiment. <FIG> illustrate individual components of secondary reactor <NUM>, according to an embodiment. In the illustrated embodiment, secondary reactor <NUM> comprises a substantially cylindrical body <NUM> that is open on both ends, with a flange 420A on one end, a flange 420B on the other end, and a flange <NUM> around a substantially cylindrical lip <NUM> that intersects cylindrical body <NUM> at an orthogonal angle to thereby provide an open pathway into the interior of cylindrical body <NUM> through the side of cylindrical body <NUM>.

Cylindrical body <NUM> is substantially cylindrical, with openings on both ends and a circular hole defined by a cylindrical lip <NUM> extending out from cylindrical body <NUM>, to provide a pathway through the side of cylindrical body <NUM> into the interior of cylindrical body <NUM>. Cylindrical body <NUM> is configured to allow air from blower <NUM> to flow from one end (e.g., the opening surrounded by flange 420A) to the opposite end (e.g., the opening surrounded by flange 420B).

Flanges 420A and 420B may be, but are not necessarily, identical. Each flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough. Specifically, flange 420A may be adjoined to flange <NUM> of reducer <NUM>, with each hole <NUM> aligned to a corresponding hole <NUM> in flange <NUM>. Flange 420A may then be fixed to flange <NUM> by inserting bolts through all of the aligned holes <NUM>/<NUM>, and threading and tightening the bolts through corresponding nuts, to thereby fix secondary reactor <NUM> to reducer <NUM>. Alternatively or additionally, other mechanisms may be used to fix flanges 420A and <NUM> to each other and/or to fix secondary reactor <NUM> and reducer <NUM> to each other.

Flange <NUM> may be substantially similar to flanges <NUM>, but may have a different inner and/or outer diameter than flanges <NUM>. In the illustrated embodiment, flange <NUM> has a smaller inner and outer diameter than flanges <NUM>. However, in a different embodiment, flange <NUM> may have the same or different inner and/or outer diameters than flanges <NUM>. Similarly to flanges <NUM>, flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough.

As air flows through secondary reactor <NUM>, the air is heated by primary reactor <NUM> via a flame, produced by primary reactor <NUM>, through the hole defined by lip <NUM>. The heated air from secondary reactor <NUM> flows into heat exchanger <NUM>.

<FIG> illustrate heat exchanger <NUM> in orthogonal side views, according to an embodiment. <FIG> illustrates heat exchanger <NUM> down its longitudinal axis, according to an embodiment. <FIG> illustrate individual components of heat exchanger <NUM>, according to an embodiment. In the illustrated embodiment, heat exchanger <NUM> comprises a substantially cylindrical body <NUM> that is open on both ends, with a flange 520A on one end, a flange 520B on the other end, and at least two connector fittings <NUM> on substantially opposite sides of cylindrical body <NUM>.

Cylindrical body <NUM> is substantially cylindrical, with openings on both ends and fitting holes <NUM> (e.g., circular holes in the illustrated embodiment) cut into substantially opposite sides to receive connector fittings <NUM>. Cylindrical body <NUM> may house a coil through which fluid flows. For example, the coil may be wound around an inner circumference of cylindrical body <NUM>, with an open pathway through the center of the coil (i.e., down the longitudinal axis of cylindrical body <NUM>), such that exhaust from secondary reactor <NUM> can pass through cylindrical body <NUM> via the open pathway, while heating the coils. The fluid, flowing through the coil, may comprise water. In an embodiment, the fluid may be an aqueous solution containing ethylene glycol, which helps reduce corrosion and freezing within the coil.

Flanges 520A and 520B may be, but are not necessarily, identical. Each flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough. Specifically, flange 520A may be adjoined to flange 420B of secondary reactor <NUM>, with each hole <NUM> aligned to a corresponding hole <NUM> in flange 420B. Flange 520A may then be fixed to flange 420B by inserting bolts through all of the aligned holes <NUM>/<NUM>, and threading and tightening the bolts through corresponding nuts, to thereby fix heat exchanger <NUM> to secondary reactor <NUM>. Alternatively or additionally, other mechanisms may be used to fix flanges 520A and 420B to each other and/or to fix heat exchanger <NUM> and secondary reactor <NUM> to each other.

Connector fittings 530A and 530B may be, but are not necessarily, identical. Each connector fitting <NUM> is configured to be seated within fitting holes <NUM> in opposing sides of cylindrical body <NUM>, and be releasably connected to an external line. Within cylindrical body <NUM>, connector fittings 520A and 530B are attached to opposite ends of the coil, such that fluid may flow, through connector fitting 530A, from one end of the coil to the other end of the coil, and out connector fitting 530B. Thus, one connection fitting 520A may be used to input fluid into the coil within cylindrical body <NUM>, whereas the other connection fitting 520B may be used to output steam from cylindrical body <NUM>. An input fluid line may feed the fluid into connection fitting 520A and into the internal coil of cylindrical body <NUM>, where it is converted to steam, while an output line may allow the steam from the internal coil of cylindrical body <NUM> to flow out into an output steam line or other device or system.

<FIG> illustrate various isolated components of primary reactor <NUM>, according to an embodiment. Specifically, <FIG> illustrate various views of an air-fuel mixer <NUM> of primary reactor <NUM>, <FIG> illustrate various views and components of an air-oxidizer manifold <NUM>, <FIG> illustrate various views and components of an air-fuel distribution assembly comprising air-fuel mixer <NUM> and air-oxidizer manifold <NUM>, and <FIG> illustrate various views and components of primary reaction chamber <NUM>, according to embodiments. In addition, <FIG> illustrate various views and components of an ignition system that may be utilized to ignite primary reactor <NUM>, according to an embodiment, <FIG> illustrate a fluidizer <NUM> that may be used feed plastic waste as fuel to air-fuel mixer <NUM>, according to an embodiment, and <FIG> and <FIG> illustrate pneumatic systems <NUM> that may be used with primary reactor <NUM>, according to embodiments. While primary reactor <NUM> may comprise or utilize all of the illustrated components, it is not necessary for all embodiments of primary reactor <NUM> to comprise all of the illustrated components in the illustrated configuration. Rather, embodiments of primary reactor <NUM> may comprise a combination of some of the illustrated embodiments of components with non-illustrated embodiments of the other components, and/or may omit some of the illustrated components.

<FIG> illustrates air-fuel mixer <NUM> in a perspective view, and <FIG> illustrate air-fuel mixer <NUM> in a front view, rear view, and bottom view, respectively, according to an embodiment. <FIG> illustrates air-fuel mixer <NUM> in a cross-sectional side view, according to an embodiment. In the illustrated embodiments, air-fuel mixer <NUM> comprises an air inlet port <NUM>, a fluidized polymer inlet port <NUM>, an internal chamber <NUM>, and a fluidized polymer outlet port <NUM>.

