Patent Description:
It is known to heat biomass materials to generate synthesis gas. Synthesis gas is a gaseous mixture comprising hydrogen, carbon monoxide and methane, amongst other substances. The treatment process typically entails heating granulated or otherwise comminuted biomass waste material within a kiln. The kiln is generally heated by a heating system. It is also known to add steam to the contents of the kiln, for example to provide a reducing atmosphere within which synthesis gas may be more readily generated and/or the ratio of constituents of the synthesis gas may be controlled. The steam is typically pre-generated by heating water using a further heating system, prior to introduction of the steam into the kiln. The generated synthesis gas can then be sent on for further treatment.

<CIT> discloses a a fluidized bed furnace for heating waste to extract a combustible gas from the waste. The fluidized bed furnace includes: a plurality of wind boxes arranged on a lower side of a bottom wall of a furnace body to blow a fluidizing gas into the fluidized bed; a plurality of temperature detection sections disposed at respective positions allowing detection of temperatures of an upper position and a lower position vertically spaced in a first region, and allowing detection of temperatures of upper and lower positions vertically spaced in a second region; and a control section operable, based on the temperatures detected by the temperature detection sections, to adjust an air ratio of the fluidizing gas to be fed to each of the wind boxes, so that the temperature of the fluidized bed is raised in a direction from the first region toward the second region.

<CIT> discloses a system including a waste incinerator for purifying waste. The waste incinerator comprises a diffusion pipe vertically arranged in a combustion chamber, diffusion holes formed on the diffusion pipe in several stages, a temperature sensor detecting for the temperature in the combustion chamber and a control means for controlling the amount of fuel supplied from a fuel nozzle. Air curtain layers are created by horizontally jetting air from each of the diffusion holes, forming combustion areas among the air curtain. The gas generated by liquefaction and vaporization of the waste is converted into a high-temperature gas in the upper layer.

<CIT> concerns temperature control in a combustion process. There is disclosed an apparatus, comprising: an air feed; a fuel feed; a combustion zone, capable of mixing and combusting air and fuel therein; a temperature sensor positioned within the combustion zone, capable of measuring the temperature of at least one point within the combustion zone; and a control system, comprising: a processor to which the temperature sensor is capable of reporting the measured temperature; and an air flow adjustment apparatus controlled by the processor and capable of adjusting the flow rate of air to the combustion zone in response to the reported temperature.

As will be appreciated by one skilled in the art, the apparatus for generating synthesis gas (and for its further processing) is relatively complex. Furthermore, the treatment process is typically run continuously, for example <NUM> hours a day. Accordingly, the heating system, compression systems and the like require a relatively large quantity of energy. These relatively high energy requirements may result in relatively high operating costs for such apparatus. However, in order for hydrogen (for example) generated from biomass waste material to be economically competitive with hydrogen generated from other sources, the treatment method must necessarily be as inexpensive as possible. Accordingly, it would be advantageous to minimise the running costs of such apparatus for treating waste material.

It would also be beneficial to increase the efficiency of the method, for example relative to prior art methods. It would be beneficial to provide a relative increase in efficiency of the kiln heating method, of the steam production method, of the gasification process and/or of the production of a component of a generated gas (e.g. hydrogen).

In recent years the proliferation of plastic products and packaging has generated (and continues to generate) large volumes of waste material. Plastics waste material has traditionally been delivered to landfill, for natural decomposition. However, such plastics waste material may take a long time to naturally decompose, for example in the order of many hundreds of years. Accordingly, it has been proposed to treat waste plastics material instead of delivering it to landfill, such that by-products of the treated waste may find use. It would be convenient to separate and recycle plastics materials so that they can be reprocessed to produce useful products.

Unfortunately, recycling and recycling technologies are not universal with regards to plastics wastes materials. Further, it is relatively expensive and challenging to process contaminated waste plastics materials, or mixed plastics waste streams. Indeed, there are some plastics materials which currently impossible (or prohibitively expensive) to recycle. Unfortunately, where a waste stream is contaminated it tends to prove too expensive to separate out the recyclable plastics materials from those which are not recyclable and so the entire waste stream may not be processed.

Plastics packaging is a major source of plastics materials which are difficult to recycle, typically because of the functional properties of the plastics, e.g. plastics barrier films used in food packaging. Tyres are another difficult-to-process waste material.

In the circumstance where the waste stream cannot be recycled, the waste stream will typically be diverted to landfill.

It is an object of the current invention to provide ways in which useful work can be extracted from plastics waste materials for example mixed and or contaminated waste plastics materials and vehicle tyres.

Accordingly, a first aspect of the invention provides a method of treating comminuted waste material, in accordance with Claim <NUM>.

Advantageously, the invention provides relatively more efficient treatment of comminuted waste material than is provided by prior art methods. By adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber to maintain the temperature in the heating chamber within the predetermined temperature range the treatment of waste material is conducted at desired temperatures. Accordingly, the treatment process and conversion into a combustible gas may be more readily and accurately controlled. Less energy may therefore be needed, leading to energy and hence cost savings. Additionally, relatively greater quantities of the combustible gas and/or of desired components of the combustible gas may be generated, for example a relatively greater quantity of methane and/or hydrogen.

The comminuted waste material may comprise waste plastics materials, for example polyethylene terephthalate, high-density polyethylene, low-density polyethylene, linear low-density polyethylene, polyvinylchloride, polypropylene, or the like. The comminuted waste material may comprise rubber, biomass, tyre crumbs or the like. The comminuted waste material may comprise any suitable combination of plastics materials and or of other materials.

The term 'comminuted' as used herein should be taken to mean a substance which has been reduced to small particles or fragments.

The combustible gas may comprise a combustible hydrocarbon, for example methane or another suitable alkane. The combustible gas may form a component of a gaseous mixture, e.g. a generated gaseous mixture. The gaseous mixture may comprise synthesis gas. The synthesis gas may comprise hydrogen, methane, carbon monoxide. The synthesis gas may comprise one or more further substances. In embodiments, the synthesis gas may comprise predominantly hydrogen (e.g. a relatively greater percentage or amount of hydrogen than of other substances or components). In embodiments, the method may comprise generating a relatively greater percentage or amount of hydrogen, e.g. than of other substances or components of the generated combustible gas. In embodiments, the method may comprise further processing the generated combustible gas, for example once it has left the heating chamber. The further processing may comprise separating out one or more components of the generated combustible gas, for example separating out hydrogen.

In embodiments, adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber to maintain the temperature in the heating chamber within the predetermined temperature range may comprise adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber if the measured or determined temperature in the heating chamber is outside of the predetermined temperature range. In embodiments, adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber to maintain the temperature in the heating chamber within the predetermined temperature range may comprise adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber if the rate of change of the measured or determined temperature in the heating chamber is greater than a set value. In embodiments, adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber to maintain the temperature in the heating chamber within the predetermined temperature range may comprise adjusting the amount of heat applied by the one or more heating means or heater to the heating chamber if the measured or determined temperature in the heating chamber is within a threshold amount of one limit of the predetermined temperature range. Adjusting may be automatic for example under PID control. In embodiments, adjusting may be at least partially manual.

In embodiments, the one or more heating means or heater may comprise one or more combustion heating means or combustion heater.

In embodiments, adjusting the amount of heat applied by the one or more combustion heating means or combustion heater may comprise reducing or increasing the mass flow rate of air supplied to the one or more combustion heating means or combustion heater.

In embodiments, adjusting the amount of heat applied by the one or more combustion heating means or combustion heater may comprise reducing or increasing the mass flow rate of fuel supplied to the one or more combustion heating means or combustion heater.

