PROCESS TO OBTAIN LIQUID HYDROCARBONS BY CLEAVAGE OF CARBON AND HYDROGEN MOLECULES

Abstract

Process to obtain liquid hydrocarbons by cleavage of molecules containing carbon and hydrogen using materials with chemical waste, textile waste, biomass and whatever kind, being the same milled by a reactor and transferred to the reactor, increasing its temperatures to eliminate water, there is application of kinetic energy and friction with selected reactants to cleave the chains and separate the above mentioned elements and restructure the long or short chains to obtain the selected hydrocarbons by distillation and condensation.

Description

This application is a Continuation in Part of U.S. patent application Ser. No. 11/620,259 filed Jan. 5, 2007 which is fully incorporated by reference into this application.

The present invention studies the solution of a serious universal problem, namely, the real lack of fuels to satisfy the high demand of these days, added to the continuous search of fuels that do not derive from petroleum and the effort to decrease environment contamination.

I. BACKGROUND OF THE INVENTION

There are several ways to obtain fuels. For instance, a refinery is a large complex in which crude oil undergoes distillation or physical separation and later chemical processes. Petroleum may be classified in four categories: Paraffinic, naphtenic, asphaltic or mixed based crude and aromatic crude.

Refineries differ a lot between each other, depending on the technologies and process diagrams used, as well as on their capacity. The purpose of such may be to process soft crudes, heavy crudes or mixed based crudes. Refinery is carried out in several stages. The first step of the refinery process of crude oil is completed in the “primary distillation” towers. Within these towers, the same function nearly at atmospheric pressure and they are divided in many sections. The crude reaches these towers after passing by an oven, in which it is “baked” and turned into steam. This steam enters through the lower part of the distillation tower and elevates between the trays. As it elevates, it loses heat and cool. When each steamed component finds its own temperature, it condensates and deposits in its corresponding tray, which connect with certain ducts for the recollection of the different currents split in this stage. The “reduced crude” falls in the bottom of the tower, that is, the crude which did not evaporate in this first stage. Therefore, the “vacuum distillation” tower receives the reduced crude of the first stage and removes heavy gasoil, paraffinic bases and residues. The Cracking unit receives reduced gasoil and crudes to produce main gasoline and propane gas. The basic refining tool is the distillation unit. Hydrocarbons with lower molecular mass evaporate at lower temperatures, and larger molecules evaporate as the temperature rises. The first material distillated from crude is the gasoline fraction, followed by naphtha and finally kerosene. On the other hand there is the thermal cracking process, developed in an effort to increase the yield of distillation. In this process, the heavier parts of the crude are heated at high temperatures under pressure. Said process cracks the larger hydrocarbon molecules into smaller molecules, which in turn increases the amount of gasoline—composed of these molecules—obtained from a barrel of crude.

Later on, coking was invented. The process includes recirculation of fluids; it was a longer process with a much lower formation of coke. Many refiners have adopted this pressurized pyrolysis process.

In the 1930s other two basic processes were introduced; alkylation and catalytic cracking, which additionally increased the gasoline produced from a crude barrel. Manufacturing these products has given origin to the gigantic petrochemical industry, which produces alcohols, detergents, synthetic rubber, glycerin, fertilizers, sulfur, solvents and raw materials to produce medication, nylon, plastics, paintings, polyesters, additives and food supplements, explosives, dyes and insulating materials.

Cracking is the process whereby long hydrocarbon chains break down into shorter molecules, so that the properties of the mixture of the latter correspond with the product to be obtained, e.g. gasoil (diesel). The thermal and thermal-catalytic cracking of heavy oil fractions is known and applied industrially since the 60's, to obtain fuels and other petroleum by-products. The most relevant feature of the “conventional cracking” technology is the high pressure required.

On the other hand, “Thermo-mechanical cracking” achieves the same effects at atmospheric pressure. the process involves subjecting raw material (solid or liquid) containing carbon and hydrogen molecules, to a grinding or milling process (purely mechanical process) without the presence of air to prevent unwanted thermolysis, until the raw material is heated and vaporized. The process temperature is set and regulated to achieve the desired product in a distillation column, element constituent of the installation.