Air inlet port <NUM> may comprise an opening in the rear of air-fuel mixer <NUM> that provides a first pathway (e.g., a straight and/or cylindrical flow path) into internal chamber <NUM> within the body of air-fuel mixer <NUM>. A regulated air source (e.g., tank of compressed air) may be connected to air inlet port <NUM> to provide regulated air through air inlet port <NUM> into internal chamber <NUM>. Air inlet port <NUM> may be formed in any suitable manner, so that it may be connected to a regulated air source.

Similarly, fluidized polymer inlet port <NUM> may comprise an opening in the bottom-rear of air-fuel mixer <NUM> that provides a second pathway (e.g., a straight and/or cylindrical flow path) into internal chamber <NUM> within the body of air-fuel mixer <NUM>. A fluidizer (e.g., fluidizer <NUM>) may be connected to fluidized polymer inlet port <NUM> to provide fluidized polymer through fluidized polymer inlet port <NUM> into internal chamber <NUM>. Fluidized polymer inlet port <NUM> may be formed in any suitable manner, so that it may be connected to a fluidizer.

Fluidized polymer outlet port <NUM> may comprise an opening in the front of air-fuel mixer <NUM> that provides a third pathway (e.g., a straight and/or cylindrical flow path) out of internal chamber <NUM>. Thus, regulated air, provided through air inlet port <NUM>, and fluidized polymer, provided through fluidized polymer inlet port <NUM>, mix within internal chamber <NUM>. This air-fuel mixture within internal chamber <NUM> flows out of fluidized polymer output port <NUM>. Fluidized polymer output port <NUM> may be formed in any suitable manner, so that it may be connected to air-oxidizer manifold <NUM>. As illustrated in particular in <FIG>, the diameter of fluidized polymer output port <NUM> and/or internal chamber <NUM> may be larger than the diameter of air inlet port <NUM> and/or fluidized polymer inlet port <NUM>.

In the illustrated embodiment, air-fuel mixer <NUM> comprises a straight pathway through air inlet port <NUM>, internal chamber <NUM>, and fluidized polymer output port <NUM> (e.g., comprising the first and third pathways), and an angled pathway through fluidized polymer inlet port <NUM> into internal chamber <NUM> (e.g., comprising the second pathway). The angled pathway may be at any suitable angle with respect to the straight pathway (e.g., <NUM>°-<NUM>°). However, it should be understood that the first, second, and third pathways may be arranged in any suitable configuration with respect to each other, as long as the pathways result in the air, from air inlet port <NUM>, converging with the fluidized polymer, from fluidized polymer inlet port <NUM>, to create an air-fuel mixture that exits fluidized polymer outlet port <NUM>.

<FIG> illustrates air-oxidizer manifold <NUM> in perspective view, and <FIG> illustrates air-oxidizer manifold <NUM> in a rear view, according to an embodiment. <FIG> illustrates a close-up of a region, on the rear of air-oxidizer manifold <NUM>, defined by circle A in <FIG>, according to an embodiment. <FIG> illustrate a cut-away of a rear portion of air-oxidizer manifold <NUM> in perspective and rear views, respectively, according to an embodiment. <FIG> illustrate a deeper cut-away of the rear portion of air-oxidizer manifold <NUM>, than in <FIG>, in perspective and rear views, respectively, according to an embodiment. In the illustrated embodiments, the rear surface of air-oxidizer manifold <NUM> comprises a fluidized polymer dispersal port <NUM>, with concentric channels <NUM> and <NUM> around fluidized polymer dispersal port <NUM>. While dispersal port <NUM> and concentric channels <NUM> and <NUM> are illustrated as circular, it should be understood that other shapes could be used instead (e.g., square, triangular, etc.).

Concentric channel <NUM> may be an oxidizer distribution channel formed as a circular recess in the rear surface of air-oxidizer manifold <NUM>. Concentric channel <NUM> comprises one or more, and preferably multiple (e.g., four or more), jet holes <NUM>. Jet holes <NUM> may be arranged equidistantly apart from each other within the recessed surface of concentric channel <NUM>. Each jet hole <NUM> provides a pathway for an oxidizing agent from concentric channel <NUM> in the rear surface of air-oxidizer manifold <NUM>, through the interior of air-oxidizer manifold <NUM>, out the front surface of air-oxidizer manifold <NUM>. Each jet hole <NUM> may be angled (e.g., <NUM>°) with respect to a longitudinal axis X passing through the center of fluidized dispersal port <NUM>. This angling of jet hole(s) <NUM> facilitates the creation of a vortex as the oxidizing agent exits the front surface of air-oxidizer manifold <NUM>. The diameter of each jet hole <NUM> may be approximately <NUM> to <NUM> inches, with all jet holes <NUM> having the same diameter as each other, or alternatively, two or more jet holes <NUM> having different diameters than each other.

In addition, concentric channel <NUM> is connected to an oxidizer inlet port <NUM>. As illustrated, oxidizer inlet port <NUM> provides a pathway, along a lateral axis that is perpendicular to the longitudinal axis X, from a side surface of air-oxidizer manifold <NUM>, into concentric channel <NUM>. Thus, the oxidizing agent may flow through oxidizer inlet port <NUM>, into concentric channel <NUM>, where it is distributed through jet hole(s) <NUM>, and out of the front of air-oxidizer manifold <NUM>.

Concentric channel <NUM> may be an air distribution channel formed as a circular recess in the rear surface of air-oxidizer manifold <NUM>. Concentric channel <NUM> comprises one or more, and preferably multiple (e.g., four or more), jet holes <NUM>. Jet holes <NUM> may be arranged equidistantly apart from each other within the recessed surface of concentric channel <NUM>. Each jet hole <NUM> provides a pathway for air from concentric channel <NUM> in the rear surface of air-oxidizer manifold <NUM>, through the interior of air-oxidizer manifold <NUM>, out the front surface of air-oxidizer manifold <NUM>. Each jet hole <NUM> may be angled (e.g., <NUM>°) with respect to the longitudinal axis X passing through the center of fluidized dispersal port <NUM>. The angle may be the same or different than the angle of jet hole(s) <NUM>. This angling of jet hole(s) <NUM> facilitates the creation of a vortex as the air exits air-oxidizer manifold <NUM>. The diameter of each jet hole <NUM> may be approximately <NUM> to <NUM> inches, with all jet holes <NUM> having the same diameter as each other, or alternatively, two or more jet holes <NUM> having different diameters than each other.