In embodiments, adjusting the amount of heat applied by the one or more combustion heating means or combustion heater may comprise altering the ratio of two or more components of a fuel mixture supplied to the one or more combustion heating means or combustion heater. The two or more components of the fuel mixture may be supplied from two or more fuel supplies. The two or more components of the fuel mixture may be individually metered to control the ratio of the two or more components.

A first component of a fuel mixture may be supplied to the one or more combustion heating means or combustion heater by a first conduit. A second component of a fuel mixture may be supplied to the one or more combustion heating means or combustion heater by a second conduit. The first and second conduit may meet at a manifold or other mixing means or mixer. The first conduit may may comprise a first valve means or first valve. The second conduit may comprise a second valve means or second valve. The first and second valve means or valve may be individually controlled or controllable to control the proportion of the first component and second component being supplied to the manifold. The manifold may comprise a manifold valve means or manifold valve. The manifold may be proximate or adjacent the combustion heating means or combustion heater. The manifold valve means or manifold valve may be proximate or adjacent the combustion heating means or combustion heater.

Air may be supplied to the one or more combustion heating means or combustion heater by an air supply conduit. Air may be supplied to the manifold by an air supply conduit. The air supply conduit may have an air supply valve means or air supply valve. Air may be supplied to the manifold proximate or adjacent the combustion heating means or combustion heater. Air may be supplied to the manifold between the manifold valve means or manifold valve and the combustion heating means or combustion heater. Air may be supplied to the manifold so that the manifold valve means or manifold valve is between the air supply conduit and the combustion heating means or combustion heater.

In embodiments, step c) may comprise measuring or determining the temperature in the heating chamber using one or more temperature sensors, e.g. located inside or outside of the heating chamber. In some embodiments, one or more of the one or more temperature sensors may be located inside the heating chamber and one or more of the temperature sensors may be located outside of the heating chamber.

The first,second and third zones are defined in the heating chamber. The method comprises measuring or determining (e.g. independently) the temperature in the first zone of the heating chamber. The method comprises measuring or determining (e.g. independently) the temperature in the second zone of the heating chamber. The method comprises measuring or determining (e.g. independently) the temperature in the third zone of the heating chamber.

In some embodiments, the method may comprise feeding comminuted waste material into the heating chamber, for example through an inlet of the heating chamber.

In embodiments, the method may comprise introducing steam into the heating chamber, for example through an inlet of the heating chamber. The steam may be introduced at a temperature of between about <NUM> and <NUM>, for example between about <NUM> and <NUM>, say between about <NUM> and <NUM>, e.g. approximately <NUM>.

The predetermined temperature range may be a set temperature T plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>% of the set temperature T. Alternatively, the predetermined temperature range may be a set temperature T plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>.

In embodiments, step a) may comprise heating the comminuted waste material in a first zone of the heating chamber to a first temperature T1, for example to gasify the comminuted waste material. The first temperature T1 may comprise a first set temperature T1.

In embodiments, step a) may comprise heating the gasified material in a second zone of the heating chamber to a second temperature T2, for example to generate the combustible gas. The second temperature T2 may comprise a second set temperature T2. The second temperature T2 is greater than the first temperature T1.

In embodiments, step a) may comprise heating the combustible gas in a third zone of the heating chamber, e.g. to a third temperature T3. The third temperature T3 may comprise a third set temperature T3. The third temperature T3 is greater than the first temperature T1. The third temperature T3 may be less than the second temperature T2. The third temperature T3 greater than the second temperature T2. The third temperature T3 may be equal (e.g. substantially) to the second temperature T2.

The set temperature may comprise an average temperature (e.g. a mean temperature), for example for the heating chamber. The first set temperature may comprise an average temperature (e.g. a mean temperature), for example for the first zone of the heating chamber. The second set temperature may comprise an average temperature (e.g. a mean temperature), for example for the second zone of the heating chamber. The second set temperature may comprise an average temperature (e.g. a mean temperature), for example for the second zone of the heating chamber.

There may be a first predetermined temperature range for the first zone (where provided) of the heating chamber. There may be a second predetermined temperature range for the second zone (where provided) of the heating chamber. There may be a third predetermined temperature range for the third zone (where provided) of the heating chamber. The first predetermined temperature range in the first zone may be between <NUM> and <NUM>, say between <NUM>, <NUM>, <NUM> or <NUM> and <NUM>, <NUM>, <NUM> or <NUM>. The second predetermined temperature range in the second zone may be between <NUM> and <NUM>, say between <NUM>, <NUM>, <NUM> or <NUM> and <NUM>, <NUM>, <NUM> or <NUM>. The third predetermined temperature range in the third zone may be between about <NUM> and <NUM>, say between about <NUM>, <NUM>, <NUM> or <NUM> and <NUM>, <NUM>, <NUM> or <NUM>.

The first predetermined temperature range for the first zone (where provided) may be a first set temperature T1 plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>% of the first set temperature T1. Alternatively, the first predetermined temperature range for the first zone may be a first set temperature T1 plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>. The first set temperature T1 may be about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>.

The second predetermined temperature range for the second zone (where provided) may be a second set temperature T2 plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>% of the second set temperature T2. Alternatively, the second predetermined temperature range for the second zone may be a second set temperature T2 plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>. The second set temperature T1 may be about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>.

The third predetermined temperature range for the third zone (where provided) may be a third set temperature T3 plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>% of the third set temperature T3. Alternatively, the third predetermined temperature range for the third zone may be a third set temperature T3 plus or minus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>. The third set temperature T3 may be about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>.

In embodiments, if the measured or determined temperature in the first zone of the heating chamber is outside of (e.g. is lower or higher than) the first predetermined temperature range, then the amount of heat applied by the one or more heating means or heater to the first zone may be adjusted. If the measured or determined temperature in the second zone of the heating chamber is outside of (e.g. is lower or higher than) the second predetermined temperature range, then the amount of heat applied by the one or more heating means or heater to the second zone may be adjusted. If the measured or determined temperature in the third zone of the heating chamber is outside of (e.g. is lower or higher than) the third predetermined temperature range, then the amount of heat applied by the one or more heating means or heater to the third zone may be adjusted.

Adjusting the amount of heat applied may comprise increasing or decreasing the amount of heat applied.

The measured or determined temperature may comprise an average temperature (e.g. a mean temperature), for example in the heating chamber or in the first, second or third zone of the heating chamber (where provided).

In embodiments, the method may comprise a step e) of supplying at least a portion of the generated combustible gas to the one or more combustion heating means or combustion heater, for example for heating the heating chamber.

The heating chamber is rotatable, in use. The method may comprise a step f) of rotating the heating chamber.

The method may be or comprise a continuous method. For example, the method may be a method of continuously treating comminuted waste material.

In embodiments, at least a portion of the generated combustible gas may be sent or supplied to a gas grid. In embodiments, at least a portion of the generated comustible gas may be processed into one or more further chemicals.

A further aspect of the invention provides an apparatus, in accordance with Claim <NUM>.

In embodiments, the controller may be configured or configurable to adjust the amount of heat applied by the one or more heating means or heater to maintain the temperature in the heating chamber within the predetermined temperature range if the measured or determined temperature in the heating chamber is outside of the predetermined temperature range. In embodiments, the controller may be configured or configurable to adjust the amount of heat applied by the one or more heating means or heater to maintain the temperature in the heating chamber within the predetermined temperature range if the rate of change of the measured or determined temperature in the heating chamber is greater than a set value. In embodiments, the controller may be configured or configurable to adjust the amount of heat applied by the one or more heating means or heater to maintain the temperature in the heating chamber within the predetermined temperature range if the measured or determined temperature in the heating chamber is within a threshold amount of one limit of the predetermined temperature range.