The principle behind the process herein described is the possibility of breakage of large organic molecules into smaller ones and take profit from the well known feature of hydrocarbon having a lower boiling point as the hydrocarbon chain became shorter. For this to occur, is necessary the use of reactors and the contribution of a “mechanical catalyst”, a natural or artificial product, hard and inert, which produces friction of raw material, breakage of its molecules and heat, in other words, it produces a “thermo-mechanical cracking”.

For instance, the most significant consequence of the present invention, and its novelty, is the cleavage of molecules containing carbon and hydrogen within the reactor under kinetic forces and friction with zeolites (or other hard elements).

In the process herein described there is a complete restructuring of raw material molecules to obtain the desired saturated hydrocarbon vapors. The main effect of the process is the high shearing produced by the reactor and the friction therein with the exothermic material. These two actions together cause breakage of physical and chemical structures of raw material into its components. Inorganic components form solids and CH₂ components form saturated liquid and gas hydrocarbons, water vaporizes and oxygen atoms associate with carbon atoms forming CO₂.

The exhaustion of cheap crude and the imminent fuel crisis have determined the implementation of alternative crudes such as bio diesel and bio ethanol which “are neutral in the production of carbon emissions”. When bio fuels are burned the carbon dioxide absorbed by plants as they grew in the field is returned to the atmosphere. The impairment of these alternatives is simply that there is not enough land that may be ploughed to cultivate all the bio fuel necessary to satisfy the voracious appetite for this source of energy of industrialized countries. Bio diesel has also given a solution to the superabundance of genetically modified crops (transgenic) which are today being turned down by consumers all over the world. According to the bio diesel industry, to process bio fuels it is necessary to build large refinery plants close to agricultural areas or forests, where raw material is abundant. Thus, bio diesel must be transported to the service stations just as crude is.

On the other hand, methanol is an alternative fuel to avoid the toxicity of naphtha emissions and destruction of the ozone layer. Likewise, the caloric power of naphtha is approximately twice as high as the caloric power of methanol, therefore it is more profitable. Originally, methanol was produced by destructive distillation of wood chips. This raw material was named wood alcohol. This reaction uses high pressure and temperature, and requires large and complex industrial reactors. There are different processes to obtain methanol such as: Lurgi process and ICI process.

Upon development and analysis of the processes already known, and with the purpose of introducing the object of the invention of the present application, we should explain some of the advantages of the invention proposed which overcome in great extent the different distillation processes of crude, reduce pollution and harness natural resources.

In our novel process natural raw materials are used, such as biomass, wastes of whatever nature (explained herein below) in which the caloric power of raw materials guarantee its transformation into gasoil or other hydrocarbons, the volume of which shall be equal to 80% of its caloric power.

That is, 1 kg of gasoil of 8000 kcal is produced with four kilograms of raw material of 2500 kcal/kg.

A further object of the invention is to be able to convert through this process the initial raw material, hard to valuate, into a fuel of easy valuation and application. A further advantage is its variety of mechanical applications, which improves its performance. For example, if biomass is used to produce electricity with the steam reactor boiler cycle we would have a performance of 22%. But if we convert this same biomass into gasoil with a performance over 80%, and this gasoil is used in an electrical central unit of combined cycle with a performance of 55%, the total performance would be 44%.

Today, the fuel of the invention may be used in transportation, but not the raw material. In this process, two liters of gasoil shall be produced for each kilowatt consumed. One liter of gasoil in a small plant may amount to USD 0.21, whilst in a large plant amounts to USD 0.16. Raw material is found in any country, nature offers plenty chemical reactants; facilities may be built in all countries because the only requirement is stainless steel boilers, and reactors, on the other hand, control instruments and vacuum pumps are very common and they are highly available in the market.

The process does not increase CO₂ production, and for biomass there is negative production of CO₂, therefore there is compliance with the Kyoto treatment in this respect. With this technology it shall be possible to eliminate dumps, which are the main pollution spots for underground waters and for methane discharge into the atmosphere.

