Abstract: A continuous liquefaction and filtration system has a first device configured to melt and filter solid waste plastic material. A second device is in communication with the first device, and configured to melt solid waste plastic material. A feeding system is configured to feed waste plastic material into the first device. A vacuum unit is in communication with the first device and the second device. The vacuum unit configured to control a pressure level within the system. A method of processing solid waste plastic including the steps of providing the system and solid waste plastic; inserting the solid waste plastic into the first device; heating the solid waste plastic material; extracting the molten plastic with one of the extractors; sending a portion of the molten plastic to second device and recirculating another portion in the first device; and extracting the melt polymers.

Abstract: The invention provides a method for breaking down long chained hydrocarbons from plastic-containing waste and organic liquids based on crude oil, comprising providing material containing long-chained hydrocarbons; heating a specific volume of the material containing long-chained hydrocarbons to a cracking temperature, at which cracking temperature the chains of hydrocarbons in the material start cracking into shorter chains; and for the specific volume having a temperature above the cracking temperature, exposing the specific volume to heat which is less than or equal to 50° C. above the temperature of the specific volume. The invention also provides an apparatus for carrying out the invention.

Abstract: A continuous liquefaction and filtration system has a first device configured to melt and filter solid waste plastic material. A second device is in communication with the first device, and configured to melt solid waste plastic material. A feeding system is configured to feed waste plastic material into the first device. A vacuum unit is in communication with the first device and the second device. The vacuum unit configured to control a pressure level within the system. A method of processing solid waste plastic including the steps of providing the system and solid waste plastic; inserting the solid waste plastic into the first device; heating the solid waste plastic material; extracting the molten plastic with one of the extractors; sending a portion of the molten plastic to second device and recirculating another portion in the first device; and extracting the melt polymers.

Abstract: Various biomass reactors systems and methods of pyrolyzing biomass are disclosed. One type of biomass reactor system comprises a plurality of biomass processing stations configured in series, each station comprising an auger reactor including an auger inlet for receiving biomass and a transfer screw for conveying the biomass through the auger reactor.

Abstract: A method of treating untreated low calorific coal containing moisture and organic volatiles includes feeding untreated coal to a dryer, and drying the coal. The dried coal is subjected to a pyrolyzing step where oxygen-deficient gases are brought into contact with the coal, thereby lowering the volatile content of the coal and producing a stream of pyrolysis effluent gases. The pyrolysis effluent gases are subjected to a separation process to separate lean fuel gases from liquids and tars, wherein the separation process removes less than about 20 percent of the pyrolysis effluent gases as the liquids and tars, with the remainder being the lean fuel gases. The lean fuel gases are returned to the dryer combustor, the pyrolyzer combustor, or the pyrolyzer.

Abstract: The present technology is generally directed to horizontal heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown that spans the width of the oven between opposing oven sidewalls. The monolith expands upon heating and contracts upon cooling as a single structure. In further embodiments, the crown comprises a thermally volume-stable material. In various embodiments, the monolith and thermally-volume-stable features can be used in combination or alone. These designs can allow the oven to be turned down below traditionally feasible temperatures while maintaining the structural integrity of the crown.

Abstract: Methods for producing bio-oil from a feedstock (e.g., lignocellulosic) involving (1) pyrolyzing the feedstock in an inert atmosphere in a reactor to produce bio-oil, bio-char and non-condensable gases; (2) recycling about 10 to about 99% of the non-condensable gases to the reactor to produce deoxygenated bio-oil; wherein the method is conducted in the absence of oxygen and wherein the method does not utilize externally added catalysts.

Abstract: Biosolids in the nature of sewage sludge is processed in a controlled environment to produce a dried sludge product of relatively high dry solid content with the elimination of or reduced levels of pathogens. The water containing sewage sludge is dried while cascading within a processing chamber using heated air at a temperature below the ignition or smoldering temperature of the sewage sludge to prevent the formation of embers. The sewage sludge before discharge is retained within the processing chamber for a sufficient time and temperature as mandated by the Environment Protection Agency rules and guidelines.