In embodiments, the one or more heating means or heater may comprise one or more combustion heating means or combustion heater (e.g. combustion heater or heaters).

In embodiments, the apparatus may comprise a supply of air, for example arranged or arrangeable to supply air to the one or more combustion heating means or combustion heater.

In embodiments, the controller may be configured or configurable to reduce or increase the or a mass flow rate of air supplied from the supply of air to the one or more combustion heating means or combustion heater.

In some embodiments, the apparatus may comprise a supply of fuel, for example arranged or arrangeable to supply fuel to the one or more combustion heating means or combustion heater.

In embodiments, the controller may be configured or configurable to reduce or increase the mass flow rate of fuel supplied to the one or more combustion heating means or combustion heater (e.g. from the supply of fuel).

In some embodiments, the supply of fuel may comprises a first supply of a first fuel, e.g. and a second supply of a second fuel.

In embodiments, the controller may be configured to alter the or a ratio of the or a first and second fuel supplied to the one or more combustion heating means or combustion heater. The first fuel may be or comprise natural gas. The second fuel may be or comprise a or the combustible gas generated in the heating chamber.

The first fuel may be supplied to the one or more combustion heating means or heater by a first conduit. The second fuel may be supplied to the one or more combustion heating means or heater by a second conduit. The first and second conduit may meet at a manifold or other mixing means or mixer. The first conduit may may comprise a first valve means or first valve. The second conduit may comprise a second valve means or second valve. The first and second valve means or valve may be individually controlled or controllable to control the proportion of the first fuel and second fuel being supplied to the manifold. The manifold may comprise a manifold valve means or manifold valve. The manifold may be proximate or adjacent the combustion heating means or combustion heater. The manifold valve means or manifold valve may be proximate or adjacent the combustion heating means or combustion heater.

Air may be supplied to the one or more combustion heating means or combustion heater by an air supply conduit. Air may be supplied to the manifold by an air supply conduit. The air supply conduit may have an air supply valve means or air supply valve. Air may be supplied to the manifold proximate or adjcanent the combustion heating means or combustion heater. Air may be supplied to the manifold between the manifold valve means or manifold valve and the combustion heating means or combustion heater. Air may be supplied to the manifold so that the manifold valve means or manifold valve is between the air supply conduit and the combustion heating means or combustion heater.

In some embodiments, the one or more combustion heating means or combustion heater may be configured or configurable to heat a first zone in the heating chamber to a first temperature T1. The one or more combustion heating means or combustion heater may be configured or configurable to heat a second zone in the heating chamber to second temperature T2. The second temperature T2 is greater than the first temperature T1.

In embodiments the one or more combustion heating means or combustion heater may be configured or configurable to heat a third zone in the heating chamber to a third temperature T3. The third temperature T3 is greater than the first temperature T1.

The one or more combustion heating means or combustion heater may comprise one or more combustion heaters, for example one or more heaters using a fuel source such as gas. Supply of fuel to the one or more heaters may be controlled or controllable proximate or adjacent or relatively near to the one or more heaters to control (e.g. to fine control or fine tune) the temperature in each zone. The one or more combustion heating means or combustion heater may comprise one or more gas heaters, e.g. one or more gas burners. The fuel supplied to the one or more combustion heating means or combustion heaters may comprise a first component of a fuel mixture and a second component of a fuel mixture. The ratio of the first component and the second component of the fuel mixture may be controlled or controllable to control the temperature in each zone. Air may be supplied to the one or more combustion heating means or combustion heaters. Air supplied to the one or more combustion heating means or combustion heaters may be controlled or controllable proximate or adjacent or relatively near to the one or more combustion heating means or combustion heater to control (e.g. to fine control or fine tune) the temperature in each zone. In embodiments, the one or more combustion heating means or combustion heater may be located, in use, outside of the heating chamber. The one or more combustion heating means or combustion heater may be arranged to heat the heating chamber.

In embodiments, the one or more combustion heating means or combustion heater comprises plural combustion heating means or combustion heaters. A first combustion heating means or combustion heater may be configured or configurable to heat comminuted waste material in a or the first zone of the heating chamber, e.g. to the or a first temperature T1 (where plural zones are defined in the heating chamber). A second combustion heating means or combustion heater may be configured or configurable to heat gasified material in a or the second zone of the heating chamber, e.g. to the second temperature T2. A third combustion heating means or combustion heater may be configured or configurable to heat a third zone of the heating chamber, e.g. to a third temperature T3. In embodiments, the first zone may be at or adjacent the or an inlet of the heating chamber. The third zone may be at or adjacent the or an outlet of the heating chamber. the second zone may be in between the first and third zones. The temperature in one or more zones may be controlled or controllable by controlling the supply of fuel to the respective combustion heating means or combustion heaters. The temperature in one or more zones may be controlled or controllable by controlling the supply of fuel and the supply of air, and the proportions thereof, to the respective combustion heating means or combustion heaters.

In embodiments, the temperature sensing means or temperature sensor may comprise one or more temperature sensors. One or more of the one or more temperature sensors may be located outside of the heating chamber. One or more of the one or more temperature sensors may be located inside of the heating chamber. The one or more temperature sensors may be arranged or configured to measure or determine the temperature one, some or each of the zones of the heating chamber (where plural zones are defined therein). In embodiments, one or more temperature sensors may be arranged to measure or determine the temperature of the first zone. One or more temperature sensors may be arranged to measure or determine the temperature of the second zone. One or more temperature sensors may be arranged to measure or determine the temperature of the third zone. Where plural temperature sensors are provided they may comprise an array (e.g. plural arrays). One or more of the temperature sensors (or arrays of temperature sensors) may be located inside of the heating chamber. One or more of the temperature sensors (or arrays of temperature sensors) may be located outside of the heating chamber.

In embodiments, the controller may be configured or configurable to shut down the apparatus, for example if the temperature in the heating chamber exceeds a predetermined threshold (e.g. is higher or lower than a predetermined threshold temperature). In embodiments, the controller may be configured or configurable to alert an operator, for example if the temperature in the heating chamber exceeds a predetermined threshold. The alert may comprise an alarm which may be visual and/or audible.

In some embodiments, the apparatus may comprise a supply system, for example configured or configurable to supply to the one or more combustion heating means or combustion heater at least a portion of a combustible gas generated, in use, in the heating chamber.

In some embodiments, the apparatus may comprise a kiln, for example a rotary kiln. The rotary kiln may be of the direct or indirect type. The heating chamber may be provided or defined within the kiln. The heating chamber or kiln or a part thereof is arranged or configured to be rotatable, in use. The heating chamber may comprise a thermal conversion chamber.

In some embodiments, the apparatus may comprise a steam delivery means or steam delivery system, for example which may be configured or configurable to introduce steam into the heating chamber. The steam delivery means or steam delivery system may comprise a source of water. The steam delivery means or steam delivery system may comprise a boiler, for example arranged or arrangeable to boil water (e.g. from the source of water).

For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the apparatus may comprise any one or more features of the method relevant to the apparatus and/or the method may comprise any one or more features or steps relevant to one or more features of the apparatus.

There is also disclosed a computer program element comprising computer readable program code means or computer readable program code system for causing a processor to execute a procedure to implement one or more steps of the aforementioned method.

There is also disclosed the computer program element embodied on a computer readable medium.

There is also disclosed a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the aforementioned method.

There is also disclosed
a control means or control system or controller comprising the aforementioned computer program element or computer readable medium. For the avoidance of doubt, the terms "may", "and/or", "e.g.", "for example" and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed.

Referring now to <FIG>, there is shown a schematic representation of an apparatus <NUM> for treating comminuted waste material according to an embodiment of the invention. In use, the apparatus <NUM> converts waste material feedstock, for example granulated plastics, into synthesis gas (as will be described in greater detail below).

