Production Processes, Systems, Methods, and Apparatuses

Abstract

The present disclosure provides production processes that can include exposing a carbon-based material to liquid media to form hydrocarbon fuel. Waste to fuel conversion processes as well as waste material processing reactors are provided that can be configured to convert waste to fuel. Heat exchangers, power generation processes and combustion turbine exhaust apparatus are also provided. Fuel generation processes and generation systems are provided. Reaction media conduit systems as well as processes for servicing reactant media pumps coupled to both inlet and outlet conduits containing reactant media, are also provided.

1 . A production process comprising exposing a carbon-based material to catalytic liquid media to form hydrocarbon fuel. 
   
   
       2 . The process of  claim 1  wherein the carbon-based material comprises cellulose. 
   
   
       3 . The process of  claim 1  wherein the liquid media comprises a zeolite catalyst. 
   
   
       4 . The process of  claim 1  wherein the liquid media comprises hydrated lime. 
   
   
       5 . The process of  claim 1  wherein the liquid media comprises a petroleum-based material. 
   
   
       6 . The process of  claim 5  wherein the petroleum-based material has a boiling point of at least 370° C. 
   
   
       7 . The process of  claim 1  wherein the carbon-based material comprises hydrogen. 
   
   
       8 . The process of  claim 1  wherein the carbon-based material comprises fluff. 
   
   
       9 . The process of  claim 1  wherein the hydrocarbon fuel comprises non-condensable gases. 
   
   
       10 . The process of  claim 1  wherein the hydrocarbon fuel comprises kerosene. 
   
   
       11 . The process of  claim 1  wherein the hydrocarbon fuel comprises diesel fuel. 
   
   
       12 . A waste to fuel conversion process comprising:
 providing a low-moisture carbon-based waste material;   exposing the waste material to a catalytic liquid reaction media under a substantially oxygen-free atmosphere within a reactor; and   recovering gaseous hydrocarbon fuel from the reactor.   
   
   
       13 . The process of  claim 12  wherein the carbon-based waste material contains less that 16% (wt./wt.) water. 
   
   
       14 . The process of  claim 12  wherein the waste material comprises biomass. 
   
   
       15 . The process of  claim 12  wherein the exposing comprises providing a substantially oxygen-free atmosphere above the liquid reaction media and providing the waste material through the atmosphere and into the reaction media. 
   
   
       16 . The process of  claim 15  wherein the liquid reaction media is maintained at a temperature of at least about 310° C. during the exposing. 
   
   
       17 . The process of  claim 12  wherein the liquid reaction media is agitated during the exposing. 
   
   
       18 . The process of  claim 17  wherein the agitation comprises mechanical agitation. 
   
   
       19 . The process of  claim 12  wherein the gaseous hydrocarbon fuel comprises hydrocarbon compounds ranges in carbon chain length from C-1 to C-25. 
   
   
       20 . The process of  claim 12  wherein the atmosphere comprises N 2 . 
   
   
       21 . The process of  claim 12  wherein the waste material is provided to the reaction media during the exposing via an inert gas purged air lock. 
   
   
       22 . A waste material processing reactor configured to convert waste to fuel, the reactor comprising:
 a substantially columnar vessel extending along the vessel walls from a base portion to a top portion;   an opening within the top portion of the vessel, the opening configured to receive carbon-based waste material; and   a liquid media conduit extending from the base portion to the top portion of the vessel, the conduit configured to circulate liquid media from within the base portion of the reactor to the top portion of the reactor.   
   
   
       23 . The reactor of  claim 22  wherein the vessel is constructed primarily of carbon steel material. 
   
   
       24 . The reactor of  claim 22  further comprising an atmosphere exchange conveyor coupled to the opening, the exchange conveyor configured to exchange an oxygen-comprising atmosphere associated with the waste material with a substantially oxygen-free atmosphere within the reactor. 
   
   
       25 . The reactor of  claim 22  wherein the opening is also configured to receive an agitation apparatus. 
   