Abstract: The invention relates to an apparatus and a method for the production of charcoal from wood chips or other particulate organic waste material. The quality of charcoal produced is suitable for use in applications such as chemical reagents, fuels, and as absorbents. The reaction vessel defines a flow path extending from the input to the vessel, through to the output from the vessel, in which the thermal decomposition of the organic material progresses as the organic material passes through the reaction vessel. The vessel includes a reaction zone for autogenous reaction of organic material in a reaction bed of the organic material, and a cooling zone having at least one inlet for supplying cooling gas into the reaction bed and an outlet to extract heated gas from the reaction bed.

Abstract: The invention relates to a method of reducing emissions of byproduct gas when charging oven chambers of a battery of coking ovens, on the proviso that the oven chamber (1) to be charged is opened on the machine side (MS) of the battery of coking ovens, and a block of compressed coal (10) is introduced into the opened oven chamber (1). Byproduct gases released during introduction of the block of compressed coal (10) into the hot oven chamber (1), are discharged through a byproduct-gas manifold (11) attached to the oven chamber (1) and are then preferably freed of dust and incinerated. Crude gases formed in the closed oven chambers during coking are discharged through a crude-gas manifold (3) attached to the oven chambers (1) and are passed on for treatment by at least one gas scrubber.

Abstract: A Low Temperature Conversion apparatus composed of tri-tubes which simultaneously carries out the functions of vessel and heat exchanger is provided. The apparatus is capable of thermally decomposing any kind of organic material to obtain coal, oil, water and non-condensable gases, and also decontaminating soils and residues contaminated with organochlorides and dioxins and comprises: an outer box (2) with a hermetic lid (19); a thermal insulation layer (5) disposed throughout the inner surface of the outer box (2) and lid; and at least a structure with three concentric tubes disposed internally, positioned substantially vertically and with a wall width suitable for heating by means of gases from an inner side and outer side of said structure. An associated process for thermal decomposition using the apparatus is also provided.

Abstract: A system and method of converting tires or other solid carbon based material is disclosed, including providing a chamber, feeding the solid carbon based material into the chamber, rotating the chamber, heating and reducing the material in the chamber, collecting solid residue from the chamber, collecting vapor from the chamber, and converting vapor collected from the chamber to a liquid. In an embodiment, the material includes a whole tire. The tire is heated in the chamber causing the tire to collapse and liquefy, exposing the metal in the tire which aids in grinding the carbon material in the tire as it tumbles, collecting solid residue, for example tire carbons, and collecting vapor, for example vaporized oil, and benzene and methane gas from the chamber and converting the oil. The chamber may be heated to a temperature from about 350° F. to about 1100° F. using gases reclaimed from the material.

Abstract: Biosolids in the nature of sewage sludge is processed in a controlled environment to produce a dried sludge product of relatively high dry solid content with the elimination of or reduced levels of pathogens. The water containing sewage sludge is dried while cascading within a processing chamber using heated air at a temperature below the ignition or smoldering temperature of the sewage sludge to prevent the formation of embers. The sewage sludge before discharge is retained within the processing chamber for a sufficient time and temperature as mandated by the Environment Protection Agency rules and guidelines.

Abstract: A coke oven of a horizontal construction of the non-recovery or heat recovery type is shown. The oven has at least one coking chamber, in which laterally vertical downcomers as well as horizontal bottom flues extend underneath the coking chamber for indirect reheating of the coking chamber. At least a part of the interior walls of the coking chamber is configured as a secondary heating source by coating it with a high-emission coating (HEB) that shows an emission degree equal to or higher than 0.9, and consists of the substances Cr2O3 or Fe2O3 or a mixture containing these substances, with the portion of Fe2O3 amounting to at least 25% by weight in the mixture, and with the portion of Cr2O3 amounting to at least 20% by weight in the mixture.

Abstract: A method of treating biomass feed by pyrolyzing it in the presence of superheated steam at a selected temperature for a sufficient time to produce at least one product stream.

Abstract: Systems and methods for treating carbon-containing waste materials include a gasifying system, a drier system for pre-drying the material, and an energy-recovery system for recovering waste heat and/or producer gas from the gasifying system/method for use in pre-drying the material. The energy-recovery system can include a recirculation system for recovering the waste heat and/or a thermal oxidizer or other combustion device for burning the producer gas, along with a heat-transfer-loop for transferring the recovered heat energy to the drier for pre-drying the material. In another aspect of the invention, the gasifying systems and methods use a thermal-screw conveyor with a product chamber and rotary thermal screws, and an oxygen-delivery system configured for delivering oxygen into the product chamber for immediate absorption into the material, with or without the dryer system and/or the energy-recovery system.