In addition, concentric channel <NUM> is connected to an air inlet port <NUM>. As illustrated, air inlet port <NUM> provides a pathway, along a lateral axis that is perpendicular to the longitudinal axis X, from a side surface of air-oxidizer manifold <NUM>, into concentric channel <NUM>. Thus, the air may flow through air inlet port <NUM>, into concentric channel <NUM>, where it is distributed through jet hole(s) <NUM>, and out of the front of air-oxidizer manifold <NUM>. As illustrated in <FIG>, jet hole(s) <NUM> and <NUM> may be offset from each other, such that no jet hole <NUM> is aligned with any jet hole <NUM> along a lateral axis passing through the center of fluidized dispersal port <NUM>. For example, the pattern of jet holes <NUM> and the pattern of jet holes <NUM> may be such that the distances of jet holes <NUM> from jet holes <NUM> is maximized. In the illustrated embodiment, the pattern of jet holes <NUM> is a square (e.g., a jet hole <NUM> positioned at each corner of a square), and the pattern of jet holes <NUM> is a square that is rotated <NUM>° with respect to the square pattern of jet holes <NUM>.

As illustrated by the cut-away views in <FIG>, concentric channel <NUM> is deeper (i.e., recessed farther from the rear surface of air-oxidizer manifold <NUM>) than concentric channel <NUM>. Consequently, as shown by <FIG> and <FIG>, oxidizer inlet port <NUM> is also deeper (i.e., farther from the rear surface of air-oxidizer manifold <NUM>) than air inlet port <NUM>. Notably, a first pathway is provided through air-oxidizer manifold <NUM> by the combination of oxidizer inlet port <NUM>, concentric channel <NUM>, and jet(s) <NUM>, and a second pathway is provided through air-oxidizer manifold <NUM> by the combination of air inlet port <NUM>, concentric channel <NUM>, and jet(s) <NUM>. While the first pathway will be described as providing a flow of oxidizing agent and the second pathway will be described as providing a flow of air, this configuration could be reversed, such that the first pathway provides the flow of air and the second pathway provides the flow of oxidizing agent. Also, it should be understood that the different pathways may provide different fluids at different times. For example, the first pathway may provide a flow of oxidizing agent during ignition, but be switched to provide a flow of air once a temperature in the primary reactor <NUM> exceeds a certain threshold temperature value (e.g., <NUM>). In addition, air-oxidizer manifold <NUM> could comprise additional pathways than those illustrated, including, for example, additional inlet ports, concentric channels, and/or jet holes.

Air-oxidizer manifold <NUM> may also comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may pass through both the front and rear surfaces of air-oxidizer manifold, parallel to longitudinal axis X, and be configured to receive a bolt therethrough.

<FIG> illustrate an air-fuel distribution assembly <NUM> in front and rear perspective views, respectively, and <FIG> illustrates air-fuel distribution assembly <NUM> in a side view, according to an embodiment. <FIG> illustrates air-fuel distribution assembly <NUM> in a cross-sectional side view, according to an embodiment, and <FIG> illustrate various components of air-fuel distribution assembly <NUM>, according to an embodiment. In the illustrated embodiments, air-fuel distribution assembly <NUM> comprises a combination of air-fuel mixer <NUM> and air-oxidizer manifold <NUM>.

A transfer tube <NUM> with a flange <NUM> may be used to join air-fuel mixer <NUM> with air-oxidizer manifold <NUM>. For example, a hollow transfer tube <NUM> may be inserted into fluidized polymer outlet port <NUM> and/or otherwise attached and/or fixed to air-fuel mixer <NUM>, so as to maintain an open pathway out of fluidized polymer outlet port <NUM>. Alternatively, transfer tube <NUM> may be integral with air-fuel mixer <NUM>.

A flange <NUM> may be mounted on or integral with transfer tube <NUM>. Flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough. Hole(s) <NUM> may correspond to and align with hole(s) <NUM> in air-oxidizer manifold <NUM>, such that a bolt can be inserted through each hole <NUM> into a corresponding hole <NUM> to adjoin flange <NUM> with the rear surface of air-oxidizer manifold <NUM>.

Air-fuel distribution assembly <NUM> may also comprise an air inlet fitting <NUM>, fluidized polymer inlet fitting <NUM>, an oxidizer fitting <NUM>, and/or an air fitting (not shown). Air inlet fitting <NUM> is installed in air inlet port <NUM> of air-fuel mixer <NUM>, and fluidized polymer inlet fitting <NUM> is installed in fluidized polymer inlet port <NUM> of air-fuel mixer <NUM>. Similarly, oxidizer fitting <NUM> is installed in oxidizer inlet port <NUM> in air-oxidizer manifold <NUM>, and an air fitting may be installed in air inlet port <NUM> of air-oxidizer manifold <NUM>. Each fitting may be configured to be seated within its respective port and be releasably connected to an input line or other device. Each port permits its respective fluid (e.g., air, oxidizing agent, or fluidized polymer) to flow into air-fuel distribution assembly <NUM>.

As regulated air flows through air inlet fitting <NUM> into air inlet port <NUM> and fluidized polymer flows through fluidized polymer inlet fitting <NUM> into fluidized polymer inlet port <NUM>, the regulated air and fluidized polymer mix in internal chamber <NUM> to form an air-fuel mixture. The air-fuel mixture flows out of output port <NUM> and through dispersal port <NUM> in air-oxidizer manifold <NUM>.

In an embodiment, air-fuel distribution assembly <NUM> comprises a dispenser nozzle <NUM> and/or a dispenser cone <NUM>. Dispenser cone <NUM> causes the air-fuel mixture, passing through dispenser nozzle <NUM>, to spray out of the front surface of air-fuel distribution assembly <NUM> in a substantially conical pattern. <FIG> illustrates dispenser nozzle <NUM> in isolation, <FIG> illustrates dispenser cone <NUM> in isolation, and <FIG> illustrates the combination of dispenser nozzle <NUM> and dispenser cone <NUM>. As illustrated, dispenser cone <NUM> comprises one or more, and preferably multiple (e.g., three), feet, that are configured to slide into corresponding slots <NUM> around an edge of an opening in dispenser nozzle <NUM>. The opposite end of dispenser nozzle <NUM> is configured to fit into dispersal port <NUM> through the front surface of air-oxidizer manifold <NUM>.

As the air-fuel mixture sprays out of air-fuel distribution assembly <NUM>, oxidizing agent flows through oxidizer fitting <NUM> into oxidizer inlet port <NUM>, into channel <NUM>, through jet holes <NUM>, and out of the front surface of air-fuel distribution assembly <NUM>. Similarly, as the air-fuel mixture sprays out of air-fuel distribution assembly <NUM>, air flows through the air fitting into air inlet port <NUM>, into channel <NUM>, through jet holes <NUM>, and out of the front surface of air-fuel distribution assembly <NUM>. As discussed above, jet holes <NUM> and <NUM> may be angled with respect to the longitudinal axis X, such that the oxidizing agent and air exit jet holes <NUM> and <NUM>, respectively, at an angle.