II. DETAILED DESCRIPTION OF THE INVENTION

The object of the present invention is to obtain liquid hydrocarbons by cleavage of molecules containing carbon and hydrogen. For achieving this purpose, raw material should be liquid or solid containing organic compounds, such as, biomass, paper and carton, thermoplastic and thermosetting plastic material, rubbers, textile products, fats and oils, glycerin and others. It may be combined with inorganic material, such as: fillings in plastics, finishing agents in textiles, kaolin and others in paper and carton, in relatively high rates. Therefore, many industrial and urban residues may also be used as raw material for the process.

For a material to be considered potential raw material of the process, its amount of convertible matter should be viable, the eventual inorganic component it includes should be finely graded (<0.1 mm). It should be dry and the particle size should be no more than 6 mm. Dust and impalpable elements should be insignificant.

Oxygen transforms the convertible matter into carbon dioxide and water, thermolysis, since in the process, a significant part of the components of the raw material reach their spontaneous combustion temperatures. Although thermolysis in undesired, it may reduce the need of electric energy in the process, and it enables a recovery of energy which shall be applied in the process, i.e the drying processes.

Any specific raw material which does not meet the specifications described, should be previously treated. This usually includes, preparation of the raw material for its processing, and includes, mainly, crushing and grinding operations until the particle size is <6 mm, with the corresponding sieving and drying operations.

Regardless of the already mentioned raw material, there are so-called “inputs” in the process. These are the reagents, which have one of the two following functions in the process:

• • Adjuvant in the grinding operations of raw material.
  • Regulator of pH of the mass in process.

Grinding adjuvants are hard natural or artificial commercial inorganic compounds. Combined with raw material, they intensify molecular friction in reactors. This favors the desired cracking. They are known as cutting agents. So their function is purely mechanic.

The action of cutting agents, and more specifically, the action of zeolites, is not of chemical catalysts, but of shearing agents in the physical/mechanical stage, that cleave raw material down to about the size of a colloid. To achieve the shearing effect, it is also possible to use other materials such as alumino-silicate clays and most silicates and other inorganic materials of hard composition. The preferred cutting agents are zeolites since their physical characteristics contribute to prevent reactor or reactors deterioration, and while these shearing materials do not have any chemical catalytic effect during the process, they still accelerate molecule cleavage because of the physical effect of crashing, since, in their absence, cleavage would take place only by crashing against reactor walls and with inorganic components that are part of the raw material itself.

The controllers of pH, i.e. the acidity of the mass being processed, neutralize the acids which may be part of the raw material; such as chlorine in PVC, as well as acetic acid and sulphur in plant biomass. This produces inert inorganic salts. Thus, they cause a chemical reaction.

Products and sub-products of the process:

• • Gasoil (Diesel). Diesel fuel for automobiles is a mixture of hydrocarbons, petroleum fraction distilling within 280-320° C., generally being linear molecules of 18-22 carbon atoms, with a molecular weight of 200 to 250. It should be borne in mind that the final product of the process herein described corresponds exactly and without distinction, with that obtained through the conventional process of oil refining. This distinguishes it from the so-called biodiesel product of the esterification of fats and oils.
  • Water in the process. Produced condensed water, originated from the humidity traces of the load, and also, from thermolysis reactions, in which part of the oxygen atoms of the compositions in the raw material react with hydrogen atoms of the same raw material.
  • Non-condensable compounds. This is gas matter produced in the Process, mainly, carbon dioxide from the thermolysis reactions already described, reactions of oxygen with carbon from the raw material, also, methane and non-condensable hydrocarbons, which occasionally originate from the substances which are combined with the raw material, such as solvents, glue and varnish. Moreover, it is possible to obtain “malicious” traces of gas which should be treated appropriately regardless of the amount produced. Namely, carbon monoxide, sulfur oxide and combustible organic gases.
  • Inorganic compounds. These are inorganic solids obtained from the process. They include, ashes from biomass, plastic fillings, textiles and other materials, cutting agents and neutralizing salts, as well as improper inorganic matter which may be combined with the raw material.

The process involves two distinct stages. It starts by a physical/mechanical stage, in which there is milling, shearing, and friction of the raw material with a material capable of generating exothermic reactions, the most frequent of which are synthetic zeolite beads such as those used in petrochemical industry. This first physical/mechanical process causes the section of raw material to reduce its size up to molecular dimensions and further breakage of the molecular bonds with friction. The use of zeolites can be explained by the fact that it is a material that produces exothermic reactions and hard enough to produce shearing of the raw material.