Abstract: A method for torrefaction of water containing cellulosic materials is performed in an inert atmosphere. The cellulosic material is cascaded through the apparatus between a plurality of rotatable trays vertically stacked within multiple processing zones. Steam being generated from heating of the cellulosic material is recycled back to the apparatus to provide an inert atmosphere. The steam may be superheated in a heat exchanger. Exhaust from the torrefaction zone of the apparatus has some moisture and other volatiles removed prior to being reheated in a burner. The heated exhaust is used in the heat exchanger to superheat the recycled steam.

Abstract: The invention pertains to a method for operating a coke furnace arrangement, wherein the coke oven gas accumulated during the coking process is utilized as a working gas. According to the invention, a synthesis gas produced from fossil fuel, preferably coal, by means of a gasification process is supplied as fuel gas in order to provide at least part of the thermal energy required for the coking process.

Abstract: A method of treating biomass material, which can achieve volume reduction or carbonization of biomass material can be achieved at extremely low cost, is disclosed.

Abstract: A process for the pyrolysis of at least one material includes: introducing the material into a pressurized rotary retort system, heating the material in the pressurized rotary retort system within a desired temperature range and within a desired pressure range for a desired period of time; and, advancing the heated and pressurized material from a first end to a second end of the pressurized rotary retort by rotating the pressurized retort about its longitudinal axis; where at least a quantity of the material is converted into one or more end products. Also the system generally includes: a pressurized rotary retort system configured for producing at least one gaseous product from pyrolysis of material, and having a pressurized furnace vessel and a retort positioned within the pressurized furnace vessel; and; a solids reactor system operatively connected to the rotary retort for receiving material from the pressurized rotary retort system.

Abstract: The invention relates to a method for reclaiming biogenic mass, in particular sludge, wherein the product to be reclaimed is first dried and then thermally decomposed in a pyrolysis reactor for the purpose of creating pyrolysis gas. The method according to the invention is characterized in that the product is thermally dried in at least two drier stages arranged after one another, wherein the waste heat of the drier stage downstream of the product in the transport direction is used as process heat for the respectively upstream drier stages. The invention further relates to a system for reclaiming biogenic mass, in particular sludge.

Abstract: A method and apparatus for continuously carbonizing materials while co-producing gases in a coking chamber closed to the atmosphere, having a charger at one end comprising a pushing ram surrounding a mandrel that surrounds an air or oxygen injection lance. The other end of the coking chamber collects and separates coke from gases, with coke directed to a closed quenching chamber and gases directed to a cleanup. Thermal energy for converting coal into coke derives from combusting some metallurgical coal by said lance.

Abstract: A process for treating bituminous coal includes providing dried, pulverized coal, and treating the pulverized coal in a vessel with a gas stream having an oxygen content sufficient to form oxides on surface of coal particles. The treated coal is transferred into a pyrolyzing chamber and passed into contact with an oxygen deficient sweep gas, the sweep gas being at a higher temperature than the temperature of the coal so that heat is supplied to the coal. The process further includes providing additional heat to the coal indirectly by heating the chamber, wherein the heating of coal by the sweep gas and by the indirect heating from the chamber causes condensable volatile components to be released into the sweep gas. Some of the oxides are converted into paramagnetic mineral components, which are removed from coal to form a coal char having reduced ash and sulfur.

Abstract: Described is a thermal decomposition treatment system and method of using the thermal decomposition treatment system wherein flammable waste is inputted into a trash burner which is shielded from air or gas and the waste is thermally decomposed and carbonized. The thermal decomposition treatment chamber includes a plurality of heating tubes wherein the flammable waste is inputted into the chambers while hot air is passed through the heating tubes which indirectly heats the flammable waste in an anaerobic environment the resulting gases are purified, recovered and reused.

