MATERIAL CONVERSION APPARATUS

Abstract

A material conversion apparatus for converting waste material to vapor or ash includes: (a) a rotatable housing, (b) a chamber for treating the material provided within the housing, (c) an electrical induction coil surrounding the housing and (d) an exhaust tube for evacuating the treated content from the chamber. The housing is inclined to the horizontal at about 5° to about 20°. The exhaust tube extends into a concentric sheath surrounded by a second electrical induction coil. The sheath is in fluid communication with an afterburner encircled by a further electrical induction coil. The afterburn is connected to an exhaust stack which opens to the atmosphere.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part patent application of co-pending U.S. Patent Application Serial No. 17/578,611 filed on January 19, 2022, which, in turn, is a completion application which claims the priority benefit of U.S. Provisional Patent Application Serial No. 63/139,851, filed January 21, 2021 for “Material Conversion Apparatus,” the disclosure of which is hereby incorporated by reference in its entirety including the drawing.

PRIOR ART

In the above referenced co-pending application, there is disclosed an electrical induction apparatus for converting biomass as well as various waste materials into substantially a gas, a liquid or ash. While the device is efficacious for its purposes it has been determined that improved means for emptying the device as well as modifying its construction would provide an easier implementation thereof and which would be more economical to operate.

BACKGROUND OF THE INVENTION

As known to the skilled artisan, gas fired incinerators create problems due to the under utilized heat they generate and the concomitant consumption of fuel(s) which, typically, is a byproduct of oil drilling or the like. Also, gas incinerators emit pollutants into the atmosphere and, at the same time, are incapable of reducing various materials to the point where they can easily be disposed of or otherwise converted or incinerated.

Electrical induction furnaces, on the other hand, typically reduce carbon footprints. They can be operated at high temperatures for reducing, vaporizing, oxidizing, pyrolyzing or gasifying materials without releasing external pollutants or other similar byproducts into the atmosphere.

The present invention as described hereinafter provides a new and improved electrical induction furnace and adjunct apparatus over that taught in the copending application, as well as other prior art and which can be used to convert waste, biowaste or biomass and other materials with significantly reduced pollution associated therewith, while eliminating pollution from outside fuels.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a material conversion apparatus or electrical induction furnace which, generally, comprises: (a) a housing or barrel; (b) a chamber or volume for treating biomass or waste material disposed or placed within the housing; (c) an electrical induction coil surrounding the housing which transmits sufficient heat into the chamber to convert the biomass or waste material to a liquid, vapor, gas or ash depending upon the nature of the material; and (d) means for exhausting or evacuating the post-conversion residual content or material from the chamber.

The electrical induction coil surrounds or envelops or wraps around the barrel and creates sufficient heat which penetrates through the wall of the barrel to pyrolyze, incinerate or otherwise heat the biomass or other waste material contained therein to the point where it is reduced to vapor, gas or ash, or is otherwise rendered disposable.

Preferably, the induction coil is constructed of copper wire, copper tubing, copper windings, aluminum, aluminum windings, zinc, or nickel or any other type of low resistance material. The coil may be used dry or fluid cooled during use.

The means for exhausting the content of the chamber, preferably, includes an exhaust pipe or tube in fluid communication with the chamber of the barrel.

A concentric sheath surrounds the exhaust tube and creates a gap or tunnel therebetween. Diverter vanes are fixed within the sheath causing air to swirl in the chamber and to facilitate gas or vapor and external combustion air into the afterburner.

An electrical induction coil surrounds the sheath for post treatment of materials.

An afterburner is in fluid communication with the sheath to provide further treatment of the waste material and from which minimal or non-pollutant gas or vapor is vented into the atmosphere.

A hand-held ladle can be used to remove any ash from the chamber.

Optimally, the barrel may be fitted with wheels to render the entire apparatus portable.

