Abstract: This invention relates to a method and apparatus for gasifying or liquifying coal. In particular, the method comprises reacting a coal with a molten aluminum or aluminum alloy bath. The apparatus includes a reaction vessel for carrying out the reaction, as well as other equipment necessary for capturing and removing the reaction products. Further, the process can be used to cogenerate electricity using the excess heat generated by the process.

Abstract: Disclosed is a system and method for the recycling of waste composite feed materials such as printed circuit boards (PCBs), batteries, catalysts, plastic, plastic composites such as food packaging materials, for example Tetra Pak®, mattresses, compact disks (CDs, DVDs), automobile shredder residue (ASR), electric cable wastes, liquid display panels, mobile phones of various sizes or combinations of the above using a new pyrolysis system and method.

Abstract: An exemplary embodiment of the present invention provides a reactor system comprising: a reaction vessel comprising a reactant, a heat transfer fluid and a first reaction product, wherein the heat transfer fluid has a greater density than the first reaction product such that at least a portion of the first reaction product floats on a surface of the heat transfer fluid; a first outlet positioned at a surface level of the first reaction product, the first outlet configured to output a first outlet flow comprising at least a portion of the first reaction product and at least a portion of the heat transfer fluid; wherein the heat transfer fluid is configured to provide thermal energy to the reactant in the reaction vessel to form the first reaction product.

Abstract: A system and method for a constituent rendering of biomass and other carbon-based materials is provided. The system can be configured for receiving a feedstock material to be rendered into its constituent components, grinding the feedstock to a desired size and/or consistency, and placing the feedstock in contact with a hot mix heat transfer medium within a pressure chamber. Pyrolysis of the feedstock can lead to a breakdown of the feedstock into constituent components that can then be collected.

Abstract: The invention relates to a reactor for gasifying and/or cleaning, especially for depolymerizing a plastic material (12), which reactor comprises: a reactor vessel (14) for receiving a starting material (12), especially the plastic material (12); a metal bath (26) which is arranged in the reactor vessel (14) and includes a liquid metallic material that has a metal bath melting temperature (TSchmelz); a plurality of filling elements (25) in the metal bath (26); a heater (18) for heating the plastic material (12) in the reactor vessel (14); and a residual material removal device for at least partially removing residual material (38) which is produced during the gasification and/or cleaning of the starting material (12). According to the invention, the residual material removal device comprises an overflow which is centrally arranged in the reactor vessel (14) so that residual material (38) floating on the metal bath (26) can be removed via the overflow.

Abstract: A method and apparatus for pyrolytic destruction of polymer products including whole vehicle vulcanised rubber tires is disclosed. The apparatus 111 has a reaction chamber 153 into which a tire can be placed, and immersed for pyrolytic decomposition in a molten alloy of zinc with a minor proportion of aluminium. The apparatus 111 has a heated reservoir 155 in which the alloy is maintained in a molten state, and from where it can be transferred to the reaction chamber 153 to immerse the tire. Fluid hydrocarbon byproducts are drawn off for condensation and recovery, and solid zinc sulphides are also recovered. Where steel belted tires are processed, carbon and steel residues are also recovered.

Abstract: An apparatus for thermally decomposing organic feedstock material utilizing a series of connected vessels. Each of the vessels is provided with an inlet and an outlet for transferring the organic feedstock material between the vessels. Separate heat exchangers are located between the inlet and outlet of each vessel. A catalyst material, such as a permeable mesh, is included between the inlet and outlet of each vessel to accelerate liquefaction of gaseous hydrocarbons.

Abstract: A process for converting organic waste into reusable hydrocarbons and a system for doing so, the system including a feeding mechanism for the waste, a reactor and a residue-disposing mechanism. The waste is to be fed into the reactor in which a molten lead bath is confined in an oxygen-free atmosphere. The system is used to practice a process for the pyrocatalytic conversion of the waste, which process comprises, feeding the waste into a reaction zone of a pyrocatalytic reactor, the waste being essentially free of a halogenated synthetic resinous material, and mixing the waste with a minor proportion by weight of a particulate catalyst in the bath held at a temperature in the range from about 450° C. to 550° C. in an elongated vat. The catalyst consists essentially of a major proportion by weight of particulate bauxite <2 mm, in combination with a minor proportion of aluminum powder <0.