Abstract: The invention provides a process for sequestration of carbon dioxide by mineral carbonation comprising the following steps: (a) converting a magnesium or calcium sheet silicate hydroxide into a magnesium or calcium ortho- or chain silicate by bringing the silicate hydroxide in direct or indirect heat-exchange contact with hot synthesis gas to obtain the silicate, silica, water and cooled synthesis gas; (b) contacting the silicate obtained in step (a) with carbon dioxide to convert the silicate into magnesium or calcium carbonate and silica.

Abstract: A method and a device for the hot-repairing of the heating flues of a coke-oven battery according to which the completed sections of a heating flue still under construction are heated by means of a heated gas. The heated gas comprises the air usually provided for combustion in the heating flues during coking operations. The air is guided through the flow paths provided for in the coke-oven battery for combustion air and waste gases as well as through the regenerator, heated as it passes through the flow paths and then guided through the heating flues to be repaired. The completed section of the heating flue is separated from the non-completed portion by an air-reversion device that also directs the heated air.

Abstract: An improved method is disclosed for reclaiming volatile products and non-volatile residue through the pyrolysis of a polymeric material comprising placing the polymeric material in a reactor and establishing an oxygen deficient atmosphere in a reactor. The polymeric material is simultaneously compressed and heated to a temperature sufficient to pyrolyze the polymeric material to produce volatile products and non-volatile residue. The volatile products and non-volatile residue are subsequently removed from the reactor and collected.

Abstract: The invention provides a method and apparatus for decreasing gas flow rates in a sole flue gas system for a coke oven during at least an initial coking operation after charging a coking oven with coal. The method includes providing a duct system between a first coke oven having a first coking chamber and a second coke oven having a second coking chamber to direct at least a portion of gas from a gas space in first coking chamber to the second coke oven thereby reducing a gas flow rate in the first sole flue gas system of the first coke oven. Reduction in sole flue gas flow rates has a beneficial effect on product throughput, the life of the coke oven and environmental control of volatile emissions from coke ovens.

Abstract: A method of forming liquid hydrocarbons from solid coal. The coal is pulverized to provide a particulate coal feed, which is then extruded to provide a hollow tube of compressed coal supported inside of a support tube. A clay feed is extruded to provide a hollow tube of compressed clay supported inside of the coal tube and a combustible fuel is burned inside of the clay tube. The temperature of combustion is sufficient to fire the extruded clay and pyrolyze the extruded coal to produce hydrocarbon gases and coal char. The support tube has holes for releasing the hydrocarbon gases, which contain suspended particles formed during combustion. The suspended particles are removed from the hydrocarbon gases to provide clean gases, which are passed through an ionizing chamber to ionize at least a portion thereof. The ionized gases are then passed through a magnetic field to separate them from each other according to their molecular weight.

Abstract: A residuum oil solvent extraction process is improved by using direct fired convection heaters for heating the asphaltene, the solvent-deasphalted oil phase, the deasphalted oil and the stripping steam, instead of hot oil heat exchangers. The convection heaters are fired using recirculated flue gas so that the hot flue gas supplied to the convection heaters has a temperature between 800.degree. F. and 1400.degree. F.

Abstract: The invention concerns a process for recovering synthetic raw materials and fluid fuel components from used or waste plastics in accordance with patent application P 43 11 034,7. At least a partial flow of the depolymer produced according to this process is subjected, together with coal, to a coking process, fed to a thermal utilization system or introduced as a reducing agent into a blast furnace process. The depolymer can be used as an additive for bitumen and bituminous products.

Abstract: A method and apparatus for producing wood charcoal by pyrolysis of wood products or vegetable biomasses in general, the method including the steps of: loading the wood products, or vegetable biomasses in general, onto transport trolleys; introducing the trolleys, which contain the wood products, in a treatment tunnel wherein a pyrolysis chamber is formed; indirectly heating the wood products inside the pyrolysis chamber until pyrolysis of the wood products is obtained, with continuous extraction, from the pyrolysis chamber, of the gas generated by the pyrolysis process; and extracting the trolleys from the tunnel to unload from the trolleys the charcoal that constitutes the residue of the pyrolysis of the wood products.