As shown in <FIG>, the apparatus <NUM> comprises a heating chamber <NUM>, which is provided within an indirect rotary kiln <NUM> in this embodiment. The apparatus <NUM> further comprises a waste feed system <NUM>, a heating system <NUM>, a steam system <NUM>, a cleaning system <NUM>, a storage system <NUM> and a further processing system <NUM>. The heating system <NUM> comprises plural combustion heaters <NUM>. The plural combustion heaters <NUM> are arranged to heat, in use, the contents of the indirect rotary kiln <NUM>. The waste feed system <NUM> is arranged to introduce, in use, comminuted waste material into the indirect rotary kiln <NUM>. The steam system <NUM> is arranged to introduce, in use, steam into the indirect rotary kiln <NUM>. The indirect rotary kiln <NUM> is fluidly connected to the heating system <NUM> by a supply system S. The supply system S comprises the cleaning system <NUM> and the storage system <NUM> in this embodiment. In embodiments, however, the supply system S may be absent one or each of the cleaning system <NUM> and the storage system <NUM>.

The cleaning system <NUM> is arranged to receive, in use, generated synthetic gas from the indirect rotary kiln <NUM>. The storage system <NUM> is arranged to receive, in use, cleaned synthetic gas from the cleaning system <NUM>. The storage system <NUM> is arranged to send at least a portion of cleaned synthetic gas to the further processing system <NUM>.

Referring now to <FIG>, there is shown a detailed schematic view of portions of the apparatus for treating comminuted waste material shown in <FIG>.

As shown in <FIG>, the indirect rotary kiln <NUM> comprises an inlet <NUM> and an outlet <NUM>. The inlet <NUM> and outlet <NUM> are disposed at opposite ends of the indirect rotary kiln <NUM>, in this embodiment. The indirect rotary kiln <NUM> comprises a drum <NUM>. The drum <NUM> comprises an outer shell 23a. The outer shell 23a surrounds a layer of insulating refractory bricks 23b. The insulating refractory bricks 23b surround a rotatable tube 23c. The rotatable tube 23c extends beyond the ends of the outer shell 23a on either end. A heating space 23d is defined between the insulating refractory bricks 23b and the rotatable tube 23c. In use, the outer shell 23a and insulating refractory bricks 23b are stationary whilst the rotatable tube 23c is rotated. The rotatable tube 23c may have a diameter of about <NUM>. The rotatable tube 23c may have a heated length of about <NUM>.

The indirect rotary kiln <NUM> is installed, for use, at an angle relative to the horizontal of approximately <NUM>°. The indirect rotary kiln <NUM> is arranged such that the inlet <NUM> is relatively higher than is the outlet <NUM>. A variable speed drive motor 26a is provided, which in this embodiment is located adjacent the inlet <NUM> of the indirect rotary kiln <NUM>. A mechanical drive chain 26b is also provided. The mechanical drive chain 26b links the variable speed drive motor 26a to the rotatable tube 23c. In use, activation of the variable speed drive motor 26a causes the mechanical drive chain 26b to move and, hence causes the rotatable tube 23c to rotate. The rotary kiln <NUM> is supported on water cooled bearings (not shown). The rotatable tube 23c is sealed using nitrogen purge sprung seals (not shown).

A discharge hood 22a is provided adjacent the outlet <NUM> of the indirect rotatable kiln <NUM>. The discharge hood 22a is in fluid communication with the outlet <NUM>. An inspection hatch 22b is provided on the discharge hood 22a.

A heating chamber <NUM> is defined within the rotatable tube 23c. The heating chamber <NUM> is divided into a first zone 28a, a second zone 28b and a third zone 28c. The first zone 28a is adjacent the inlet <NUM>. the third zone 28c is adjacent the outlet <NUM>. The second zone 28b is provided between the first and second zones 28a, 28c. In this embodiment, each of the zones 28a, 28b, 28c are of approximately equal length and/or volume. In embodiments, however, this need not be the case and one or more of the zones 28a, 28b, 28c may be of different lengths and/or volumes.

The apparatus <NUM> comprises an array <NUM> of temperature sensors, in this embodiment. The array <NUM> comprises temperature sensors 29a, 29b, 29c, 29d, 29e, 29f located inside of the rotatable tube 23c, in this embodiment. Two of the temperature sensors 29a, 29b, 29c, 29d, 29e, 29f located inside of the rotatable tube 23c are located inside each of the zones 28a, 28b, 28c, in this embodiment. The array <NUM> also comprises temperature sensors <NUM>, <NUM>, 29i, 29j, <NUM>, <NUM> located in the heating space 23d.

The apparatus comprises a pressure sensor <NUM>. The pressure sensor <NUM> is configured or arranged to monitor the pressure in the heating space 23d.

The heating space 23d contains three exhaust vents 25a, 25b, 25c are provided through the outer shell 23a. The exhaust vents 25a, 25b, 25c are in fluid communication with the heating space 23d. One of the exhaust vents 25a, 25b, 25c is located adjacent each of the zones 28a, 28b, 28c of the heating chamber <NUM>, respectively.

The apparatus <NUM> further comprises a first nitrogen supply 21a. The first nitrogen supply 21a is in fluid communication with the inlet <NUM> of the indirect rotary kiln <NUM>. The apparatus <NUM> further comprises a second nitrogen supply 22c. The second nitrogen supply 22c is in fluid communication with the discharge hood 22a. A check valve 21b is provided between the first nitrogen supply 21a and the rotatable tube 23c. A check valve 22d is provided between the second nitrogen supply 22c and the discharge hood 22a.

The feed system <NUM> comprises a feed screw (not shown) in this embodiment. However, in embodiments the feed system <NUM> may comprise any suitable means for feeding waste material into the indirect rotary kiln <NUM>, as will be appreciated by one skilled in the art. As shown in <FIG>, a flow sensor <NUM> is arranged to monitor the amount (e.g. the mass flow rate) of comminuted waste material into the heating chamber <NUM>.

Referring now to <FIG>, the heating system <NUM> comprises plural combustion heaters <NUM> which are gas burners 40a, 40b, 40c, 40d, 40e, 40f, in this embodiment. The gas burners 40a, 40b, 40c, 40d, 40e, 40f are arranged, in use, to heat the heating space 23d. The gas burners 40a, 40b, 40c, 40d, 40e, 40f are lean burn high efficiency gas burners. The gas burners 40a, 40b, 40c, 40d, 40e, 40f are configured to be individually controllable (as will be described in greater detail later). In this embodiment, two of the gas burners 40a, 40b, 40c, 40d, 40e, 40f are located adjacent each of the zones 28a, 28b, 28c. The gas burners 40a, 40b, 40c, 40d, 40e, 40f are equally spaced along the length of the indirect rotary kiln <NUM>. Each gas burner 40a, 40b, 40c, 40d, 40e, 40f is provided with a respective monitoring device <NUM>, <NUM>, 40i, 40j, <NUM>, <NUM>. The monitoring devices <NUM>, <NUM>, 40i, 40j, <NUM>, <NUM> are flame detectors, in this embodiment.

The heating system <NUM> comprises a natural gas supply <NUM>. The natural gas supply <NUM> is in fluid communication with gas control valves 44a, 44b, 44c, 44d, 44e, 44f via a natural gas pipeline 41a. The natural gas pipeline 41a has parallel branches 41b, 41c, 41d, 41e, 41f, <NUM>. On each branch 41b, 41c, 41d, 41e, 41f, <NUM> there is located a gas control valve 44a, 44b, 44c, 44d, 44e, 44f, respectively. A flow sensor <NUM> is also provided. The flow sensor <NUM> is arranged to monitor flow through the natural gas pipeline 41a, e.g. flow between the natural gas supply <NUM> and the first branch 41b.