<FIG> illustrates primary reactor chamber <NUM> in a perspective view, <FIG> illustrated primary reactor chamber <NUM> in a top view, <FIG> illustrate primary reactor chamber <NUM> in opposing side views, <FIG> illustrate primary reactor chamber <NUM> in rear and front views, respectively, and <FIG> illustrates primary reactor chamber <NUM> in a cross-sectional top or bottom view, according to an embodiment. In the illustrated embodiments, primary reactor chamber <NUM> comprises a substantially cylindrical body <NUM> that is open on both ends, with a flange 920A on one end, and a flange 920B on the other end.

Cylindrical body <NUM> is substantially cylindrical, with openings on both ends. A portion <NUM> of cylindrical body <NUM> may extend beyond flange 920B, and may be sized to fit into cylindrical lip <NUM> in cylindrical body <NUM> of secondary reactor <NUM>. Notably portion <NUM> may comprise an angled opening and/or a lip <NUM> extending over the opening. The opening may be angled at an angle θ (e.g., <NUM>°) with respect to longitudinal axis X, as illustrated in <FIG>. Advantageously, this angled opening in conjunction with lip <NUM> can stabilize the pressure between primary reactor <NUM> and secondary reactor <NUM>.

Cylindrical body <NUM> may comprise a plurality of holes cut, perpendicular to the longitudinal axis X, through the sides of cylindrical body <NUM>. The plurality of holes may be cut as pairs of holes, which each hole in each pair aligned along a lateral axis extending, perpendicularly to the longitudinal axis, through opposite sides of cylindrical body <NUM>. Each hole is fitted with an electrode support body <NUM> that is configured to receive an electrode, and, for each pair of holes, one hole is configured to receive a positive electrode <NUM> (e.g., tungsten electrode) and the other hole is configured to receive a ground electrode <NUM> (e.g., tungsten electrode). Each electrode <NUM> and <NUM> may be seated within a respective electrode support body <NUM> in its respective hole and fixed to cylindrical body <NUM> by a ferrule nut <NUM> that is threaded and tightened over electrode support body <NUM>.

When a positive electrode <NUM> and ground electrode <NUM> are fixed within a pair of holes, they are aligned with each other along a lateral axis extending through the sides of cylindrical body <NUM> and intersecting longitudinal axis X at a right angle. Primary reactor chamber <NUM> may comprise a plurality of these electrode pairs. For example, in the illustrated embodiment, primary reactor chamber <NUM> comprises three electrode pairs oriented horizontally through primary reaction chamber <NUM> and two electrode pairs oriented vertically through primary reactor chamber <NUM>. In other words, one subset of electrode pairs is oriented in a plane that is orthogonal to a plane in which another subset of electrode pairs is oriented. In addition, the orientation of the three horizontal electrode pairs and the two vertical electrode pairs alternate, such that no positive electrodes <NUM> are adjacent to each other on the same side of cylindrical body <NUM> and no ground electrodes <NUM> are adjacent to each other on the same side of cylindrical body <NUM>. Conversely, each positive electrode <NUM> is adjacent to at least one ground electrode <NUM>. Furthermore, the lateral axes, on which each pair of electrodes is aligned, are offset from each other so that they intersect the longitudinal axis X at different points, such that none of the electrode pairs intersect each other.

Flanges 920A and 920B may be, but are not necessarily, identical. Each flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough.

Flange 920A may be adjoined to the front surface of air-oxidizer manifold <NUM> in air-fuel distribution assembly <NUM>, with each hole <NUM> aligned to a corresponding hole <NUM> in air-oxidizer manifold <NUM> and each hole <NUM> aligned to a corresponding hole <NUM> in flange <NUM> of air-fuel distribution assembly <NUM>. Flange 920A may then be fixed to air-fuel distribution assembly <NUM> by inserting bolts through all of the aligned holes <NUM>, <NUM>, and <NUM>, and threading and tightening the bolts through corresponding nuts, to thereby fix primary reaction chamber <NUM> to air-fuel distribution assembly <NUM>. Alternatively or additionally, other mechanisms may be used to fix flanges 920A and <NUM> to each other and/or to fix primary reaction chamber <NUM> and air-fuel distribution assembly <NUM> to each other.

Similarly, flange 920B may be adjoined to flange <NUM> on secondary reactor <NUM>, with each hole <NUM> aligned to a corresponding hole <NUM> in flange <NUM> of secondary reactor <NUM>. Flange 920B may then be fixed to flange <NUM> by inserting bolts through all of the aligned holes <NUM> and <NUM>, and threading and tightening the bolts through corresponding nuts, to thereby fix primary reactor <NUM> to secondary reactor <NUM>. Alternatively or additionally, other mechanisms may be used to fix flanges 920B and <NUM> to each other and/or to fix primary reactor <NUM> and secondary reactor <NUM> to each other.

In operation, an air-fuel mixture sprays, from dispersal port <NUM> of air-oxidizer manifold <NUM> in air-fuel distribution assembly <NUM>, into the opening at the end of cylindrical body <NUM> that is opposite portion <NUM>. In addition, an oxidizing agent and air may be jetted out of jet holes <NUM> and <NUM>, respectively, of air-oxidizer manifold <NUM>, into the same opening of cylindrical body <NUM>.

As discussed elsewhere herein, jet holes <NUM> and <NUM> may facilitate the creation of a vortex within cylindrical body <NUM>, which saturates the air-fuel mixture with the oxidizing agent and air. This vortex of fuel within cylindrical body <NUM> is ignited by the electrode pairs formed by aligned positive electrodes <NUM> and ground electrodes <NUM>, as described elsewhere herein. The resulting flame through the opening in portion <NUM> heats the air flowing within secondary reactor <NUM> between blower <NUM> and heat exchanger <NUM>.

<FIG> illustrates a distributor system <NUM> in a perspective view, <FIG> illustrate distributor system <NUM> in orthogonal side views, and <FIG> illustrate distributor system <NUM> in bottom and top views, respectively, according to an embodiment. <FIG> illustrates a distributor within distributor system <NUM> in a cross-sectional side view, and <FIG> illustrates the movement within a distributor within distributor system <NUM> in a phantom view, according to an embodiment. In the illustrated embodiments, distributor system <NUM> comprises a high-energy spark generator <NUM> and a ground distributor <NUM>, joined by a timing belt <NUM> that is rotated by a belt hub <NUM> driven by a motor <NUM> via a motor shaft <NUM>.

High-spark energy generator <NUM> and ground distributor <NUM> both comprise a distributor cap <NUM> on top of a distributor body <NUM>, and a pulley <NUM> attached to a distributor shaft <NUM> that spins with the pulley <NUM> and extends into distributor body <NUM>, where it is attached to a rotor <NUM>. Each distributor cap <NUM> comprises a central tower <NUM> and a plurality of towers <NUM> (e.g., five) encircling central tower <NUM> and spaced equidistantly apart from each other.