Abstract: A thermal decomposition apparatus for plastics wherein plastics are melted and thermally decomposed, and the resulting decomposition gas is cooled for condensation and recovered in the form of a thermal decomposition oil. The apparatus comprises a thermal decomposition reactor for melting and thermally decomposing the plastics therein, an extraneous matter discharge duct having one end opened in a melt of plastics within the reactor, an extraneous matter collecting container connected to the other end of the discharge duct, and an aspirator for aspirating extraneous matter within the reactor together with the melt through the discharge duct into the container.

Abstract: An energy efficient process for beneficiating and dewatering high water content carbonaceous materials utilizing a pneumatic stream to entrain, transport, dewater and to carbonize organic carbonaceous material in a fluidized bed. The process utilizes physical separation for principal removal of moisture and reduces contact between organic carbonaceous matter and hot process water, thereby retaining a high organic content in the product fuel. The organic carbonaceous materials are chemically beneficiated during carbonization in a fluidized bed contactor. Heat exchange and heat recovery procedures provide an economical, energy efficient process.

Abstract: A coke-oven door for use in combination with a coke-oven chamber having an upright doorjamb has a door panel whose periphery is complementary to the doorjamb and which is provided with a seal extending around that periphery between the same and the doorjamb. A plug with a heat-insulating outer wall is carried on this panel within the seal and projects through the doorjamb into the chamber. This plug is formed with a vertically extending and upwardly open passage bounded by a metallic inner wall having gaps by which gases produced during coking adjacent the plug enter the passage on their way to a flue, exchanging heat through the metallic wall with the charge in the oven and thereby aiding the coking operation.

Abstract: Hydrocarbon-bearing substrate particles are pre-heated by heating the same with a solid heat-bearing medium by indirect counter-current flow using a series of heat transfer loops each containing a circulating heat transfer medium chosen such that the whole series permits a staged rise in temperature of the substrate particles and a staged drop in temperature of the solid heat-bearing medium. Preferably the heat transfer fluid in the loops circulates between the substrate and the hot spent substrate by means of the so-called thermosyphon effect.An apparatus for carrying out the method is described.

Abstract: A dry thermal processor for recovering hydrocarbons from oil sand solids comprises concentric, radially spaced, horizontal inner and outer tubular members connected for rotation together. The inner member provides a substantially open preheat zone and vaporization zone while the outer member provides, in the annular space between the tubular members, a substantially open combustion zone and heat transfer zone. The ends of the outer member are sealed by stationary feed end and product end structures. Advance means move the oil sand solids from the feed end structure through the preheat and vaporization zones to the product end structure and back through the combustion and heat transfer zones. Rotation of the inner member causes size reduction of the oil sand feed in the preheat zone, and oversize is discharged directly into the annular space at the second end of the preheat zone.

Abstract: This invention is directed to a process for making coke and recovering the heat therefrom for preheating the firing gas to the coke oven. The process involves the use of the coke oven firing gas to extract the sensible heat from the hot coke from the coking oven to both preheat the firing gas for the coke oven and cool the hot coke. Significant economies are achieved in the two-fold function of coke production and heat recovery in accordance with the method disclosed.

Abstract: An improved method and apparatus for converting a substance containing organic matter into hydrocarbon vapors and solids residue by feeding the substance into the upstream portion of a substantially cylindrical retort having a substantially horizontal longitudinal axis, substantially conveying the substance through the retort toward the downstream portion thereof, heating the retort by means of a fluidized bed of heated particles to a sufficient temperature to convert the substance into hydrocarbon vapors and solids residue and removing the hydrocarbon vapors and solids residue from the retort.

Abstract: A process comprising heating coal in a substantially air-free environment to liberate volatile materials and produce coke, condensing at least some of the volatile materials so liberated to liquefied products and dispersing the coke therein to form a coke slurry, feeding the coke slurry to a slurry pipeline, and pumping the coke slurry through the pipeline to a destination.Apparatus comprising a tube furnace having an external heating means for indirectly heating powdered coal therein in a substantially air-free environment to a temperature adequate to liberate volatile materials and produce coke, means to feed powdered coal to the furnace under pressure and force the volatile materials and coke produced in the furnace through the furnace to a condensing means in which at least some of the volatile materials are condensed with the coke dispersed therein to form a coke slurry, and means to convey the coke slurry from the condensing means to a pipeline for transport to a destination.