The second stage is a chemical process, in which neutralization of the chemically active substances occurs at temperatures under 400° C., as well as inorganic molecules linked to the chains of molecular carbon and hydrogen. The recurrent elements are halogen, chloride and fluoride, which are in turn treated with lime, sodium, potassium or magnesium; those hardly ever found are mercury and chrome, heavy metals, active at process temperatures, that are neutralized by ions (which also react with other ionic substances).

For this chemical stage to develop, the existence of an essential element is needed. The main properties of this essential element are the following: condition (fine dust), shape (such that there is friction with raw material molecules), capable of producing exothermic reactions. These materials are very used in chemical industry and may be one of the following: soil or clay, containing aluminum and silicon, aluminum chlorides, but most used are synthetic zeolites which are highly available, since they have been used in petrochemical industry since the 60s. These materials make it possible to control temperatures during the process, since the main function is to produce friction with raw material molecules by friction within the reactor. The capability of producing exothermic reactions produces the temperature of materials to rise. Therefore, to initiate the feed of raw material it must be mixed with reactants and zeolites; the amounts depend on the raw material.

To start the process of this invention the raw material should be conditioned, so if the same contains suspended water, temperature shall be increased to 240° C. by heat exchangers; in said first stage it shall be completely dehydrated. Later on, it shall be introduced into the main process at 160-180° C., while the dehydrated raw material may be incorporated directly to the process. Viscous humid material shall be treated as already described herein. While highly viscous dehydrated materials may also be treated at temperatures below 240° C. to decrease viscosity and increase fluidity which improves the inclusion of the same in the main system (i.e: tar). Solid dehydrated material (i.e: plastics) should receive a previous milling process up to 3 mm, which is small enough to be introduced directly in the process herein. Solid humid raw material (i.e: biomass) should also receive a previous milling treatment up to a 3 mm section simultaneously with the drying process. Said standard drying process in the market (accomplished by several procedures) should yield raw material with 10% and 15% of humidity since a 10% reduction is very difficult for biomass. It is then normally introduced to the process. It should also be necessary to carry out the previous treatment of said material which contains crystalline water, which cannot be eliminated in the first state of the process.

Main Process

The operation shall include starting the facility, which implies using the starting fluid (residual organic liquid used to start and stop by order of the facility), which adds heat to the facility. This process may last 12 to 24 hours, then the loading of solids to the equipment begins progressively. Depending on the raw material, the mixture hydrocarbon:starting fluid is in a ratio (100-70):(0-30) % respectively.

Once the equipment is tempered, the dehydrator is loaded automatically. The load shall provide to the transporter the amount of raw material required in each stage, regulated by amount of load, located conveniently in the facility. This transporter shall have a weight system to control the entry of raw material. Likewise, the cutting material and the necessary reagents shall be added to this same transporter.

The transporter shall direct the load to the dehydrator, which eliminates the traces of humidity in the raw material. This humidity shall be dragged by warm air from the heating battery. The heat provided by this battery shall be part of the recovered product of the Process.

Then, the dry load is heated at temperatures lower than the spontaneous combustion temperature, until it reaches 160-180° C. The operation is carried out in the heater, equipment of hot air, in closed circuit, produced by the heat recovered from the process.

Once the heating temperature is achieved, the feeder shall be loaded by another transporter, which includes an endless screw, with a heating jacket with thermal oil, which compresses the load, and prevents the input of air, O₂, and heats the load at 200-250° C., approximately.

The exit of the feeder includes an expansion mechanism where some water vapour from eventual remaining humidity traces is released. The flow named back flow also reaches this point. It is an organic fluid coming from the distillation column. The back flow surrounds the load from the feeder, resulting in a solid solution in the liquid medium. This solution is pumped by an impeller and is introduced by pressure in a mechanical device called reactor, in which the physical/mechanical stage takes place.

The reactor provides the mechanical energy used to produce the friction required for molecular cracking. This friction is activated by the cutting agents. The mass is thus heated.