The heating system <NUM> also comprises a synthesis gas supply pipeline 42a in fluid communication with a store of generated synthesis gas <NUM> (as will be described in greater detail later). The synthesis gas supply pipeline 42a is in fluid communication with the gas control valves 44a, 44b, 44c, 44d, 44e, 44f. The synthesis gas pipeline 42a has parallel branches 42b, 42c, 42d, 42e, 42f, <NUM>. A pressure sensor <NUM> is also provided. The pressure sensor <NUM> is configured to measure or determine the pressure of gas in the synthesis gas pipeline 42a, e.g. between the distal branch <NUM> and the store <NUM> of synthesis gas.

The natural gas pipeline 41a is fluidly connected to each gas burner 40a, 40b, 40c, 40d, 40e, 40f by, respectively, a gas pipe 45a, 45b, 45c, 45d, 45e, 45f. The synthesis gas supply pipeline 42a is fluidly connected to each gas burner 40a, 40b, 40c, 40d, 40e, 40f by, respectively, a gas pipe 45a, 45b, 45c, 45d, 45e, 45f. Each gas pipe 45a, 45b, 45c, 45d, 45e, 45f comprises a gas control valve 44a, 44b, 44c, 44d, 44e, 44f. Each gas pipe 45a, 45b, 45c, 45d, 45e, 45f comprises a temperature control valve 42aa, 42bb, 42cc, 42dd, 42ee, 42ff.

Each gas control valve 44a, 44b, 44c, 44d, 44e, 44f is located between the respective branch 41b, 41c, 41d, 41e, 41f, <NUM> of the natural gas pipeline 41a and the respective gas pipe 45a, 45b, 45c, 45d, 45e, 45f. Each gas control valve 44a, 44b, 44c, 44d, 44e, 44f is located between the respective branch 42b, 42c, 42d, 42e, 42f, <NUM> of the synthesis gas pipeline 42a and the respective gas pipe 45a, 45b, 45c, 45d, 45e, 45f.

The heating system <NUM> further comprises a combustion air supply <NUM>. The combustion air supply <NUM> is in fluid communication with a combustion air fan <NUM>, via a combustion air pipeline 43a. The combustion air fan <NUM> comprises an electric drive motor 46a. The combustion air pipeline <NUM> is fluidly connected to each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f, e.g. via branches 43b, 43c, 43d, 43e, 43f, <NUM>, respectively. An air control valve <NUM>, 43i, 43j, <NUM>, <NUM>, <NUM> is provided on the line between each gas burner 40a, 40b, 40c, 40d, 40e, 40f and each respective branch 43b, 43c, 43d, 43e, 43f, <NUM>. Each branch 43b, 43c, 43d, 43e, 43f, <NUM> of the combustion air pipeline <NUM> is connected to the respective gas pipe 45a, 45b, 45c, 45d, 45e, 45f between the temperature control valve 42aa, 42bb, 42cc, 42dd, 42ee, 42ff and the gas burner 40a, 40b, 40c, 40d, 40e, 40f.

Referring now to <FIG>, the steam system <NUM> is provided with a water source <NUM>. The water source <NUM> is in fluid communication with a steam superheater <NUM> via a steam pipeline 51a. A flow sensor 51b is arranged to measure the flow of water from the water source <NUM> to the steam superheater <NUM>. A flow control valve 51c is located in the steam pipeline 51a. The steam superheater <NUM> is in fluid communication with the inlet <NUM> of the rotatable tube 23c via the steam pipeline 51a.

The steam superheater <NUM> is heated by excess heat from the heating space 23d. The exhaust vents 25a, 25b, 25c are in fluid communication with the superheater <NUM>, to provide the excess heat thereto. The excess heat heats the water to provide superheated steam to the inlet <NUM> of the rotateable tube 23c.

Referring now to <FIG>, the discharge hood 22a is in fluid communication with a synthesis gas fan <NUM>, e.g. via an outlet pipe <NUM>. The discharge hood 22a is in fluid communication with a pressure control valve <NUM>, e.g. via the outlet pipe <NUM>. The pressure control valve <NUM> is in fluid communication with the pressure relief system (not shown). The synthesis gas fan <NUM> is in fluid communication with the cleaning system <NUM>. The synthesis gas fan <NUM> comprises a variable speed electric drive motor 60a. A pressure sensor <NUM> is arranged to monitor the pressure inside the rotatable tube 23c at and/or adjacent its outlet <NUM>. A pressure sensor <NUM> is arranged to monitor the pressure inside the discharge hood 22a. A temperature sensor <NUM> is arranged to monitor the temperature of a gas flowing, in use, from the discharge hood 22a to the synthesis gas fan <NUM>. A pressure sensor <NUM> is arranged to monitor the pressure of gas flowing, in use, from the synthesis gas fan <NUM> to the cleaning system <NUM>.

Referring again to <FIG>, the apparatus comprises a residue removal system <NUM> arranged to receive residue from the discharge hood 22a. This residue may be sent on for further processing in a residue processing system (not shown).

The apparatus <NUM> further comprises a control system (not shown). The monitoring devices <NUM>, <NUM>, 40i, 40j, <NUM>, <NUM> are in wired connection to the control system. The check valves 21b, 22d are in wired communication with the control system. The pressure transmitter <NUM> is in wired communication with the control system. The temperature transmitters 29a, 29b, 29c, 29d, 29e, 29f, <NUM>, <NUM>, 29i, 29j, <NUM>, <NUM> are in wired communication with the control system. The variable speed drive motor 26a is in wired communication with the control system. The gas control valves 44a, 44b, 44c, 44d, 44e, 44f are in wired communication with the control system. The flow sensor <NUM> is in wired communication with the control system. The pressure sensor <NUM> is in wired communication with the control system. The temperature control valves 42aa, 42bb, 42cc, 42dd, 42ee, 42ff are in wired communication with the control system. The electric drive motor 46a is in wired communication with the control system. The air control valves <NUM>, 43i, 43j, <NUM>, <NUM>, <NUM> are in wired communication with the control system. The flow sensor 51b and flow control valve 51c are in wired communication with the control system. The variable speed electric drive motor 60a is in wired communication with the control system. The pressure control valve <NUM> is in wired communication with the control system. The pressure sensor <NUM> is in wired communication with the control system. The pressure sensor <NUM> is in wired communication with the control system. The temperature sensor <NUM> is in wired communication with the control system. The pressure sensor <NUM> is in wired communication with the control system. The flow sensor <NUM> is in wired communication with the control system. In embodiments, one some or each of the above-described components may be in wireless communication with the control system, additionally or alternatively.

Referring now to <FIG>, there is shown a method of treating comminuted waste material according to an embodiment of the invention, using the apparatus shown in <FIG>.

In a first step S1, the apparatus <NUM> comprising the heating chamber <NUM> and the plural gas burners 40a, 40b, 40c, 40d, 40e, 40f is provided. The rotatable tube 23c is caused to rotate.

In a second step S2, comminuted waste material is fed by the feed system <NUM> into the rotatable tube 23c through the inlet <NUM> and hence into the heating chamber <NUM>. Without wishing to be bound by any theory it is believed that the angle of incline of the indirect rotary kiln <NUM> encourages feed material to move along the rotatable tube 23c, e.g. by gravity feed, toward the outlet <NUM>.

In a third step S3, steam is injected by the steam system <NUM> into the heating chamber <NUM>. Steam is introduced into the rotating tube 23c through the inlet <NUM> by the steam pipeline 51a. The steam is introduced into the rotating tube 23c at around <NUM>.