Abstract: Apparatus and method for treating waste products containing plastic materials by pyrolysis is disclosed. The method includes pyrolytically decomposing the waste products containing plastic materials by thermolysis to obtain useful liquid and gaseous organic raw materials. The method is carried out continuously.

Abstract: A process for converting organic waste into reusable hydrocarbons and a system for doing so, the system including a feeding mechanism for the waste, a reactor and a residue-disposing mechanism. The waste is to be fed into the reactor in which a molten lead bath is confined in an oxygen-free atmosphere. The system is used to practice a process for the pyrocatalytic conversion of the waste, which process comprises, feeding the waste into a reaction zone of a pyrocatalytic reactor, the waste being essentially free of a halogenated synthetic resinous material, and mixing the waste with a minor proportion by weight of a particulate catalyst in the bath held at a temperature in the range from about 450° C. to 550° C. in an elongated vat. The catalyst consists essentially of a major proportion by weight of particulate bauxite <2 mm, in combination with a minor proportion of aluminum powder <0.

Abstract: A plural zone plant form converting a carbon source to synthesis gas comprising carbon monoxide and hydrogen is disclosed. The carbon source which can consist of coal, automobile tires, or hazardous organic wastes, such as chlorinated biphenyls, polyhaloginated organics, organometallics, organic polymers, and the like is dissolved in a molten bath which can comprise iron in an oxygen deficient zone at one pressure and reacted with water, an oxygen source, or mixtures thereof in at least one other zone at higher temperatures and pressures from that present in the first zone. In one particularly advantageous embodiment, two zones, the first and the second, are at different vertical heights and circulation from one zone to the other occurs as a result of differences in density between the molten bath in the lower zone compared to that in the upper zone.

Abstract: Apparatus for the thermal conversion of solids containing hydrocarbons. In one embodiment for solids which can be converted entirely to vapour, pieces of the solids are continually fed into a molten lead bath in an oxygen free atmosphere in an elongated conversion chamber. An auger partially immersed in the lead bath carries the floating pieces along in the molten lead bath until they are gradually converted to hydrocarbon vapour which rises upwardly to a condenser. In another embodiment for solids which can be converted to a vapour, particulate matter and residual solids, the lead bath extends further into a separation chamber with an inclined retaining skirt extending between the conversion chamber and the separation chamber, The auger forces the particulate matter and residual solids remaining after vaporization down under the inclined skirt, but the hydrocarbon vapour is prevented from escaping into the separation chamber.

Abstract: Apparatus and method for reprocessing crushed organic waste products, such as rubber waste from worn car tires, by pyrolysis, the method including pyrolytically decomposing the crushed waste products in a pyrolysis bath which is one of a bed or a bath, and which has a temperature ranging from 450.degree. to 550.degree. C., into a mixture including volatilized constituents, liquid constituents, and solid constituents; collecting at least a part of the volatilized constituents from a gas space above the pyrolysis bath and transporting the collected volatilized constituents away from the pyrolysis bath for further utilization; and introducing a gas intermittently or continuously into the gas space above the pyrolysis bath.

Abstract: An apparatus for the thermal conversion and recovery of organic waste materials includes an oxygen-free chamber filled with molten lead and a method of use of the apparatus. The chamber is elongate and inclined so that organic material introduced in a lower portion of the chamber migrates through the molten lead to a higher portion of the chamber due to the organic material having a specific gravity less than that of lead. As the organic material migrates through the molten lead, the material is thermally converted to gaseous and vapor hydrocarbons that are captured in a condenser. The gaseous hydrocarbons are utilized to heat the lead in the chamber and the vapor is condensed to liquid hydrocarbons in the condenser. Residual solids flow to a reservoir connected to the chamber. Light carbon black is drawn into a receiver by a vacuum line located near the top of the reservoir and all other residual solids flow over a reservoir wall.