The fluid that flows towards the reactor is composed of oil and raw material, which is strongly sheared for about 8 to 12 minutes when entering the reactor, causing a decrease of dimension up to the size of colloids (10-30 micron) and friction among molecules of raw material with zeolite (or others), added to the mechanical action of the reactor produces heat, the fluid temperature increases up to 200-250° C. to 400° C. approximately during the process, depending on the raw material used.

When the mass is heated up to 350-380° C., the lignin of the biomass in one case, or certain plastics in others, are plasticized and the mass acquires certain viscosity or plasticity which provides part of the flow in the facility.

Raw material reduced to colloid dimensions (nearly molecular) guarantees reaction of active chemical substances within them, both free and bonded to its hydrogen and carbon molecules. Said active chemical substances shall be neutralized by the reactants provided, taking care that the mixture of hydrocarbons (both solid and liquid) and neutralizing zeolite is in the range (65-90):(0-20):(10-15) % respectively.

Oxygen atoms shall be free and may be bond to a carbon within free CO₂, which causes cleavage of initial chains of carbons. If said chains are short, vaporization temperatures shall be under or equal to the temperatures of the process, and this may produce linkage of said chains; on the contrary, if chains are long, their vaporization temperatures shall be higher than the temperature of the process therefore there is saturation of the molecule and loss of one or more carbon atoms. Crystalline water molecules within the raw material shall be free by shearing and friction. Likewise, any kind of water molecule in humid shape shall evaporate.

There may be one or many reactors assembled in series; this allows the solid inert compounds to be sent to the exit without recirculation, while the volatile compounds are released. The released vapours are recollected by a collecting pipeline with a flow temperature lower, but almost equal to coking temperature, about 400° C.

Most of the reactors are self-priming pumps; otherwise a pump should be installed for an artificial feed of fluid towards the reactor.

Any molecule containing carbon and hydrogen atoms, however saturated and chemically stable, shall be under kinetic strength and friction with zeolites (or any other element) within a reactor; therefore the same shall break in a process resembling petrol cracking. This is the more significant effect of the process herein described.

At this temperature, vapours enter the distillation column, with plates, where two flows are established: one upstream flow for vapours and one downstream flow for fluids. A device for heat exchange regulates the temperature of release of vapours of the distillation column.

This temperature regulation is key in the process, since it shall define the characteristics of the diesel fuel produced. Vapours with boiling temperature over the reference temperature become liquid and join the downstream flow of the column.

The vapours extracted from the column as such enter the condenser. These vapours have two different fractions: the diesel fuel vapours and the water vapour from thermolysis operations, combined with the non-condensable gases, mainly carbon dioxide, from thermolysis, and nitrogen from air infiltrations. These gases may be combined with other “malicious” gases, such as hydrocarbons, other organic compounds (fuels) and other gases: CO, SO₂, etc.

The condensable vapours, after their condensation, make up a mixture of gasoil and water, which are immiscible, and thus they separate. An intelligent decanting device allows the accurate separation of phases, in such a way that water contains the lowest possible amount of hydrocarbons and diesel fuel contains the lowest possible amount of water. In both cases these are the requirements established for these mixtures.

After decantation, water shall be extracted, until the separation level between phases is detected by a control element. Later, the diesel fuel is extracted, and is stored in the storage tanks.

After passing through each one of the reactors, the different fraction of the vapours shall include solids dissolved in a liquid phase, this is called sludge. The sludge exiting the reactor finds an expander through which the vapours dragged by the sludge are released and directed towards the collecting pipeline. The sludge level shall be regulated within a maximum and minimum level by a device which regulates the speed of the reactor impeller following in the series.

This impeller repeats the sludge processing operation, producing more friction and more vapour, and then what has been described happens once again.

The last reactor produces a sludge with a controlled amount of convertible or volatile matter. Furthermore, this sludge contains all the sterile compounds of raw material, plus a cutting material, plus the flow neutralizing salts.

The process temperature shall not be constantly over 400° C., since temperatures over 400° C. may produce mechanical damage to the reactor, therefore it is necessary to refrigerate the reactor. Temperatures should not be over 400° C. from the chemical point of view either to avoid occurrence of the carbonization process as well as tar formation.

