System and Method for Recycling Waste into Energy

Abstract

A system for recycling solid waste into energy includes a heated enclosure 66 , one or more input conveyors 60, 67 move waste materials through the heated enclosure, provide a flow line with a temperature gradient of at least 150 F.°, and mechanically move the waste particles and the residual solids along the flow line. A heated rotary drum 74 is in fluid communication with the flow line, and condenser unit 94, 98 receive vapors from the flow line and the rotary drum and output hydrocarbons. One or more discharge conveyors 76 discharge carbon black from the rotary drum. Control valves 80, 82 seal a vacuum downstream from the discharge conveyors, and control valves 34, 46 seal vacuum upstream from the one or more input conveyors. Various types of vacuum pumps may be used to maintain a selected vacuum between the control valves.

1 - 41 . (canceled) 
   
   
       42 . A system for recycling solid waste into energy, the system comprising:
 a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber;   one or more input conveyors for inputting waste particles to the heated enclosure and having a flow line positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150 F.°, thereby producing hydrocarbon vapors and residual solids, the input conveyors mechanically moving the waste particles and the residual solids along the flow line;   a heated rotary drum in fluid communication with an exit from the flow line for receiving the waste particles and residual solids from the flow line, the rotary drum having an interior temperature of from 730° F. to 800° F. for generating hydrocarbon vapors and the residual solids;   a condenser in fluid communication with the flow line and the rotary drum for receiving the vapors from the flow line and the rotary drum and outputting liquids including hydrocarbons and gas including hydrocarbons;   one or more discharge conveyors for discharging the residual solids from the rotary drum;   two or more input control valves each for sealing vacuum downstream from the one or more input conveyors;   two or more discharge control valves each for sealing vacuum upstream from the one or more discharge conveyors; and   a vacuum pump for maintaining a selected vacuum between the two or more input valves and the two or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser.   
   
   
       43 . The system as defined in  claim 42 , wherein a drum sensor senses a temperature within the rotating drum; and
 fuel to the burner is controlled as a function of the measured drum temperature.   
   
   
       44 . The system as defined in  claim 42 , further comprising:
 a substantially vertical input conveyor in fluid communication with the two or more input control valves for providing a plug of waste material for minimizing vacuum loss; and   a substantially vertical waste conveyor in fluid communication with the two or more discharge control valves for providing a plug of residual solids for minimizing vacuum loss.   
   
   
       45 . The system as defined in  claim 42 , wherein at least a portion of the one or more of the gas including hydrocarbons and the liquids including hydrocarbons are input into a burner within the heated enclosure. 
   
   
       46 . The system as defined in  claim 42 , wherein each of the one or more input conveyors, the one or more discharge conveyors, and the heated conveyor within the flow line includes a rotary auger, each rotary auger is rotated by a drive motor and gearbox, a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a sealed enclosure downstream from the seal for containing gases which pass by the seal. 
   
   
       47 . The system as defined in  claim 46 , further comprising:
 one or more rpm sensors for monitoring a rotational rate of the rotary augers.   
   
   
       48 . The system as defined in  claim 46 , wherein the flow line extends in one axial direction within the heated chamber and extends in a substantially opposing axial direction within the heated chamber. 
   
   
       49 . The system as defined in  claim 42 , further comprising:
 a nitrogen supply system to supply nitrogen to the residual solids discharged from the one or more discharge conveyors.   
   
   
       50 . The system as defined in  claim 42 , further comprising:
 a water chiller for cooling hydrocarbon vapors passing through the condenser.   
   
   
       51 . The system as defined in  claim 42 , further comprising:
 a condensing column upstream of the condenser for separating liquids and gases, hydrocarbon vapors being input into a lower portion of the condensing column.   
   
   
       52 . The system as defined in  claim 42 , further comprising:
 a steam line for inputting steam at a temperature of greater than 800° F. into the rotary drum.   
   