   
       26 . The reactor of  claim 25  wherein the agitation apparatus comprises a mechanical agitation apparatus that extends to within the vessel and proximate the base of the vessel. 
   
   
       27 . The reactor of  claim 22  further comprising a hydrocarbon fuel recovery conduit coupled to the reactor and in fluid communication with the interior of the vessel. 
   
   
       28 . The reactor of  claim 22  wherein the liquid media conduit extends along the vessel walls on the exterior of the reactor. 
   
   
       29 . The reactor of  claim 22  wherein the liquid media conduit is coupled to a heat exchanger. 
   
   
       30 . The reactor of  claim 22  further comprising a plurality of nozzles arranged around the top portion within the vessel, the nozzles in fluid communication with the liquid media conduit and configured to provide the liquid media to within the vessel. 
   
   
       31 . The reactor of  claim 30  wherein the nozzles form a perimeter around the opening in the top portion of the vessel and the nozzles are configured to provide the liquid media in substantially the same direction as the travel of waste-material upon entry into the vessel. 
   
   
       32 . A waste to fuel process comprising:
 exposing a solid carbon-based material to a liquid reaction media to form a hydrocarbon fuel mixture, the fuel mixture comprising non-condensable hydrocarbon fuel and condensable hydrocarbon fuel; and   separating the non-condensable hydrocarbon fuel from the condensable hydrocarbon fuel.   
   
   
       33 . The process of  claim 32  wherein the liquid reaction media has a boiling point substantially greater than a boiling point of the fuel mixture. 
   
   
       34 . The process of  claim 32  wherein upon exposing the solid carbon-based material to the liquid reaction media at least a portion of the fuel mixture is formed. 
   
   
       35 . The process of  claim 32  wherein the liquid reaction media is blanketed with a substantially oxygen-free atmosphere, and upon the exposing the fuel mixture comprises at least a portion of the atmosphere. 
   
   
       36 . The process of  claim 35  wherein the portion of the atmosphere is separated from the non-condensable and condensable fuels. 
   
   
       37 . The process of  claim 32  wherein separating comprises distilling the fuel mixture. 
   
   
       38 . The process of  claim 32  wherein the non-condensable fuel comprises C-1 to C-4 hydrocarbon compounds. 
   
   
       39 . The process of  claim 32  wherein the non-condensable fuel comprises CO and H 2 . 
   
   
       40 . The process of  claim 32  wherein the condensable fuel comprises hydrocarbon compounds having greater than 5 carbon atoms. 
   
   
       41 . A power generation process comprising:
 exposing solid carbon-based material to a liquid reaction media to form vaporized hydrocarbon fuel; and   providing the vaporized hydrocarbon fuel to a combustion turbine to generate power.   
   
   
       42 . The process of  claim 41  wherein the vaporized hydrocarbon fuel comprises C-1 to C-4 compounds. 
   
   
       43 . The process of  claim 41  wherein the exposing further comprises exposing the material to a substantially oxygen-free atmosphere. 
   
   
       44 . The process of  claim 43  wherein the providing comprises:
 generating a mixture comprising the vaporized hydrocarbon fuel and the atmosphere;   separating a substantial amount of the fuel from the atmosphere; and   providing the fuel to the combustion turbine.   
   
   
       45 . The process of  claim 44  wherein separating comprises distilling the mixture. 
   
   
       46 . The process of  claim 41  wherein the vaporized hydrocarbon fuel is substantially free of nitrogen and water upon being provided to the combustion turbine. 
   
   
       47 . The process of  claim 41  wherein the combustion turbine is configured to provide at least 1000 kW of electricity. 
   
   
       48 . The process of  claim 41  wherein the forming the vaporized hydrocarbon fuel furthering comprises separating the non-condensable hydrocarbon fuel from condensable hydrocarbon fuel. 
   