As motor <NUM> rotates motor shaft <NUM>, motor shaft <NUM> rotates belt hub <NUM>, which rotates timing belt <NUM>. In turn, timing belt <NUM> rotates pulleys <NUM>, which each rotates a respective distributor shaft <NUM>, which rotates distributor rotor <NUM> attached to the other end of distributor shaft <NUM>. As illustrated in <FIG>, distributor rotor <NUM> comprises a platform that is connected to central tower <NUM> and is sized to pass under each tower <NUM>. Thus, as illustrated in <FIG>, as distributor rotor <NUM> rotates, it will repeatedly pass under each tower <NUM> in a sequence of tower 1054A, 1054B, 1054C, 1054D, 1054E, 1054A, and so on and so forth.

It should be understood that this rotation occurs simultaneously in both high-spark energy generator <NUM> and ground distributor <NUM>. Thus, for example, as the distributor rotor <NUM> in high-spark energy generator <NUM> is underneath tower 1054A in high-spark energy generator <NUM>, the distributor rotor <NUM> in ground distributor <NUM> is also underneath tower 1054A, as the distributor rotor <NUM> in high-spark energy generator <NUM> is underneath tower 1054B in high-spark energy generator <NUM>, the distributor rotor <NUM> in ground distributor <NUM> is also underneath tower 1054B, and so on and so forth.

Each tower <NUM> in high-spark energy generator <NUM> may be electrically attached to a different one of the positive electrodes <NUM> in primary reactor chamber <NUM>. Similarly, each tower <NUM> in ground distributor <NUM> may be electrically attached to a different one of the ground electrodes <NUM> in primary reactor chamber <NUM>. In other words, there is a one-to-one correspondence between positive electrodes <NUM> and towers <NUM> on high-spark energy generator <NUM>, and a one-to-one correspondence between ground electrodes <NUM> and towers <NUM> on ground distributor <NUM>.

As the distributor rotor <NUM> in high-spark energy generator <NUM> passes underneath the tower 1054A on high-spark energy generator <NUM> and the distributor rotor <NUM> in ground distributor <NUM> passes underneath the tower 1054A on ground distributor <NUM>, a spark is generated from positive electrode 930A to ground electrode 940A. This spark ignites the fuel mixture within primary reactor chamber <NUM>. It should be understood that the same chain of events may occur for each of the corresponding towers <NUM> and their connected electrode pairs <NUM>/<NUM>.

<FIG> illustrates a fluidizer <NUM> in a perspective view, <FIG> illustrates fluidizer <NUM> in a side view, and <FIG> illustrates fluidizer <NUM> in a front view down a longitudinal axis of fluidizer <NUM>, according to an embodiment. <FIG> illustrates fluidizer <NUM> in an exploded perspective view, according to an embodiment. In the illustrated embodiment, fluidizer <NUM> comprises a substantially cylindrical body <NUM>, with a base <NUM> on one end and a lid <NUM> on the opposite end. For example, lid <NUM> may be attached to one end of cylindrical body <NUM>, and the other end of cylindrical body <NUM> may be seated (e.g., upright) on top of base <NUM>.

Base <NUM> is substantially cylindrical, with a fitting hole <NUM> (e.g., circular hole in the illustrated embodiment) cut into the side to receive air connection fitting <NUM>. Air connection fitting <NUM> is configured to be seated within fitting hole <NUM>, and be releasably connected to a fluid line. Thus, an external fluid line may feed air, through air connection fitting <NUM>, into an interior of base <NUM>. Base <NUM> may also comprise a porous separation membrane <NUM> that is positioned between an air chamber in base <NUM> and an internal cavity of cylindrical body <NUM>.

Cylindrical body <NUM> may be substantially cylindrical, and may contain one or more layers of polymer, created by pulverizing plastic waste. For example, processed micro-fine polymers may be placed inside the internal cavity of cylindrical body <NUM>, partially filling the internal cavity. Air pressure inside base <NUM> is forced through the pores of porous membrane <NUM>, and bubbles through the micro-fine polymers inside cylindrical body <NUM>. This bubbling action agitates the polymers inside cylindrical body <NUM>, causing a static charge to build up in the polymers, which, in turn, causes the polymer particles to repel each other. This creates a statically charged cloud of fluidized polymer.

Lid <NUM> may comprise an exit fitting <NUM>. As illustrated, exit fitting <NUM> may be fitted onto the front, external surface of lid <NUM>, to provide a pathway from the internal cavity of cylindrical body <NUM> to an exterior of fluidizer <NUM>. In practice, the cloud of fluidized polymer in cylindrical body <NUM> is forced out of exit fitting <NUM> by the positive air pressure created inside cylindrical body <NUM> by the air flow from base <NUM> through porous membrane <NUM>.

In an embodiment, fluidizer <NUM> is connected to fluidized polymer inlet port <NUM> of air-fuel mixer <NUM>. For example, exit fitting <NUM> may be connected directly to fluidized polymer inlet fitting <NUM> of air-fuel distribution assembly <NUM>, or may be indirectly connected to fluidized polymer inlet fitting <NUM> via a line. Alternatively, exit fitting <NUM> may be connected directly to or integrated with fluidized polymer inlet port <NUM>, such that no fluidized polymer inlet fitting <NUM> is required.

In practice, fluidizer <NUM> operates in a similar manner as a powder-coating gun, and may even comprise a powder-coating gun. Powder-coating guns are used to apply micro-fine polymer to surfaces to, for example, protect the surfaces from environmental elements. For instance, a powder-coating gun may be used to apply fine polymer powder to a surface, which is then heated by thermal energy to set the powder as a protective coating.

<FIG> and <FIG> illustrate a pneumatic system <NUM> that may be used to supply fluid to various components of primary reactor <NUM>, according to an embodiment. Specifically, pneumatic sources <NUM> may be connected to the various inlet ports described herein with one or more valves <NUM> and/or gauges <NUM> along pathways <NUM>. Although particular configurations are illustrated, it should be understood that pneumatic system <NUM> may be implemented in different configurations. Each valve <NUM> may comprise a manual or automatic valve that regulates pressure. The pneumatic pressure in each pathway <NUM> is measured by a gauge <NUM>.

In the embodiment of pneumatic system 1200A, illustrated in <FIG>, a first pneumatic source 1210A is connected, via a first pathway 1240A, to air inlet port <NUM>. In addition, the first pneumatic source 1210A is connected, via a second pathway 1240B, to oxidizer inlet port <NUM>. A second pneumatic source 1210B is connected, via a third pathway 1240C, to air inlet port <NUM>. In addition, the second pneumatic source 1210B is connected, via a fourth pathway 1240D, to oxidizer inlet port <NUM>. Each of the four pathways 1240A-1240D comprises a respective valve 1220A-1220D and a respective gauge 1230A-1230D. First pneumatic source 1210A may comprise a tank of oxidizing agent (e.g., gas), whereas second pneumatic source 1210B may comprise a tank of air.