Hot water is provided to the steam superheater <NUM> from the hot water source <NUM>. The flow rate of hot water to the steam superheater <NUM> is monitored by the flow sensor 51b and the measurement is sent to the control system. By adjusting the flow control valve 51c, the control system can adjust the flow rate of hot water to the steam superheater <NUM>. The hot water is heated to steam in the steam superheater <NUM> for introduction to the rotatable tube 23c.

Advantageously, the steam provides a reducing atmosphere for the generation of synthesis gas. Accordingly, without wishing to be bound by any particular theory, it is believed that the waste material in the heating chamber <NUM> is more readily and efficiently gasified into synthesis gas in the presence of steam. Furthermore, the steam acts to transfer heat directly to the waste material inside the heating chamber <NUM>. Beneficially, the heat required from the gas burners to reach the required temperatures in the zones 28a, 28b, 28c may therefore be relatively reduced.

In a fourth step S4, the comminuted waste material in the heating chamber <NUM> is heated using the gas burners 40a, 40b, 40c, 40d, 40e, 40f.

As the waste material moves along the rotatable tube 23c it passes through the three zones 28a, 28b, 28c. In an embodiment, the first temperature T1 in the first zone 28a is about <NUM>; the second temperature T2 in the second zone 28b is about <NUM>; and the third temperature T3 in the third zone 28c is about <NUM>. The temperature adjacent the outlet <NUM> of the heating space 23d may be about <NUM>. In embodiments, however the first, second and/or third temperature T1, T2, T3 may be different.

In a fifth step S5, synthesis gas is generated in the heating chamber <NUM>. The synthesis gas comprises a mixture of hydrogen, methane and carbon monoxide, in embodiments.

Additional gaseous substances may also be present, for example carbon dioxide and oxygen, dependent on the comminutued waste material used. The ratio of hydrogen and methane in the generated synthesis gas can be adjusted by adjusting various operating factors of the apparatus <NUM>. For example, it has been found that a relatively greater ratio of hydrogen to methane can be generated by heating to relatively higher temperatures in the second and/or third zones 28b, 28c. Such relatively higher temperatures may be in the range of <NUM> to <NUM>, for example. In this way maximum hydrogen production can be achieved. Conversely, relatively lower temperatures in the second and/or third zones 28b, 28c may result in a relatively higher ratio of methane to hydrogen in the generated synthesis gas. Such relatively lower temperatures may be in the range of <NUM> to <NUM>, for example. Under such relatively lower temperatures relatively more methane may be present in the synthesis gas which is removed from the rotatable tube 23c. This may be advantageous for sending at least a portion of the generated synthesis gas on to the gas burners for heating the heating chamber <NUM>. Additionally or alternatively, at least a portion of the generated synthesis gas may be sent to a generator for generating electrical energy. This electrical energy can be used to power at least part of the apparatus and/or can be sent to the electricity grid and/or to power other machinery.

Heating of the waste material in the heating chamber <NUM> leads to the generation of synthesis gas (which comprises a combustible gas) in the heating chamber <NUM>, e.g. the fifth step S5.

Generated synthesis gas may have a residence time within the kiln <NUM> of about <NUM> seconds. The residence time of the generated synthesis gas can be altered by increasing or reducing the draw generated by the synthesis gas fan <NUM>. Increasing the power to the synthesis gas fan <NUM> may act to relatively increase the flow of synthesis gas from the rotatable tube 23c.

In a sixth step S6, at least a portion of the generated synthesis gas is supplied from the heating chamber <NUM> to the plural gas burners 40a, 40b, 40c, 40d, 40e, 40f. In some embodiments, the fuel used by the plural gas burners 40a, 40b, 40c, 40d, 40e, 40f may be provided mostly or entirely by generated synthesis gas. In embodiments, the generated synthesis gas (or at least a portion thereof) may be treated prior to being supplied to the plural gas burners 40a, 40b, 40c, 40d, 40e, 40f. For example, one or more components (for example hydrogen) of the generated synthesis gas may be removed prior to supply to the plural gas burners 40a, 40b, 40c, 40d, 40e, 40f.

The time between comminuted waste material entering the rotatable tube 23c and the relevant residue being removed by the residue removal system <NUM> is in the range of <NUM> to <NUM> minutes.

Generated synthesis gas exits the rotatable tube 23c through the outlet <NUM>. The synthesis gas is drawn from the rotatable tube 23c by action of the synthesis gas fan <NUM>. The synthesis gas then enters the discharge hood 22a. The synthesis gas is then drawn from the discharge hood 22a to the cleaning system <NUM>. Additionally, internal distributors (not shown) aid in transporting solid residues through the heating zone <NUM> to the discharge hood 22a. These solid residues are then removed and processed in the residue removal system <NUM>. Additionally, advantageously, the internal distributors also introduce turbulence to the gases and steam within the heating zone <NUM>. Without wishing to be bound by any theory it is believed that this turbulence enhances the efficiency of synthesis gas generation, for example through enhanced mixing of gasified waste material with steam. The generated synthesis gas is cleaned in the cleaning system <NUM>. The cleaned synthesis gas is then sent to the storage system <NUM>. At least a portion of the synthesis gas is then sent from the storage system <NUM> to the gas burners 40a, 40b, 40c, 40d, 40e, 40f.

Advantageously, the method and apparatus <NUM> described above provides a relatively more efficient system than prior art systems. For example, by utilizing synthesis gas generated by the apparatus <NUM> as a fuel source for the plural gas burners 40a, 40b, 40c, 40d, 40e, 40f the amount of external fuel is relatively reduced. The cost of heating the heating chamber <NUM> may, accordingly, be relatively reduced with respect to prior art apparatus and methods.

As will be appreciated by one skilled in the art, the various steps described above may occur simultaneously. For example, waste material may be fed into the indirect kiln <NUM> at the same time as previously fed waste material is being heated by the gas burners.

The pressure in the rotable tube 23c is monitored by the pressure sensor <NUM>. The temperature in the outlet pipe <NUM> is monitored by the temperature sensor <NUM>. The control system receives the monitored pressure and temperature. If the monitored pressure is greater than a predefined threshold then the control system is configured to actuate the pressure control valve <NUM> to allow synthesis gas to escape from the rotatable tube 23c. A pressure increase could be caused by, for example, an incident such as a blockage in the rotatable tube 23c. If the monitored pressure is less than a predefined threshold then the control system increases the draw of the fan <NUM>. The pressure in the rotatable tube 23c may be set to about <NUM> bar, e.g. atmospheric pressure.

The residue removal system <NUM> removes solids residue from the discharge hood 22a to be processed appropriately.

The control system may periodically provide a nitrogen purge to the inlet of the rotatable tube 23c from the first nitrogen supply 21a, by opening the check valve 21b. The control system may also provide a nitrogen purge to the discharge hood 22a from the second nitrogen supply 22c by opening the check valve 22d.

Referring now to <FIG>, there is shown a method of treating comminuted waste material according to a further embodiment of the invention.

In a first step S11, comminuted waste material in the heating chamber <NUM> is heated using the gas burners 40a, 40b, 40c, 40d, 40e, 40f.

In a second step S12, the temperature in the heating chamber <NUM> is measured by the temperature sensors 29a, 29b, 29c, 29d, 29e, 29f, <NUM>, <NUM>, 29i, 29j, <NUM>, <NUM>. The measured temperature is sent to the control system. The temperature inside of the heating space 23d is measured by the temperature sensors <NUM>, <NUM>, 29i, 29j, <NUM>, <NUM>. This measured temperature is sent to the control system. As will be appreciated. the temperature in each of the zones 28a, 28b, 28c of the heating chamber <NUM> can be measured or determined individually. Additionally or alternatively, the temperature in the heating space adjacent each of the zones 28a, 28b, 28c can also be measured or determined individually.