For a more complete understanding of the present invention, reference is made to the following detailed description and accompany drawing. In the drawing, like reference characters refer to like parts throughout the several views in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view, partly in cross-section and partly in phantom of the material conversion apparatus hereof;

FIG. 2 is a top side view, partly in cross-section, of the apparatus hereof;

FIG. 3A is a partial top view of the barrel used herein with the guillotine entry door in a closed position;

FIG. 3B is a side view of the entryway with the guillotine door in a closed position;

FIG. 4A is a view similar to FIG. 3A but with the guillotine door in an open position;

FIG. 4B is a view similar to FIG. 3B but with the guillotine door in an open position;

FIG. 5 is a cross-sectional view of the barrel depicting a ladle for collecting residual ash;

FIG. 6 is an end view of the interior of the housing with the ladle in use; and

FIG. 7 is a perspective view of an alternate embodiment hereof.

DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1-6, there is depicted therein a first embodiment of the present invention and generally denoted at 10. As shown, the apparatus includes a cylindrical barrel or housing 12. The housing has an outer wall 14 and an inner wall 16. The interior volume of the housing defines a chamber 19 for converting or reducing any material emplaced therein to gas, vapor, liquid or ash.

It is to be understood that the geometry of the housing is not critical hereto. Thus, it may be cylindrical (as shown), rectangular or any other geometric configuration that is suitable for the materials to be treated and which defines an interior chamber.

With more particularity and in accordance with this embodiment, the housing is formed from any suitable insulating-type material. Preferably, the housing is formed from a metal alloy, such as, for example, stainless steel, Inconel, or the like; a refractory material, and a ceramic material or other material, which can easily withstand the temperatures within the chamber which are generated by the coil, and which ranges upward of from about 1600° F to about 3000° F.

The barrel is supported by any suitable means, including posts, stanchions or the like as at 70. The barrel is removably mounted on wheels 25, which in turn, are fixed to frame 23. Similarly, the frame 23 is disposed at an angle θ ranging from about 5° to about 20° with respect to the horizontal. This facilitates removal of any ash or liquid remaining in the barrel after treatment of the biomass or waste.

An electrical induction coil 20 surrounds the housing. The coil may be fluid cooled. However, it is to be understood that a dry coil can be used.

As shown in the drawing the barrel, itself, has a first end or first end wall 21 and an opposed second end or second end wall 22. The first end 21 has an endcap or sealing door 27 associated therewith for sealing off the housing at the first end. An entryway 28 is provided with the first end wall 21 of the housing to provide access for feeding biomass or waste material to be treated in the chamber 19. Both the access and the first end can be sealed when the induction coil is operational. As detailed hereinafter, the sealing door, preferably, comprises a translatable or slidable guillotine door 27 movable between open and closed positions.

An exhaust port or discharge opening 26 is formed in the rear wall 22 through which any post-treatment residue is exhausted, via means 31, as described below.

A plurality of circumferentially spaced apart vanes 32 are secured to the interior chamber wall 16 and are used to distribute any material to be pyrolyzed, such as biomass so that there is continuous exposure to the heat generated by the coil. The vanes 32 are secured to the chamber wall through any suitable means, such as by welding, etc. The vanes may be curvilinear or otherwise irregular to assist in the movement, rotation and tumbling of the material during the conversion process. The vanes keep the material in contact with the interior wall of the chamber and the tumbling breaks up the material.

The electrical induction coil 20, itself, extends from proximate the first end wall to proximate the second end wall. It should be noted that the coil 20 is not limited to a helical coil, as shown. Rather, the induction coil may be a single low resistance winding with limited numbers of windings or plural windings, as shown.

The coil 20 can comprise any suitable low resistance material which can be coiled or wrapped around the chamber such as, for example, copper wire, copper tubing, aluminum, aluminum windings, zinc, nickel and their alloys, and the like. Preferably, the coil is formed from copper and may be used in a dry state or cooled with a circulating fluid such as water or a gas such as air, nitrogen, argon and the like. Preferably the coil is a cooled coil.

A plurality of wheels 25 may be secured to the housing to enable portability and mobility of the present apparatus.

The guillotine door 27 when moved to its open position, provides access into the interior volume or chamber of the housing through the entryway 28. The guillotine door 27 slides in a track 76 between an open position (FIGS. 1, 4A & 4B) and a closed position (FIGS. 3A & 3B). The door 27 seals against the end plate or end wall 21.

The second or opposite end or rear wall 22 is closed and permanently sealed, save for the exit port 26.