At the outlet of the reactor light hydrocarbons exits as vapor and higher hydrocarbons exit as liquids (oils). Those hydrocarbons that exit as vapor are absorbed by the negative pressure of the distillation tower, whilst those liquid hydrocarbons precipitate in the reactor depending on its density in relation to the downward flow. The heavier oils are the first to enter in the reactor cycle. The inorganic solid materials and those coming from the chemical reactions precipitate in the bottom of the reactor. In the distillation tower, hydrocarbon vapors flow from inside of condensed oils in its different sections, which have the density provided by the distillation tower, these vapors exit through the upper section. Heavier molecules return to the reactor to undergo once more the process (this is essentially the normal process of a distillation tower).

Water and oil vapor molecules overcome the process of the distillation tower and exit as vapor by the upper part, and then they pass by a heat exchanger the flow of which is fed by the vacuum pump at the outlet of the same, in its interior vapors condensate and pass by a separator that produces elutriation of the hydrocarbon water. When these hydrocarbons represent the end of the process the automotive gasoil.

There exists a gas purger for the outlet of CO₂ derived from raw material molecular oxygen, generally the amount of the emission is very low, the emission shall be high for glycerin and alcohols. Solid residues remaining at the end of the process precipitate in the bottom of the chute shaped reactor and they are extracted through a tube and an on-line valve which opens when the same reach certain level of the chute. These solid remains are impregnated with liquid hydrocarbons, therefore they are transferred through a heat exchanger or electric resistance to evaporate these hydrocarbons and they are returned to the upper part of the reactor. These solids generally include: Inorganic remains carrying raw material, products of the chemical reactions and remains of zeolites reactants (or others).

In short, in the process of the present invention there is complete restructuring of raw material molecules to obtain the desired saturated hydrocarbon vapors. The main effect of the process is the high shearing produced by the reactor and the friction therein with the exothermic material. These two actions together cause breakage of physical and chemical structures of raw material into its components. Inorganic components form solids and CH₂ components form saturated liquid and gas hydrocarbons, water vaporizes and oxygen atoms associate with carbon atoms forming CO₂. Carbon atoms which have not bonded with available hydrogen atoms form bonds between them. This event produces coke carbon granules. Without reactants and its neutralizing effect the desired effect would not be produced, because in the event of active chemical substances, said substances would be part of the process and other substances than the desired substances would be produced.

Flows of Main Process

There is only one entrance. If there is more than one reactor the entrance is subdivided into one per reactor. Through this entrance the following enter: Selected raw material and the pulverized chemical reactants required.

There are four exits, three of which are located at the exit of the condenser, one of them for the selected hydrocarbon (gasoil), the second one for water and the third one for gases. The fourth exit is located at the bottom of the reactor for solid residues.

In some cases gasoil obtained in the process may be rather shady, and this may be caused by the raw material used or some distortion of the process. Thus there shall be a distillation tower independent from the main process, in which a second distillation shall be carried out, the residues of this process being returned to the reactor. The water recollected in the condenser passes by a filter system to settle hydrocarbons dragged by said water. Said hydrocarbons are returned to the reactor. Later, said water is distilled and is not a problem. In relation to the solids recollected at the end of the main process, if the facility is large enough, there is a possibility to recollect part of the zeolites (if this material is used) which have been precipitated or dragged by inorganic substances. There is raw material such as lignin of the wood which contains a significant higher amount of carbon atoms than hydrogen molecules, which produces a great amount of coke carbon. Coke carbon is later recovered, by separating it from the rest of the solid residues by decantation.

If raw material is rice straw and husk, the silicon contained therein would be recovered. In case of paper slurry silicon, alumina and carbon is recovered. From high sulfured crude, which is useless for conventional distillation, may produce high amounts of sulfur. Many other examples could be mentioned.

Components may be separated from each other by several technologies, and the most suitable shall be applied for each particular case.

These facilities shall be named SMRF: The components of which are of simple manufacture. The only requirement is a stainless steel boiler, reactors, engines and other elements that may be acquired in any country since there are plenty of manufacturers of these components. The size and production of the same is very diverse, from a few liters to thousands of liters per hour. They do not mean a risk to the environment, and they do not require any external service. Therefore, they may be installed in the same location as the raw material.