Abstract: Green petroleum coke is indirectly dried, then calcined in a cylindric rotary kiln and indirectly cooled utilizing a one-way gas flow in the system. Most of the dust in the vapor from the drying step is directly burned in a steam boiler whose off-gases are used to heat the dryer. Any residual dust in the gas is collected in an electro-filter. This dust together with dust which settles out from the dryer and the kiln is collected and added in controlled amounts to the dried coke before calcining. Hydrocarbons expelled during calcining are partially burned off with a stream of secondary air introduced at the coke exit end of the kiln. Most of the remaining hydrocarbons are burned off before they leave the coke inlet end of the kiln. The calcined coke product contains 0.1% by weight of hydrocarbons. The final off-gas from the process has a residual dust content of less than 100 mg/nm.sup.3.

Abstract: A continuous process recovers values from a solid carbonaceous material by directly contacting a stream containing volatilized hydrocarbons resulting from the pyrolysis of the solid carbonaceous material with incoming feed carbonaceous material to quench the volatilized hydrocarbons, then pyrolyzing the carbonaceous material to yield a product stream containing volatilized hydrocarbons and a particulate residue.

Abstract: Raw tar sand is treated in a fluidized bed reactor means wherein the raw tar sands are fed into an area below the top of the bed. The bitumen is converted in the process in a reducing atmosphere including steam to produce hot coked sand and hot off-gases. Off-gases from the reactor means pass through a heat exchanger means to preheat fresh (raw) tar sand. The cooled off-gases are separated to recover raw oil, while at least a portion of the separated gases are recycled to the reactor means, to retrieve and retain heat in the system by passing upwardly through hot spent sand. Steam and oxygen are injected into the lower area of the fluid bed in an area above the spent sand zone to burn off coked sand so as to produce heat for the cracking zone.

Abstract: Apparatus for treating oil shale by microwave energy for recovering heated volatile fractions thereof. The microwave oven includes a sloping feeder made of glass, pyrex, or ceramic material, which feeder is reciprocated back and forth along a declining plane so as to advance slowly but progressively oil shale deposited on the top end thereof to the discharge end of the vibrator. Means are provided to evacuate volatile fractions and to feed such gases through preheater tubes to a condenser unit. The preheater tubes are disposed in line with and through the flow of incoming materials so as to tend to regulate material descent as well as preheat the shale. An additional solids heat exchanger is employed underneath the discharge end of the vibratory feeder means so as to slow the descent of the spent shale onto its ultimate conveyor as well as taking heat therefrom and from the magnetron tubes of the oven to conduct such heat upwardly to further increase the preheating effect upon incoming shale.

Abstract: A process and apparatus for decomposing kerogen and recovering oil, high BTU gas and energy for the process wherein a crushed oil shale is fed to a rotary preheater (300.degree. to 350.degree. F.) hence into a rotary retort (850.degree.-1050.degree. F.) where the kerogen is decomposed and the oil evaporated, removed and condensed. From the retort the crushed shale goes to a hopper where any residual oil is stripped out by super heated steam leaving a char on the crushed shale. The stripped shale is fed into a furnace wherein the char is burned to provide heat for the process. To supplement the char and provide enough BTU's for the process, it is necessary to add a small amount of coal to the feed to the process. The hot gases from the furnace first pass into contact with the rotary retort and hence indirectly heat the oil shale in the retort. The hot furnace gases (or a portion thereof) then pass into direct contact with the crushd oil shale feed in the preheater.

Abstract: Organic and pseudo-organic materials, such as waste materials, for example, are processed in a converter system and decomposed into various usable and reusable forms. Inorganic metals and salts are treated likewise in the same converter system and processed into various usable and reusable forms. While being carried by a conveyor through a controlled atmosphere treatment chamber, virtually free from combustion supporting air or other oxidizing agents, the feed material is caused to progressively thermally break down into its more basic constituents which flow out of the material treatment chamber in a continuous liquid and gaseous vapor stream. Negative pressure is applied upstream from the material treatment chamber to lead the liquid and gaseous vapor stream through successive processing stages of collection containers, condensers and gas scrubbers. The variable negative pressure is sufficient to maintain the pressure in the material treatment chamber within a range of slightly above ambient pressure.