In the embodiment of pneumatic system 1200B, illustrated in <FIG>, a pneumatic source 1210B is connected, via a fifth pathway 1240E, to air inlet port <NUM>. In addition, the pneumatic source 1210B is connected, via a sixth pathway 1240F, to air connection fitting <NUM>. Each of the two pathways 1240E and 1240F comprises a respective valve 1220E and 1220F and a respective gauge 1230E and 1230F. Pneumatic source 1210B may comprise a tank of air, to thereby supply air to air inlet port <NUM> and air connection fitting <NUM>, via pathways 1240E and 1240F, respectively.

Pneumatic systems 1200A and 1200B may be combined, such that a tank 1210A of oxidizing gas is connected to oxidizer inlet port <NUM> (e.g., pathway 1240B), and a tank 1210B of air is connected to air inlet port <NUM> via pathway 1240C, oxidizer inlet port <NUM> via pathway 1240D or 1240E, and air connection fitting <NUM> via pathway 1230F. Thus, the air tank can supply air to oxidizer inlet port <NUM>, for example, when a temperature within primary reactor chamber <NUM> exceeds a predetermined value (e.g., <NUM>).

As illustrated in <FIG>, primary reactor <NUM> is connected perpendicularly to secondary reactor <NUM>. Specifically, end portion <NUM> of primary reactor <NUM> is inserted into cylindrical lip <NUM>, and flange 920B of primary reactor <NUM> is fixed (e.g., bolted) to flange <NUM> of secondary reactor <NUM>, to join primary reactor <NUM> to secondary reactor <NUM>. Thus, the diameter of secondary reactor <NUM> should be larger than the diameter of primary reactor <NUM>, so that end portion <NUM> of primary reactor <NUM> can be accommodated within secondary reactor <NUM>.

In an embodiment, plastic-powered power generator <NUM> may include a catalytic converter to reduce toxic gas and pollutants in the exhaust of plastic-powered power generator <NUM>. <FIG> illustrates a catalytic converter <NUM> in a perspective view, <FIG> illustrates catalytic converter <NUM> in a side view, and <FIG> illustrates catalytic converter <NUM> in a front or rear view down the longitudinal axis of catalytic converter <NUM>, according to an embodiment. In the illustrated embodiment, catalytic converter <NUM> comprises a substantially cylindrical body <NUM> that is open on both ends, with a flange 1320A on one end, and a flange 1320B on the other end.

Cylindrical body <NUM> is substantially cylindrical, with openings on both ends, to provide a pathway for emissions through catalytic converter <NUM>. As illustrated, cylindrical body <NUM> may have slightly conical sections on either end, sandwiched between a cylindrical central section, and cylindrical end sections on which flanges <NUM> are mounted or integral. Emissions enter catalytic converter <NUM>, through an opening in one end of catalytic converter <NUM> (e.g., the opening encircled by flange 1320A), and are cleaned by catalyzing a redox reaction. This catalytic conversion can be performed in any known manner. In an embodiment, catalytic converter <NUM> is a multi-phasic catalytic converter.

Flanges 1320A and 1320B may be, but are not necessarily, identical. Each flange <NUM> may comprise one or more, and preferably multiple (e.g., four or more), holes <NUM>. Each hole <NUM> may be configured to receive a bolt therethrough. Specifically, flange 1320A may be adjoined to flange 520B of heat exchanger <NUM>, with each hole <NUM> aligned to a corresponding hole <NUM> in flange 520B. Flange 1320A may then be fixed to flange 520B by inserting bolts through all of the aligned holes <NUM> and <NUM>, and threading and tightening the bolts through corresponding nuts, to thereby fix catalytic converter <NUM> to heat exchanger <NUM>. Alternatively or additionally, other mechanisms may be used to fix flanges 1320A and 520B to each other and/or to fix catalytic converter <NUM> and heat exchanger <NUM> to each other.

<FIG> illustrates the Rankine cycle for power generation using plastic-powered power generator <NUM>, according to an embodiment. As illustrated, heat exchanger <NUM> uses heated air from secondary reactor <NUM> to convert water <NUM> into steam <NUM>. For instance, water may be pumped by pump <NUM> into connector fitting 530A. The water may flow through a coil, comprising a high-pressure water line, within heat exchanger <NUM>, and exit heat exchanger <NUM> as steam via a steam pressure line connected to connector fitting 530B.

Steam <NUM> from the steam pressure line turns turbine <NUM>, which spins electrical generator <NUM> to produce Direct Current (DC) power. Left-over steam <NUM> then exits the turbine through a steam pressure line, and enters a water-cooling heat exchanger <NUM>, that cools steam <NUM> back into water <NUM>. Heat exchanger <NUM> may utilize a flow of cool air to cool steam <NUM> back into water <NUM>. Essentially, heat exchanger <NUM> is the reverse of heat exchanger <NUM>, which uses hot air to convert water <NUM> into steam <NUM>. Water-cooling heat exchanger <NUM> may be used as a source of clean heat, for example, to operate a heat pump.

Water <NUM> flows out of a water line attached to heat exchanger <NUM> and is pumped by pump <NUM> back into heat exchanger <NUM>. It should be understood that this cycle of converting water to steam and steam to water may be maintained continuously, in a closed-loop system, to rotate electrical generator <NUM> for as long as plastic-powered power generator <NUM> is supplied with plastic waste.

<FIG> illustrates an electrical system of plastic-powered power generator <NUM>. Electrical generator <NUM> supplies DC power to an inverter <NUM>, which converts the DC power to Alternating Current (AC) power before the power is supplied to the grid. Inverter <NUM> may also convert AC power from the grid into DC power.