   
       49 . A combustion turbine exhaust apparatus comprising:
 a substantially columnar housing extending along a plane from an inlet portion to outlet portion;   a substantially columnar exhaust chute within the housing and extending parallel along the plane, the exhaust chute recessed from the walls of the housing, the exhaust chute and housing defining a space between the chute and housing; and   a plurality heating fluid conduits within the space and extending along the plane.   
   
   
       50 . The apparatus of  claim 49  wherein dampers are associated with inlet portion of the housing, the dampers configured to manipulate the flow of exhaust from the turbine between the chute and the space. 
   
   
       51 . The apparatus of  claim 50  wherein the dampers are hinged proximate the apparatus. 
   
   
       52 . The apparatus of  claim 49  wherein the plurality of heating fluid conduits comprises separate groups of conduits. 
   
   
       53 . The apparatus of  claim 52  wherein the groups of conduits comprise at least two conduits within a channel extending between the chute and housing within the space. 
   
   
       54 . The apparatus of  claim 53  wherein the channel is defined by channel walls extending substantially normally between the housing and chute. 
   
   
       55 . The apparatus of  claim 53  wherein the channel is defined by channel walls extending within space between the inlet and outlet portions substantially parallel with the walls of the chute and housing. 
   
   
       56 . The apparatus of  claim 53  wherein each of the channels defines a continuous volume extending between the inlet and outlet portions of the apparatus. 
   
   
       57 . The apparatus of  claim 53  wherein the groups are dispersed around the chute. 
   
   
       58 . The apparatus of  claim 53  wherein in one cross section the groups are evenly dispersed around the chute. 
   
   
       59 . The apparatus of  claim 53  wherein baffles extend between the groups with the space. 
   
   
       60 . A fuel generation process comprising:
 exposing a solid carbon-based material to a liquid reaction media to form a mixture of hydrocarbon fuel;   separating the fuel into at least two portions, a first portion and a second portion;   providing the first portion to a combustion turbine to generate power; and   storing the second portion for use as fuel.   
   
   
       61 . The process of  claim 60  wherein the exposing comprises providing a substantially dry carbon-based material to a substantially oxygen-free reaction zone housing the liquid reaction media. 
   
   
       62 . The process of  claim 61  wherein the reaction zone houses a zeolite catalyst, the exposing further comprising exposing the material to the catalyst in the presence of the media. 
   
   
       63 . The process of  claim 61  wherein the reaction zone houses lime, the exposing further comprising exposing the material to the catalyst in the presence of the media. 
   
   
       64 . The process of  claim 60  wherein the first portion comprises non-condensable hydrocarbons and the second portion comprises condensable hydrocarbons. 
   
   
       65 . The process of  claim 60  wherein the first portion comprises non-condensable hydrocarbons and kerosene and the second portion comprises diesel fuel. 
   
   
       66 . The process of  claim 60  wherein the providing the first portion to the combustion turbine comprises vaporizing the first portion. 
   
   
       67 . The process of  claim 60  wherein the liquid reaction media is heated with heat transfer fluid and the providing further comprises generating power as well as an exhaust from the combustion the turbine, wherein the exhaust is used to heat the heat transfer fluid. 
   
   
       68 . The process of  claim 60  wherein the first portion comprises kerosene and the second portion comprises diesel fuel. 
   
   
       69 . The process of  claim 68  wherein separating comprises distilling the mixture to separate the portions. 
   
   
       70 . A fuel generation system comprising:
 a reactor configured to house a liquid reaction media and receive solid carbon based material;   a distillation apparatus coupled to the reactor and configured to receive gaseous hydrocarbon fuel from the reactor; and   a combustion turbine coupled to the distillation apparatus and configured to receive distillate portions from the distillation apparatus.   
   
   
       71 . The system of  claim 70  further comprising a conveyor apparatus associated with reactor, the conveyor apparatus configured to convey material to a receiving portion of the apparatus. 
   
   
       72 . The system of  claim 70  further comprising a heat exchanger coupled to the reactor, the heat exchanger configured to heat the liquid reaction media by providing heat from a heat exchanger fluid. 
   