Additionally, the monitoring devices <NUM>, <NUM>, 40i, 40j, <NUM>, <NUM> record the presence or absence of a flame at each gas burner 40a, 40b, 40c, 40d, 40e, 40f, respectively. The pressure sensor <NUM> measures the pressure of synthesis gas in supply pipeline 42a. The flow sensor <NUM> measures the flow rate of natural gas through the natural gas pipeline <NUM>.

In a third step S13, the control system compares the monitored or determined temperature in the heating chamber <NUM> with a predetermined temperature range. In particular, the monitored or determined temperature in the first zone 28a of the heating chamber <NUM> is compared with a predetermined temperature range for the first zone 28a. The monitored or determined temperature in the second zone 28b of the heating chamber <NUM> is compared with a predetermined temperature range for the second zone 28b. The monitored or determined temperature in the third zone 28c of the heating chamber <NUM> is compared with a predetermined temperature range for the third zone 28c.

Additionally, the control system uses data received from the monitoring devices <NUM>, <NUM>, 40i, 40j, <NUM>, <NUM>, the pressure sensor <NUM> and the flow sensor <NUM> to monitor the operation of the heating system <NUM>.

In a fourth step S14, the control system adjusts the amount of heat applied by one or more of the gas burners 40a, 40b, 40c, 40d, 40e, 40f to the heating chamber <NUM> if the measured or determined temperature in the heating chamber is outside of the predetermined temperature range. If, for example the measured or determined temperature in the first zone 28a of the heating chamber <NUM> is lower than the predetermined temperature range, then the control system adjusts one or each of gas burners 40a and 40b to increase the amount of heat they are applying to the first zone 28a.

The predetermined temperature range in the first zone 28a may be between <NUM> and <NUM>, say between <NUM>, <NUM>, <NUM> or <NUM> and <NUM>, <NUM>, <NUM> or <NUM>. The predetermined temperature range in the second zone 28b may be between <NUM> and <NUM>, say between <NUM>, <NUM>, <NUM> or <NUM> and <NUM>, <NUM>, <NUM> or <NUM>. The predetermined temperature range in the third zone 28c may be between about <NUM> and <NUM>, say between about <NUM>, <NUM>, <NUM> or <NUM> and <NUM>, <NUM>, <NUM> or <NUM>. The predetermined temperature range may be altered or set dependent on the composition of the waste material (for example the waste material to be fed into the heating chamber <NUM>).

The temperature in each of the zones 28a, 28b, 28c of the heating chamber <NUM> is controlled by controlling the heat applied by each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f. The heat applied by each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f is independently controlled by the control system. For example, the control system can increase or reduce the mass flow rate of air supplied to one, some or each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f. The control system can also increase or reduce the mass flow rate of fuel to one, some or each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f. The fuel may comprise a mixture of natural gas and synthesis gas. Additionally or alternatively, the control system can alter the ratio of the mixture of natural gas to synthesis gas in the fuel. Each gas control valve 44a, 44b, 44c, 44d, 44e, 44f can alter the amount of natural gas supplied to the respective gas burner 40a, 40b, 40c, 40d, 40e, 40f, or prevent any natural gas from being supplied to the respective gas burner 40a, 40b, 40c, 40d, 40e, 40f. Each gas control valve 44a, 44b, 44c, 44d, 44e, 44f can alter the amount of synethisis gas supplied to the respective gas burner 40a, 40b, 40c, 40d, 40e, 40f, or prevent any synthesis gas from being supplied to the respective gas burner 40a, 40b, 40c, 40d, 40e, 40f. In embodiments, only synthesis gas may be supplied to one, some or each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f. In embodiments, only natural gas may be supplied to one, some or each of the gas burners 40a, 40b, 40c, 40d, 40e, 40f. Only natural gas may be supplied to the gas burners 40a, 40b, 40c, 40d, 40e, 40f when, for example, there is insufficient synthesis gas available. Such a situation may occur during initial start-up and running of the apparatus <NUM>.

The temperatures in the three temperature zones 28a-c may additionally be controlled by the control system altering the rotational velocity of the rotatable tube 23c. The control system is configured to control the variable speed drive motor <NUM> to rotate the rotating tube 23c at the desired rotational velocity.

The combustion air fan <NUM> is operable (e.g. by the control system) at a constant speed or at variable speeds. The electric drive motor 46a can be controlled by the control system.

Because the flow rate of combustion air to the gas burners 40a, 40b, 40c, 40d, 40e, 40f is determined by the combustion air control valves <NUM>, 43i, 43j, <NUM>, <NUM>, <NUM>, variable control of the electric drive motor 46a on the combustion air fan <NUM> is only provided to improve the operating efficiency of the heating system <NUM>.

In a first, optional step S21, a ratio of mass flow of steam to mass flow of comminuted waste material is calculated. In embodiments this may be calculated by or using the control system. The ratio is calculated to provide a target amount of a component of synthesis gas generated in the heating chamber <NUM>. In embodiments, the ratio is calculated to provide a target amount of methane or hydrogen. The ratio may be calculated based upon historical operating data. The ratio may be based upon theoretical analysis, and modelling via proprietary process simulation software. The ratio may be calculated based upon a combination of historical operating data and theoretical analysis. The ratio is calculated based upon the specific geometry and operating conditions of the indirect rotary kiln <NUM> and of the type and granularity of the comminuted waste material.

In a second step S22, comminuted waste material is fed into the heating chamber <NUM> in a manner similar to that described with respect to step S2 of the method described in respect of <FIG>. In a third step S23, steam is introduced to the heating camber <NUM>.

In a second step S24, the steam is contacted with the comminuted waste material, which comprises mixing, in this embodiment. Comminuted waste material is fed into the heating chamber <NUM> in a manner similar to that described with respect to step S2 of the method described in respect of <FIG>. Steam is introduced to the heating camber <NUM>. In this embodiment, mixing of steam and comminuted waste material occurs inside of the heating chamber <NUM>. However, in embodiments, mixing (and, indeed contacting) may occur at least partially external to the heating chamber <NUM>.

In a third step S25, the steam and comminuted waste material are heated inside the heating chamber <NUM> to generate a synthesis gas. This generated synthesis gas then exits the heating chamber <NUM> and enters the cleaning system <NUM> for further processing, as described above.

In a fourth step S26, the ratio of mass flow of steam to mass flow of comminuted waste material is adjusted such that the generated synthesis gas comprises the target amount of the component (e.g. methane or hydrogen) thereof, at a given temperature or temperatures in the zones 28a, 28b, 28c of the heating chamber <NUM>.

The mass flow rate of comminuted waste material fed into the heating chamber <NUM> is measured or determined. In embodiments, this is accomplished by monitoring the mass of comminuted waste which is fed into the heating chamber <NUM> by the feed screw. This may be accomplished by measuring or determining the angular velocity of the feed screw. In embodiments, the angular velocity of the feed screw can be measured directly (for example via measurement or knowledge of the angular velocity of the motor driving the feed screw rotation) and/or can be measured indirectly (for example using an encoder).

The mass flow rate of steam into the heating chamber <NUM> is measured or determined by monitoring the flow of water via the flow sensor 51b, in this embodiment. In embodiments, however, any suitable means for monitoring the mass flow rate of steam into the heating chamber <NUM> may be used.