DC power from electrical generator <NUM> and/or from DC-to-AC inverter <NUM> is supplied to various components of plastic-powered power generator <NUM>. For example, the DC power may be supplied to blower <NUM> via an electrical path 1505A, an ignition system <NUM> via an electrical path 1505B, and pump <NUM> via an electrical path 1505C. Ignition system <NUM> may comprise distributor system <NUM>, and the power may drive motor <NUM> of distributor system <NUM>. Electrical path 1505A may comprise a switch 1530A and potentiometer 1540A. When switch 1530A is closed, variable power can be supplied through potentiometer 1540A to blower <NUM> (i.e., blower <NUM> is on to force air into secondary reactor <NUM> through reducer <NUM>), and when switch 1530A is open, no power is supplied to blower <NUM> (i.e., blower <NUM> is off). Similarly, electrical path 1505B may comprise a switch 1530B and potentiometer 1540B. When switch 1530B is closed, variable power can be supplied through potentiometer 1540B to ignition system <NUM> (i.e., ignition system <NUM> is on to ignite primary reactor <NUM>), and when switch 1530B is open, no power is supplied to ignition system <NUM> (i.e., ignition system <NUM> is off). In addition, electrical path 1505C may comprise a switch 1530C. When switch 1530C is closed, power is supplied to pump <NUM> (i.e., pump <NUM> is on to pump water <NUM> into heat exchanger <NUM>), and when switch 1530C is open, no power is supplied to pump <NUM> (i.e., pump <NUM> is off). Each switch <NUM> may comprise a Single Pole Single Throw (SPST) switch.

In addition, the DC power may be supplied to a battery <NUM> via an electrical path 1505D. Battery <NUM> may comprise a multi-cell battery. Battery <NUM> can be used to store electrical energy from electrical generator <NUM> and/or the grid (e.g., via inverter <NUM>), and may power blower <NUM>, ignition system <NUM>, and/or pump <NUM> (e.g., when electrical generator <NUM> is not generating power, or when electrical generator <NUM> is not generating sufficient power to power the entire system).

The embodiments described herein are merely given as examples. Thus, it should be understood that the described embodiments do not limit the invention. An embodiment does not have to contain all of the components described herein. Rather, a particular embodiment may comprise a subset of the components described herein, the subset at least comprising the features of claim <NUM>.

In addition, each of the components described or implied herein may be implemented in a variety of manners, including in a manner that is different than disclosed herein. For example, any of the various flanges described herein may integral with a component (e.g., formed as one piece with the component), or manufactured separately and seated and fixed to a component (e.g., welded, adhered, threaded, etc.). In addition, the various bolt holes described herein may all be identical, or alternatively, a subset of the bolt holes may be different than another subset of the bolt holes. However, it would generally be more efficient for all of the bolt holes to be identical, since the same bolts could be used for every bolt hole.

<FIG> illustrates the usage and operation of plastic-powered power generator <NUM>, according to an embodiment. While the process is illustrated with a certain arrangement and ordering of steps, the process may be implemented with fewer, more, or different steps, and a different arrangement and/or ordering of steps, the operation at least comprising the arrangement and steps as defined in claim <NUM>. In addition, it should be understood that any step, which does not depend on the completion of another step, may be executed before, after, or in parallel with that other independent step, even if the steps are described or illustrated in a particular order.

Initially, in step <NUM>, waste products, including plastic waste, are sorted and collected. Then, in step <NUM>, the sorted and collected plastic waste is pulverized. This pulverization may comprise a shredding step, followed by a pelletizing step. Specifically, the plastic waste may firstly be passed through a shredding device that reduces the plastic waste to objects ranging in size from <NUM>,<NUM> to <NUM>,<NUM> microns. Then, this shredded plastic waste may secondly be passed through a pulverizing device that further reduces the plastic waste to pellets ranging in size from <NUM> to <NUM> microns, i.e., micron or sub-micron size.

In step <NUM>, the pulverized plastic waste pellets may be powder coated as a layer of polymer in a fluidizing bed, such as cylindrical body <NUM> of fluidizer <NUM>. Then, in step <NUM>, air pressure, supplied by air connection fitting <NUM> into base <NUM>, passes through porous separation membrane <NUM>, and agitates the layer of polymer in cylindrical body <NUM>, thereby inducing a positive static charge. The static charge facilitates the polymer molecules in repelling each other, forming a cloud of fluidized polymer molecules within cylindrical body <NUM>.

In step <NUM>, a line fitted to air inlet fitting <NUM> supplies regulated air, through air inlet port <NUM>, into internal chamber <NUM>. The air, input to air-fuel distribution assembly <NUM>, may be pressurized to approximately <NUM> to <NUM> pound-force per square inch (psi). The pressure of the air flow through internal chamber <NUM> creates a vacuum of low pressure, which pressurizes fluidized polymer inlet port <NUM>. Simultaneously, fluidized polymer molecules flow, through exit fitting <NUM> in fluidizer <NUM>, which is connected, directly or indirectly, to fluidized polymer inlet fitting <NUM> in air-fuel distribution assembly <NUM>, through fluidized polymer inlet port <NUM>, and into internal chamber <NUM>.

In step <NUM>, the pressurized fluidized polymer flows through internal chamber <NUM>, through output port <NUM>, through dispersal port <NUM>, and sprays out of dispenser nozzle <NUM> (e.g., spreading in a substantially conical spray pattern, caused by dispenser cone <NUM>) at the center of air-oxidizer manifold <NUM>. As the pressurized fluidized polymer sprays into primary reactor chamber <NUM>, simultaneously, oxidizing agent jets (e.g., at an angle) out of jet holes <NUM>, and air jets (e.g., at an angle) out of jet holes <NUM>, into primary reactor chamber <NUM>. As discussed elsewhere herein, jet holes <NUM> and <NUM> may be angled to facilitate the rotation of the fluids exiting from jet holes <NUM> and <NUM>. Thus, as oxidizing agent and air flow into primary reactor chamber <NUM> from jet holes <NUM> and <NUM>, they create a vortex which saturates the pressurized fluidized polymer, spraying from dispenser nozzle <NUM>, with the oxidizing agent and air. The vortex enhances thermo-energy and reliability within primary reactor chamber <NUM>. At this point, the pressurized fluidized polymer, mixed with air and oxidizing agent, can be referred to as "fuel. " In a preferred embodiment, the oxidizing agent is gaseous oxygen. However, other oxidizing agents may be used, including, a mixture of oxygen and some other gas, ozone, and the like.

In step <NUM>, the fuel is ignited within primary reactor chamber <NUM>. As described elsewhere herein, each positive electrode <NUM> is aligned with exactly one ground electrode <NUM> along a lateral axis of primary reactor chamber <NUM>, and these pairs of positive and ground electrodes <NUM>/<NUM> are aligned along different lateral axes from each other, along and around a longitudinal axis X of primary reactor chamber <NUM>. In an embodiment, a plurality of electrode pairs may be aligned along lateral axes that are perpendicular to the lateral axes along which a different plurality of electrode pairs are aligned.