   
       53 . A system for recycling waste into energy, the system comprising:
 a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber;   one or more input conveyors for inputting waste particles to the heated enclosure;   a flow line within the heated enclosure in fluid communication with the one or more input conveyors for receiving waste particles and positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of 150 F.°, thereby producing hydrocarbon vapors and residual solids, the flow line extending in one axial direction within the heated chamber and extending in a substantially opposing axial direction within the heated chamber;   a heated conveyor within the flow line mechanically moving the waste particles and the residual solids along the flow line;   a heated rotary drum in fluid communication with an exit from the flow line for receiving the waste particles and residual solids from the flow line, the rotary drum having an interior temperature of from 730° F. to 800° F. for generating hydrocarbon vapors and the residual solids;   a condenser in fluid communication with the flow line and the rotary drum for receiving the vapors from the flow line and the rotary drum and outputting liquids including hydrocarbons and gas including hydrocarbons;   one or more discharge conveyors for discharging the residual solids from the rotary drum;   each of the one or more input conveyors, the one or more discharge conveyors, and the heated conveyor within the flow line includes a rotary auger;   each rotary auger is rotated by a drive motor and gearbox, a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a sealed enclosure downstream from the seal for containing gases which pass by the seal; and   a vacuum pump for maintaining a selected vacuum of less than 5 inches of water within the condenser, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser.   
   
   
       54 . The system as defined in  claim 53 , wherein at least a portion of one or more of the gas including hydrocarbons and the liquids including hydrocarbons are input into a burner within the heated closure. 
   
   
       55 . The system as defined in  claim 53 , further comprising:
 a substantially vertical input conveyor in fluid communication with the one or more input control valves for providing a plug of waste material for minimizing vacuum loss; and   a substantially vertical waste conveyor in fluid communication with the one or more discharge control valves for providing a plug of the residual solids for minimizing vacuum loss.   
   
   
       56 . The system as defined in  claim 53 , further comprising:
 a plurality of sensors for detecting a leak within a vacuum system between the one or more input control valves and the one or more discharge control valves.   
   
   
       57 . The system as defined in  claim 53 , further comprising:
 a steam line for inputting steam at a temperature of greater than 800° F. into the rotary drum; and   a boiler heated by at least one of the gas including hydrocarbons and liquids including hydrocarbon for generating steam to the steam line.   
   
   
       58 . The system as defined in  claim 53 , wherein a drum sensor senses a temperature within the rotating drum; and
 fuel to the burner is controlled as a function of the measured drum temperature.   
   
   
       59 . The system as defined in  claim 53 , further comprising:
 a condensing column upstream of the condenser for separating liquids and gases, hydrocarbon vapors being input into a lower portion of the condensing column; and   a water chiller for cooling hydrocarbon vapors passing through the condenser.   
   
   
       60 . A system for recycling waste into energy, the system comprising:
 a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber;   one or more input conveyors for inputting waste particles to the heated enclosure;   a flow line within the heated enclosure in fluid communication with the one or more input conveyors for receiving waste particles and positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of 150 F.°, thereby producing hydrocarbon vapors and residual solids;   a heated conveyor within the flow line mechanically moving the waste particles and the residual solids along the flow line;   a heated rotary drum in fluid communication with the flow line for receiving the waste particles and the residual solids from the flow line;   a condenser in fluid communication with the flow line for receiving the vapors from the flow line and outputting liquids including hydrocarbons and gas including hydrocarbons;   one or more discharge conveyors for discharging the residual solids;   one or more input control valves each positioned along the one or more input conveyors for sealing vacuum downstream from the one or more input conveyors;   one or more discharge control valves each positioned along the one or more discharge conveyors for sealing vacuum upstream from the one or more discharge conveyors;   a vacuum pump for maintaining a selected vacuum of less than 5 inches of water between the one or more input valves and the one or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser;   a steam line for inputting steam at a temperature of greater than 800° F. into the rotary drum;   each of the one or more input conveyors, the one or more discharge conveyors, and the heated conveyor within the flow line includes a rotary auger;   one or more rpm sensors for monitoring a rotational rate of one or more of the augers; and   a processor for controlling a rotational speed of each rotary auger in response to the one or more rpm sensors.   
   
   
       61 . The system as defined in  claim 60 , wherein each rotary auger is rotated by a drive motor and gearbox, a seal engaging a rotary shaft connected to each auger for sealing vacuum, and a sealed enclosure downstream from the seal for containing gases which pass by the seal. 
   
   
       62 . The system as defined in  claim 60 , wherein the flow line extends in one axial direction within the heated chamber and in a substantially opposing axial direction within the heated chamber. 
   
   
       63 . The system as defined in  claim 60 , further comprising:
 the heated rotary drum having an interior temperature of from 730° F. to 800° F. for generating hydrocarbon vapors and the residual solids.