The feed rate of comminuted waste material into the heating chamber <NUM> can then be controlled by adjusting the angular velocity of the feed screw. Additionally or alternatively, the mass flow rate of steam into the heating chamber <NUM> can be controlled by adjusting (e.g. automatically or manually) the flow control valve 51c. In this way, the mass flow rate of comminuted waste material into the heating chamber <NUM> can be adjusted to reach the calculated ratio of mass flow of steam to mass flow of comminuted waste material. In this way, the target amount of the component (e.g. hydrogen or methane) of the generated synthesis gas is achieved.

As will be appreciated by one skilled in the art, the first, optional step S21 can be carried out at any time prior to or simultaneously (e.g. at least partially) any of the other steps of the method. The steps S22, S23, S24 and S25 may, in embodiments, be continuous (or substantially continuous) during the treatment of the comminuted waste material. The first, optional step S21 may be run a single time or multiple times during the treatment of the comminuted waste material. For example, a different target amount of the component of the generated synthesis gas may be set. Additionally or alternatively, a different component of the generated synthesis gas may be set. Additionally or alternatively, one or more operating characteristics of the heating chamber (e.g. one or more temperatures therewithin and/or a rate of rotation thereof) may be altered and/or the composition and/or type of the comminuted waste material (e.g. a different plastics materials or mixture of plastics materials and/or a different size or range of sizes of comminuted particles of the waste material) may be used. A new calculation, where performed, may be based on any one or more of the above-identified characteristics and/or target component amounts. In embodiments, the optional step S21 may be carried out once one or more of the other steps has already begun. In embodiments, the sixth step S26 may be carried out subsequent to the optional step S21, for example and may be based on the results from the optional step S21.

Theoretical analysis using proprietary process modelling software was undertaken to provide calculations of the ratio of mass flow of steam to mass flow of comminuted waste necessary to provide a target amount of a component of generated synthesis gas (e.g. the optional first step S21).

In one example, the comminuted waste material was polypropylene, the operating temperature within the heating chamber <NUM> was set to be <NUM>. The target component was set to be methane and its target amount was set to be <NUM>% v/v of the generated synthesis gas.

Using the theoretical analysis it was determined that the ratio of mass flow of steam to mass flow of comminuted waste material was <NUM>.

It has been surprisingly found that by increasing the ratio of steam to comminuted waste material between a ratio of <NUM> and <NUM> results in a decrease in the amount of hydrogen (on a percentage v/v of the generated synthesis gas) generated. Increasing the ratio of steam to comminuted waste material between a ratio of <NUM> and <NUM>, however, results in an increase in the amount of hydrogen (on a percentage v/v of the generated synthesis gas) generated.

The first three steps S31, S32, S33 of the method shown in <FIG> are similar to the first three steps S21, S22, S23, respectively, of the method shown in <FIG>.

The method shown in <FIG> includes a fourth step S34 comprising a feed-back loop (e.g. a closed loop) for controlling the amount of a component contained in generated synthesis gas.

The fourth step S34 comprises a first stage S35 of measuring the amount of the component in generated synthesis gas. This measurement may occur outside or inside the kiln <NUM>, and/or may be achieved through use of a gas analysis means or system (not shown). The gas analysis means or system may comprise a gas chromatograph and/or may use gas chromatography and/or any other suitable technique as known to one skilled in the art. In embodiments, one or more other component of the generated synthesis gas may be measured (e.g. additionally).

In a second stage S36 the controller determines or calculates the difference between the target amount of the component of the generated synthesis gas and the measured amount of the component. If there is a difference then the controller calculates an alteration to the angular velocity of the feed screw and/or an alteration to the flow control valve 51c to, respectively, adjust the feed rate of comminuted waste material and the mass flow rate of steam into the heating chamber <NUM> in order to produce the target amount of the component. This calculation may be at least partially automated or may be performed by an operator.

In a third stage S37a, S37b an adjustment is made to the flow control valve 51c to increase or decrease the mass flow rate of steam entering the heating chamber and/or an adjustment is made to the angular velocity of the feed screw to increase or decrease the feed rate of comminuted waste material into the heating chamber. The adjustment(s) is/are made responsive to the calculation performed in the second stage S36. In one embodiment, only the mass flow rate of steam is adjusted. In another embodiment, only the feed rate of comminuted waste material is adjusted.

The above-described feed-back loop of the fourth step S34 provides for monitoring and control of the generated synthesis gas such that the target amount of the component is generated. Advantageously, this allows for maintaining a target amount of a component of the generated synthesis gas during operation. Further advantageously, this allows the target amount and/or the component to be changed during operation of the method. In this way, changes to end-use requirements can be more rapidly and readily met.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention, as defined-by the claims. For example, one or more steps or stages of one method may be used, additionally or alternatively, in any of the other methods. Furthermore, the control system may be automated (e.g. at least partially) or manually monitored and/or controlled (e.g. at least partially). The control system may be located remotely or at or adjacent the apparatus <NUM>. Additionally or alternatively, although a natural gas source <NUM> is described, this could instead be another combustible fuel, such as oil or coal or the like. Additionally or alternatively, although six gas burners are shown there may instead be any suitable number, for example more or less than six. Additionally or alternatively, although a single indirect rotary kiln is shown there may instead be plural indirect rotary kilns. Where more than one indirect rotary kiln is provided there may be a heating system, steam system, supply system, etc. for each indirect rotary kiln. Alternatively, where more than one indirect rotary kiln is provided a heating system, steam system, supply system or the like may be shared between two or more indirect rotary kilns.

Additionally or alternatively, any of the above-described methods may comprise a step of cleaning generated synthesis gas and/or any component thereof. Additionally or alternatively, any of the above-described methods may comprise a step of preparing or delivering generated (and/or cleaned) synthesis gas and/or any component thereof to or for a gas grid. Additionally or alternatively, any of the above-described methods may comprise a step of further processing generated synthesis gas and/or any component thereof, for example to produce a particular component or compound (e.g. methanol or carbon monoxide or the like).

Additionally or alternatively, although the apparatus <NUM> is described as comprising an indirect rotatable kiln <NUM> this need not be the case and, instead, the kiln may be a direct kiln, e.g. a direct rotatable kiln.

Additionally or alternatively, whilst the comminuted waste material and the steam are described as being mixed, said mixing may be due to introduction of the comminuted waste material into contact with the steam, only. Alternatively, mixing may comprise use of a mixing means or mixer configured to aid or enhance mixing of the comminuted waste material and steam. Where provided, the mixing means or mixer may be provided inside the kiln <NUM>, for example inside the heating chamber <NUM>. Alternatively, the mixing means or mixer may be provided at least partially outside of the kiln <NUM> (e.g. at least partially outside of the heating chamber <NUM>).

Claim 1:
A method of treating comminuted waste material, the method comprising:
a) heating comminuted waste material in a first, second and third zone (28a, 28b, 28c) of a rotatable heating chamber (<NUM>) using one or more heating means (<NUM>) to generate a combustible gas,
b) measuring or determining the temperature in the first, second and third zone (28a, 28b, 28c) of the rotatable heating chamber (<NUM>);
c) comparing the measured or determined temperature in the first, second and/or third zone (28a, 28b, 28c) of the rotatable heating chamber (<NUM>) with a predetermined temperature range for each of the first, second and third zone (28a, 28b, 28c); and
d) adjusting the amount of heat applied by the one or more heating means (<NUM>) to the first, second and third zone (28a, 28b, 28c) of the rotatable heating chamber (<NUM>) to maintain the temperature in each of the first, second and third zone (28a, 28b, 28c) of the rotatable heating chamber (<NUM>) within the predetermined temperature range for each of the first, second and third zone (28a, 28b, 28c); wherein the first zone (28a) has a first temperature T1, the second zone (28b) has a second temperature T2 and the third zone (28c) has a third temperature T3 and wherein the second and third temperatures T2 and T3 are higher than the first temperature T1.