   
       73 . The system of  claim 72  wherein the heat exchanger is coupled to the combustion turbine. 
   
   
       74 . The system of  claim 73  wherein at least a portion of the heat exchanger fluid of the heat exchanger circulates within an exhaust apparatus of the combustion turbine. 
   
   
       75 . The system of  claim 70  wherein the reactor comprises a media circulating conduit configured to circulate the liquid reaction media. 
   
   
       76 . The system of  claim 75  wherein conduit comprises a fluid pump, the conduit further configured to have the fluid pump removed from the conduit while maintaining substantially all the fluid within the conduit. 
   
   
       77 . The system of  claim 75  wherein the conduit defines an access configured to allow for removal of a portion of the media during the circulating. 
   
   
       78 . The system of  claim 77  further comprising a filter press in fluid communication with the access. 
   
   
       79 . The system of  claim 70  wherein the distillation apparatus comprises at least one condenser configured to receive gaseous compounds from the apparatus. 
   
   
       80 . The system of  claim 70  wherein the distillation apparatus comprises a plurality of serial condenser-decantor apparatus, the condenser-decantor apparatus configured to receive gaseous compounds from the distillation apparatus and return liquid compounds to the distillation apparatus. 
   
   
       81 . The system of  claim 70  wherein the distillation apparatus comprises a condenser coupled to a demister, the demister configured to demist gaseous compounds received from the condenser. 
   
   
       82 . The system of  claim 81  wherein the distillation apparatus is coupled to a combustion turbine. 
   
   
       83 . The system of  claim 82  wherein a condenser is inline between the distillation apparatus and combustion turbine. 
   
   
       84 . The system of  claim 70  wherein the distillation apparatus is configured to separate portions of condensable hydrocarbon fuel. 
   
   
       85 . The system of  claim 84  wherein the portions comprise kerosene and/or diesel fuel. 
   
   
       86 . A reaction media conduit coupled to a reaction media pump, a portion of the conduit proximate the pump comprising a jacket defining a volume configured to receive a refrigerant material. 
   
   
       87 . The conduit of  claim 86  wherein the conduit and pumps are configured to transfer the reaction media, the reaction media comprising an industrial grade high molecular weight oil. 
   
   
       88 . The conduit of  claim 86  wherein the conduit has an internal diameter of at least 2.54 cm. 
   
   
       89 . The conduit of  claim 86  wherein the conduit and pump are configured to transfer reaction media from an industrial grade reactor. 
   
   
       90 . The conduit of  claim 86  wherein the conduit and pump are configured to transfer reaction media to an industrial grade heat exchanger. 
   
   
       91 . The conduit of  claim 86  wherein the conduit extends from entrance and exit portions of the pump and the jacket is proximate either the exit or entrance portions of the pump. 
   
   
       92 . The conduit of  claim 86  wherein conduit extends from entrance and exit portions of the pump and these portions both comprise jackets. 
   
   
       93 . The conduit of  claim 86  wherein the jacket defines a continuous volume surrounding the entire perimeter of the portion of the conduit. 
   
   
       94 . The conduit of  claim 86  wherein the refrigerant material comprises liquid nitrogen. 
   
   
       95 . A process for servicing reactant media pumps coupled to both inlet and outlet conduits containing reactant media, the process comprising:
 at least partially solidifying portions of the reactant media proximate to the pump and within each of the inlet and outlet conduits; and   uncoupling at least a portion of the pump from either of the conduits while maintaining a majority of the reactant media within the conduits.   
   
   
       96 . The process of  claim 95  wherein the inlet conduit is coupled to an industrial grade reactor. 
   
   
       97 . The process of  claim 95  wherein the outlet conduit is coupled to an industrial grade heat exchanger. 
   
   
       98 . The process of  claim 95  wherein the partially solidifying comprises providing a refrigerant proximate the inlet and outlet conduits. 
   
   
       99 . The process of  claim 95  wherein the reactant media comprises industrial grade oil.