The exit port 26 is operatively connected to the exhaust means, generally denoted at 31.

The exhaust means include an exhaust tube 33 in fluid communication with the port 26.

The exhaust tube 33 is journalled onto the port 26 at one end and extends within the sheath.

A sheath 34 encircles the exhaust tube 33 and is concentric therewith. As a consequence, a gap or tunnel 35 is defined between the tube and the sheath, exteriorly of the housing. The gap 35 allows outside air shown by arrow 92 to be admixed with the gas and/or vapor air as shown by arrow 90, and to aid in the combustion process that occurs in the exhaust apparatus.

An exhaust electrical induction coil 36, similar to the electrical induction coil 20, surrounds the sheath as shown to provide post treatment of any residual waste.

Preferably, a plurality of circumferentially spaced apart diverter vanes 40 are mounted interiorly of the sheath rearward of the terminus of the exhaust tube. The vanes cause air to swirl and to facilitate the gas or vapor 90 and outside air 92 to swirl in the afterburner, as shown. The sheath 34 is open at its terminus 37 and projects into an afterburner 38.

The afterburner 38 is in fluid communication with the sheath 34 and the exhaust tube 33, as shown. The afterburner 38 is disposed downstream from the exhaust tube 33 and further incinerates any remaining residue. The sheath 34 is fixed in position within the afterburner by any suitable means.

The sheath 34 has a tangential entry 37 into the afterburner to create swirl and internal recalculation to increase residence time, as well as the swirling or mixing of the circulation air and chamber gas and/or vapor in the afterburner.

The afterburner 38 comprises a housing 42. An electrical induction coil 44, similar to induction coil 20, surrounds the housing 42.

An externally mounted electrical igniter 49 secured to the exterior of the afterburner 38 creates a spark within the afterburner to aid in combustion.

An exhaust conduit 45 extends outwardly and upwardly from the afterburner. An exhaust fan assembly generally denoted at 46 is in fluid communication with the afterburner.

A damper 48 regulates the entry of atmospheric cooling air, as at 100, into the exhaust assembly. The exhaust assembly opens to the atmosphere and enables discharge into the atmosphere of cool air which is substantially free of any pollutants or contaminants.

Referring now to FIG. 2, the apparatus hereof further includes means for rotating the barrel. The means for rotating include a motor 50, a chain drive 52 and roller ring 54. The motor is connected to the chain drive, which is indirectly connected to the roller ring which surrounds the exit or exhaust tube 33. When the motor is actuated, the barrel rotates. As the barrel rotates, the vanes 32 cooperate to tumble the biomass or waste within the chamber.

At least one sensor 84 is used to regulate or measure the temperature and air composition within the chamber. The requisite temperature and air composition is directly related to the amount and type of biomass or other waste material being converted therewithin. Once the temperature and the conversion cycle have been completed, the induction coil 20 is shut off and, although not necessary, may be allowed to cool down.

Referring to FIGS. 5 and 6, a hand-held ladle 60 is inserted into the chamber 19 to facilitate disposal of ash within the chamber while the motor continues to rotate the barrel and whether or not the chamber is cooled,

A hopper 62 is emplaced or provided at the terminus of the handle to that portion of the handle which is present in the chamber. A rest 64 is secured to the hopper, as shown, and which seats on the exit port to stabilize the ladle as it is being held.

As the barrel rotates, ash, which is accumulated on the vanes, is deposited into the hopper 62.

It is to be understood that the ladle can be electronically controlled but for ease of facilitation, it is optimal to hand hold the ladle and insert it into the chamber.

Referring now to FIG. 7, there is depicted an alternate material conversion apparatus, generally, denoted at 110 in accordance with the present invention. In accordance with the present invention, the apparatus hereof generally comprises: (a) housing which is shown as a barrel or drum 112, (b) a chamber is defined by the interior of the barrel for treatment of the biomass or waste material to be converted or treated; (c) an electrical induction coil 116 surrounds the housing and (d) means 118 for exhausting or evacuating the post-conversion content of the chamber.

The housing further includes a first and a second or opposite end wall 120, 122, respectively. The end wall, 122 has an exit port 124 similar to that provided in the first embodiment hereof.