The ground electrode <NUM> in each electrode pair acts as a grounding field that attracts the fuel entering primary reactor chamber <NUM> from air-fuel distribution assembly <NUM>. Specifically, as discussed elsewhere herein, the fluidized polymer is statically charged. Thus, the particles of fluidized polymer seek a grounding point in order to discharge. In an embodiment, to facilitate this attraction between the fuel and ground electrodes <NUM>, primary reactor chamber <NUM> is dielectric (e.g., formed from or coated with ceramic materials), such that the interior walls of primary reactor chamber <NUM> do not attract the charged particles of fluidized polymer. Instead, the charged particles of fluidized polymer are attracted to the currently grounded ground electrode <NUM> (e.g., which are grounded in sequence as discussed elsewhere herein). Thus, the grounding of each ground electrode <NUM> provides a dual purpose: (<NUM>) a ground for the spark from the corresponding positive electrode <NUM>, as generated by high-spark energy generator <NUM>; and (<NUM>) a ground for the statically charged particles of fluidized polymer.

As the fuel exits air-fuel distribution assembly <NUM> and is propelled towards a ground electrode <NUM>, the paired positive electrode <NUM> creates a spark towards the ground electrode <NUM>, which ignites the fuel. For example, as described elsewhere herein, distributor system <NUM> may rotate a distributor rotor <NUM> in each of a pair of high-spark energy generator <NUM> and ground distributor <NUM>, to provide a spark through electrode pairs in sequence. Thus, each of the electrode pairs, each comprising an aligned positive electrode <NUM> and ground electrode <NUM>, fire in sequence, as described elsewhere herein, to ignite the fuel in primary reactor chamber <NUM>.

In an embodiment, when the operating temperature within primary reactor chamber <NUM> reaches a predetermined threshold value, the oxidizing agent being jetted from jet holes <NUM> may be replaced with compressed air or a mixture of compressed air and oxidizing agent, via pneumatic system <NUM>. The predetermined threshold value may be <NUM>° Celsius. At this temperature, the reaction no longer requires the oxidizing agent, but continues to require air. It should be understood that, during the ignition in step <NUM>, assuming that tank 1210A holds the oxidizing agent (e.g., gas) and tank 1210B holds compressed air, normally, valve 1220A should be off, valve 1220B should be on, valve 1220C should be on, and valve 1220D should be off. Referring to <FIG>, to replace the oxidizing agent with compressed air, valve 1220B may be shut off to prevent oxidizing agent from tank 1210A from flowing to oxidizer inlet port <NUM>, and valve 1220D may be turned on to allow compressed air from tank 1210B to flow to oxidizer inlet port <NUM>. To replace the oxidizing agent with a mixture of compressed air and oxidizing agent, valve 1220B may be turned down, and valve 1220D may be turned up, to create a mixture of oxidizing agent and compressed air at oxidizer inlet port <NUM>. Primary reactor chamber may comprise a temperature sensor, and a control device that monitors the output of the temperature sensor (e.g., a value representing the temperature within primary reactor chamber <NUM>), and, when the monitored temperature value exceeds the predetermined threshold value, automatically controls valves <NUM> (e.g., as described above) to replace the flow of oxidizing agent with air or some mixture of oxidizing agent and air (or simply turn of the flow of oxidizing agent).

In step <NUM>, the flame front, created by the ignited fuel in primary reactor chamber <NUM>, heats the air in secondary reactor <NUM> via the opening in end portion <NUM>, which intrudes perpendicularly into secondary reactor <NUM>. Specifically, blower <NUM> pushes air through secondary reactor <NUM> along an axis that is orthogonal to the longitudinal axis X of primary reactor <NUM>. Heated air exits primary reactor chamber <NUM>, rotationally in a vortex, and creates a low-pressure area at the junction of secondary reactor <NUM> and primary reactor <NUM>. This low-pressure area draws the flame from primary reactor chamber <NUM> into the air flow passing through secondary reactor <NUM> from blower <NUM>. In other words, the air flow from blower <NUM> mixes with the flame from primary reactor chamber <NUM>, inside secondary reactor <NUM>, thereby increasing the temperature and speed of the flame. In other words, the air flow from blower <NUM> increases the thermal output of primary reactor <NUM>, thereby improving the overall efficiency of plastic-powered power generator <NUM>.

In step <NUM>, the heated air and/or flame front from secondary reactor <NUM> flows into heat exchanger <NUM>, where it heats water <NUM>, in the fluid flowing within the coil in heat exchanger <NUM>, to create steam <NUM>. Specifically, aqueous fluid flowing into the coil through connector fitting 530A is heated within the coil to create steam and increased pressure. The pressure pushes the steam out of connector fitting 530B. In addition, the heated exhaust gas may flow from heat exchanger <NUM> into catalytic converter <NUM>, which removes pollutants from the exhaust gas prior to emitting the exhaust gas from plastic-powered power generator <NUM> (e.g., into the environment, or to be used as heat for another device and/or process).

In step <NUM>, the steam output from connector fitting 530B passes through a turbine <NUM>, causing turbine <NUM> to spin. In other words, the thermal energy from heat exchanger <NUM> is used to drive turbine <NUM>. The spinning turbine <NUM> rotates electrical generator <NUM> to produce electrical power. It should be understood that steps <NUM>-<NUM> may operate continuously, for as long as plastic-powered power generator <NUM> is supplied with polymer, to produce a continuous supply of electrical power.

The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles described herein can be applied to other embodiments without departing from the scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly not limited any further than by the appending claims.

Claim 1:
A plastic-powered power generator (<NUM>) comprising:
a primary reactor (<NUM>) comprising an air-fuel distribution assembly (<NUM>), an ignition system (<NUM>), and a primary reactor chamber (<NUM>), wherein the primary reactor chamber (<NUM>) comprises a first opening on one end of the primary reactor chamber (<NUM>) and a second opening on a second end of the primary reactor chamber (<NUM>), wherein the air-fuel distribution assembly (<NUM>) is configured to supply fluidized polymer, air, and an oxidizing agent through the first opening in the primary reactor chamber (<NUM>), and wherein the ignition system (<NUM>) is configured to ignite a mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber (<NUM>);
a secondary reactor (<NUM>) comprising a secondary reactor body with a first opening on one end of the secondary reactor body, a second opening on a second end of the secondary reactor body, and a third opening on a side of the secondary reactor body, wherein the second end of the primary reactor chamber (<NUM>) extends through the third opening in the side of the secondary reactor body, such that the second opening of the primary reactor chamber (<NUM>) is within the secondary reactor body;
a heat exchanger (<NUM>) comprising a first opening on one end of the heat exchanger (<NUM>), a second opening on a second end of the heat exchanger (<NUM>), and a coil, configured to contain fluid, between the first opening and the second opening, wherein the first opening of the heat exchanger (<NUM>) is connected to the second opening of the secondary reactor (<NUM>); and
a blower (<NUM>) configured to create air flow through the secondary reactor (<NUM>) into the heat exchanger (<NUM>), such that the air flow is heated in the secondary reactor (<NUM>) through the second opening of the primary reactor (<NUM>), and the heated air flow from the secondary reactor (<NUM>) heats the coil in the heat exchanger (<NUM>).