EXAMPLES

To start the process, the reactor is fed with mineral oil, vegetal oil or glycerin. Said liquids are heated and re-circulated in the process and when they reach 150° C., 20% of Zeolite and 15% of potassium are added to neutralize the acidity. When 350° C. are reached, diesel starts being produced and then the solid raw material may be added.

Some examples of embodiments using different raw materials are:

Example 1

Raw Material from Biomasses

Raw material is prepared before it is included in the process. Biomass is ground to a diameter of 5 mm. Following, biomass is dried and dehumidified, continuing with the heating up of the raw material to 120° C., so that the elimination of all the water is guaranteed, and the raw material is then compressed to remove the air it contains. Once the foregoing preparation is done, the raw material is included in the reactor. Lignin and other vegetal materials are liquid below the temperature of the process (350° C.) that occurs in the reactor. The relation to achieve the optimum viscosity for the process is 50% of solid material and 50% of liquid material.

Example 2

Obtaining Hydrocarbons from Plastics

If necessary, the raw material is prepared by drying, dehumidification not being necessary. The raw material is fed to the system, and since many plastics have their fusion temperature below 350° C., part of the raw material shall turn liquid at the temperature of the process. The approximate relation to achieve the optimum viscosity for the process is 50% of solid material and 50% of liquid material. In case of plastics of industrial residues, where plastics with high fusion temperatures can be found, such as PVC, the composition once the process has started is 40% plastic, 25% oils or glycerin, 20% Zeolite and 15% of potassium.

Example 3

Obtaining Hydrocarbons from Tyres

Tyres and all rubbers, as raw materials, imply two big problems: initial grinding to 5 mm and the separation of the metals. First, and in case it is necessary, the raw material is prepared by means of drying. Then, the raw material is heated up to 220° C., the addition of cutting material not being necessary given the high silica content, that guarantees the shearing effect. After the kinetic energy is provided to provoke the collision of particles, and at a temperature of 400° C., a diesel is produced, heavier than the prior ones, suitable for large engines and/or boilers. Lastly, that 60% of the initial raw material, made up by solid residues, is available and must be taken into account. Said residual material is heated up to 500° C. so that all the organic material is decomposed and the inert elements are recovered.

Claims

1. Process to obtain liquid hydrocarbons by cleavage of carbon and hydrogen molecules, that comprises a previous stage of filling a facility with starting fluid, loading the facility with the raw material and submitting, in at least one reactor, the mixture of starting fluid and raw material to a first physical/mechanical stage and a second chemical stage.

2. The process of claim 1 in which the raw material can be selected from the group consisting of biomass, paper and carton, thermoplastic and thermosetting plastic material, rubbers, textile products, fats and oils, glycerin, fillings in plastics, finishing agents in textiles, kaolin and others in paper and carton, industrial and urban residues.

3. The process of claim 1 in which the previous stage of filling the facility takes 12-24 hours before the loading of raw material could begin.

4. The process of claim 1 in which the mixture hydrocarbon:starting fluid is in a ratio (100-70):(0-30) %.

5. The process of claim 1 in which in the physical/mechanical stage the mixture of starting fluid and raw material is heated until it reaches 200-250° C., it is mixed with cutting agents and neutralizers and raw material is strongly milled and sheared for about 8 to 12 minutes when entering the reactor until it is reduced to the size of colloids (10-30 microns), increasing the temperature of the fluid up to 350-380° C.

6. The cutting agents of claim 5 in which they can be selected from the group consisting of zeolites, alumino-silicate clays and silicates.

7. The process of claim 1 in which in the chemical stage sodium- or calcium-based zeolites and elements selected from the group consisting of sodium, calcium, potassium or magnesium are added as neutralizers taking care that the mixture of hydrocarbons (both solid and liquid) and neutralizers is in the range (65-90):(0-20):(10-15) % respectively and that the temperature of the mixture is under 400° C.

8. The process of claim 1 in which the raw material is reduced to a 3 mm particle size before being fed to the facility.

9. The process of claim 1 in which the solid humid raw material is submitted to a drying process until it reaches a 10-15% of humidity.

10. The process of claim 1 in which the product obtained is automotive gasoil.