The means for exhausting 118, generally, comprises an exhaust tube 144 connected to the exhaust port or opening (not shown) formed in the rear wall and extends outwardly therefrom.

The exhaust tube 144 is in fluid communication with the port at one end and an exhaust conduit 146 at its opposite end. The conduit 146 exhausts to the atmosphere, similar to that described according to the first embodiment.

In practicing the present invention, it is to be understood that certain elements have been eliminated for purposes of clarity, including insulation, monitoring sensors, means for powering the induction coils including an external power supply which is in electrical communication with heat stations. The heat stations convert the alternating electrical current from a power supply into direct current. The stations are in electrical communication with respective induction coils at a first end thereof. Further, monitoring sensors can be disposed within the afterburner, exhaust tube as well as the exhaust fan assembly.

Optimally, the sensing function is computer controlled to sense and adjust motor speed, temperature and air flow.

The raw material to be treated, itself, may consist of organic biomass, as well as inorganic materials that are able to be converted to vapor and/or reduced to ash.

Although not shown in the drawing it is to be understood that a preheater may be in communication with the apparatus which preheats the material to be heated prior to it being loaded through the loading or entry door into the chamber.

Claims

1. A material conversion apparatus comprising:

(a) a housing having an open interior defining a chamber for converting material emplaced within the housing;

(b) an electrical induction coil surrounding the chamber;

(c) means for evacuating the treated content of the chamber; and

(d) means for rotating the housing during operation and wherein the housing is disposed at an angle of about 5° to about 20° with respect to the horizontal.

2. The apparatus of claim 1 wherein the housing is a cylindrical barrel.

3. The apparatus of claim 2 wherein the barrel comprises an insulating element formed from either a metal, a refractory material, and a ceramic fiber.

4. The apparatus of claim 1 wherein the induction coil surrounds and envelops the barrel, the induction coil generating sufficient heat to vaporize or melt waste material disposed within the chamber.

5. The apparatus of claim 1 wherein the means for evacuating comprises:

(a) an exhaust tube in fluid communication with the chamber, means disposed in the exhaust tube for creating a negative pressure within the chamber to draw residue through the exhaust tube;

(b) a sheath surrounding the exhaust tube and concentric therewith to create a gap therebetween;

(c) an electrical induction coil surrounding the sheath and overlying the exhaust tube; and

(d) at least one fixed diverter vane disposed in the sheath downstream of the exhaust tube to facilitate gas or vapor and combustion downstream therefrom.

6. The apparatus of claim 5 which further comprises:

(a) an afterburner in fluid communication with the sheath and disposed downstream therefrom; and

(b) an electrical induction coil surrounding the afterburner.

7. The apparatus of claim 6 which further comprises:

an exhaust stack in fluid communication with the afterburner for exhausting any residual vapor in the afterburner to the atmosphere.

8. The apparatus of claim 1, wherein the housing comprises:

(a) a first end wall having an entryway formed therein for introducing a material to be converted;

(b) a sealing door abutting the first end wall and being movable between a first position for permitting access to the chamber for the material to be placed in the chamber and a second position for sealing the first end wall and the entryway; and

(c) a second end wall opposite the first end wall, the second wall being sealingly affixed to the housing and having central exit port formed therein to permit exhaust gas and/or vapor to escape the chamber and in communication with the means for exhausting, and an exhaust tube journalled onto the exit port to facilitate exhaustion of the chamber.

9. An exhaust system for use with the material conversion apparatus, comprising: (a) a sheath circumscribing the exhaust tube and concentric therewith, the sheath and the exhaust tube cooperating to create a gap therebetween for introduction of atmospheric air thereinto, the sheath extending beyond the exhaust tube; (b) a first electrical induction coil surround the sheath, (c) at least one diverter vane disposed in the sheath downstream of the exhaust tube; and (d) an afterburner in fluid communication with the sheath, the afterburner including a housing, an electric induction coil surro9inding the housing and an exhaust conduit extending outwardly from the afterburner and wherein the sheath is tangentially fixed within the afterburner housing to create swirling and mixing of external air and residual gas and/or vapor from the chamber delivered through the exhaust tube and sheath.