Abstract: A pyrolysis chamber includes a bath of molten salt divided by a horizontally disposed baffle into an upper layer and a lower layer. Connected to one end of the chamber is a furnace including submerged burners for heating the salt and for maintaining it in its molten state. The molten salt flows from the furnace across the upper bath layer and back to the furnace in the lower layer. Hydrocarbon containing material is fed onto the upper bath layer and is pyrolyzed as it moves toward the discharge end of the chamber where the spent material is removed; the hydrocarbon gases being recovered by an exhaust system in the chamber. The molten salt acts as a seal between the atmospheres of the furnace and the pyrolysis chamber and also functions to remove pollutants from the combustion gases of the burners in the furnace.

Abstract: Toxic chemicals such as polychlorinated biphenyls and other organic wastes are destroyed by injecting them, together with oxygen, into a metal or slag bath such as is utilized in a steelmaking facility. The metal bath may be melted initially by induction or an electric arc; the desired temperature greater than 2500.degree. F. may be maintained thereafter by the reaction of the oxygen and the organic waste. Various by-products may be obtained from the gas.

Abstract: A process for the destruction of biological waste products comprises the steps of heating said waste products in a sealed chamber, e.g. at 600.degree. C.-850.degree. C., to volatize volatiles and to pyrolyze non-voltatiles and producing an output stream comprising gas with residual biological matter entrained therein followed by treating said output stream with molten aluminum thereby effecting chemical reduction by reaction with the aluminum and producing innocuous effluent.

Abstract: Toxic chemicals such as polychlorinated biphenyls and other organic wastes are destroyed, optionally together with inorganic wastes, by injecting them, together with oxygen, into a molten bath such as is utilized in a steelmaking facility. The bath may be melted initially by induction, an electric arc or otherwise; the desired temperature greater than 2500.degree. F. may be maintained thereafter by the reaction of the oxygen and the organic waste. Various by-products may be obtained from the gas.

Abstract: Organic materials are separated and retrieved by mixing them with a liquid medium which is solid at room temperature and which is at atmosphere pressure. The material and medium are pumped by an electromagnetic pump while creating turbulence and then the velocity of the medium is decreased while heat is applied. Gases generated during the application of heat are collected. The medium is then cooled and returned to the pool at atmospheric pressure.

Abstract: An extraction vessel is provided with an inlet channel and an outlet channel. The inlet channel is adapted for introduction of carbonaceous material in molten lead into the extraction vessel which is at least partially filled with molten lead. Solvent introduced into the extraction vessel extracts the carbonaceous material floating upwardly in the vessel. From the vessel extracted solids are removed separately through the outlet channel. Solvent and extracted material is removed from the extraction vessel by means of a conduit.

Abstract: Disclosed is a method for recovering oil and gas from carbonaceous materials utilizing two molten baths. In the first molten bath reaction vessel, the carbonaceous material is thermally devolatilized. Part of the first melt from the first reaction vessel containing non-volatile constituents is passed to the second molten bath reaction vesel which contains a different melt at a higher temperature. The two melts are only partially soluble in each other so that they can be easily separated. Oxygen, air or oxides are charged to the second reaction vessel for gasifying residual quantities of carbon by oxidation. The first melt is returned to the first reaction vessel from the second reaction vessel. The melt in the first reaction vessel may comprise lead or zinc and be maintained at a temperature of 500.degree. C., while the melt in the second reaction vessel may comprise raw iron and be maintained at a temperature of 1200.degree. C.

Abstract: A system for the recovery of the vaporizable constituents of a particulate, hydrocarbon-containing composite. A suitable source material is continuously conveyed into the system through an air entry prevention means and submitted to at least one heating by a molten heat transfer material contained in a chamber surrounding the conveyor transporting the particulate composite. The vaporized products released from the particulate composite, when heated, are collected in at least one products recovery means and are condensed and separated into respective gaseous and liquid components. The particulate composite is then conveyed from the molten heat transfer liquid which is also an exit air seal, cooled, and then discarded in a conventional member.