NEW AND IMPROVED SYSTEM FOR PROCESSING VARIOUS CHEMICALS AND MATERIALS

• US 20160045841A1
• Filed: 05/15/2014
• Published: 02/18/2016
• Est. Priority Date: 03/15/2013
• Status: Abandoned Application

• Current Assignee: Transtar Group, Ltd.
• Original Assignee: Transtar Group, Ltd.
• Inventors: KAPLAN, Allen, BRADLEY, Randall
• Application Number:
  US14/776,732
• Publication Number:
  US 20160045841A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 3/06 Flash distillation
• CPC Class Codes: B01D 53/48 Sulfur compounds
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 19/24 Stationary reactors without moving elements inside B01J19/08, B01J19/26 take precedence; with stationary particles B01J8/02
• CPC Class Codes: B01J 2/00 Processes or devices for granulating materials , e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
• CPC Class Codes: B01J 2219/00864 Channel sizes in the nanometer range, e.g. nanoreactors
• CPC Class Codes: B01J 2219/00867 Microreactors placed in series, on the same or on different supports
• CPC Class Codes: B01J 2219/00871 Modular assembly
• CPC Class Codes: B01J 6/008 Pyrolysis reactions of hydrocarbons C10G9/00
• CPC Class Codes: B02C 23/00 Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group specially adapted for grain mills B02C11/00; separating or sorting in general B03, B04, B07
• CPC Class Codes: B03C 1/00 Magnetic separation
• CPC Class Codes: B09B 5/00 Operations not covered by a single other subclass or by a single other group in this subclass
• CPC Class Codes: B22F 2009/001 from scrap particles
• CPC Class Codes: B22F 3/10 Sintering only
• CPC Class Codes: B22F 9/00 Making metallic powder or suspensions thereof
• CPC Class Codes: B29B 17/00 Recovery of plastics or other constituents of waste material containing plastics; volume reduction of waste plastics, e.g. by mechanical compacting or melting disposal of solid waste B09B; chemical recovery C08J11/00
• CPC Class Codes: C01B 13/02 Preparation of oxygen by liquefying F25J
• CPC Class Codes: C01B 17/02 Preparation of sulfur; Purification
• CPC Class Codes: C01B 17/027 Recovery of sulfur from material containing elemental sulfur, e.g. luxmasses or sulfur containing ores; Purification of the recovered sulfur
• CPC Class Codes: C01B 17/48 : Sulfur dioxide; Sulfurous acid
• CPC Class Codes: C01B 17/74 : Preparation
• CPC Class Codes: C01B 2203/0205 : containing a reforming step
• CPC Class Codes: C01B 2203/0283 : containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/043 : Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
• CPC Class Codes: C01B 2203/0445 : Selective methanation
• CPC Class Codes: C01B 2203/0475 : the impurity being carbon dioxide
• CPC Class Codes: C01B 3/32 : by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
• CPC Class Codes: C01B 32/05 : Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
• CPC Class Codes: C01B 32/21 : After-treatment
• CPC Class Codes: C01B 32/50 : Carbon dioxide
• CPC Class Codes: C01G 21/02 : Oxides
• CPC Class Codes: C02F 1/00 : Treatment of water, waste water, or sewage C02F3/00 - C02F9/00 take precedence
• CPC Class Codes: C09C 1/482 : Preparation from used rubber products, e.g. tyres recovery of plastics or other constituents of waste material containing plastics B29B17/00
• CPC Class Codes: C09C 1/56 : Treatment of carbon black ; Purification
• CPC Class Codes: C10G 1/00 : Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal mechanical winning of oil from oil-shales, oil-sand, or the like B03B
• CPC Class Codes: C10G 1/02 : by distillation
• CPC Class Codes: C10G 1/10 : from rubber or rubber waste
• CPC Class Codes: C10G 11/18 : according to the "fluidised-bed" technique
• CPC Class Codes: C10G 31/08 : by treating with water
• CPC Class Codes: C10G 33/00 : Dewatering or demulsification of hydrocarbon oils by distillation C10G7/04
• CPC Class Codes: C10G 45/00 : Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
• CPC Class Codes: C10G 57/00 : Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one cracking process or refining process and at least one other conversion process
• CPC Class Codes: C10G 7/00 : Distillation of hydrocarbon oils
• CPC Class Codes: C10G 7/003 : distillation of lubricating oils
• CPC Class Codes: C10G 7/06 : Vacuum distillation
• CPC Class Codes: C10G 75/04 : by addition of antifouling agents
• CPC Class Codes: C10J 2300/093 : Coal
• CPC Class Codes: C10J 2300/0946 : Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
• CPC Class Codes: C10J 3/72 : Other features
• CPC Class Codes: C10L 2290/544 : Extraction for separating fractions, components or impurities during preparation or upgrading of a fuel
• CPC Class Codes: C10L 9/10 : by using additives
• CPC Class Codes: C22B 13/00 : Obtaining lead
• CPC Class Codes: C22B 15/00 : Obtaining copper
• CPC Class Codes: C22B 21/00 : Obtaining aluminium
• CPC Class Codes: C22B 7/00 : Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals briquetting of scrap C22B1/248; preliminary treatment of scrap C22B1/005
• CPC Class Codes: C22B 9/00 : General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
• CPC Class Codes: F27B 17/00 : Furnaces of a kind not covered by any preceding group structural combinations of furnaces F27B19/02
• CPC Class Codes: H01M 10/54 : Reclaiming serviceable parts of waste accumulators
• CPC Class Codes: H01M 8/00 : Fuel cells; Manufacture thereof
• CPC Class Codes: H02K 55/02 : of the synchronous type
• CPC Class Codes: H02K 7/09 : with magnetic bearings
• CPC Class Codes: Y02E 20/16 : Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 20/18 : Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
• CPC Class Codes: Y02P 10/143 : of methane [CH4]
• CPC Class Codes: Y02P 20/129 : Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y02P 30/40 : Ethylene production
• CPC Class Codes: Y02W 10/33 : using wind energy
• CPC Class Codes: Y02W 10/37 : using solar energy
• CPC Class Codes: Y02W 30/84 : Recycling of batteries or fuel cells

Abstract

Eco-friendly systems, methods and processes/processing (EFSMP) or an integrated Matrix encompasses stand-alone and/or interconnected modules for completely self-sustained, closed-loop, emission-free processing of multiple source feedstock that can include pretreatment, with poisoning materials isolated during pretreatment being further recycled to provide useful materials such as, for example, separated metals, carbon and fullerenes for production of nano materials, sulfur, water, sulfuric acid, gas, heat and carbon dioxide for energy production, and production of refined petroleum, at a highly-reduced cost over the best state-of-the-art refining methods/systems that meets new emissions standards as well as optimizes production output with new ultra-speed cycle times. By-products from the petroleum refining process which were previously discarded also now are recycled as renewable sources of energy (water, waste oil and rubber/coal derived pyrolyic (pyrolysis) oil, carbon gases and process gases), or recyclable resources, such as metals and precious metals, oxides, minerals, etc., can be obtained.

Claims

1. A system comprising one or more matrix modules wherein the matrix modules are each configured to function together to achieve processing, separation and recovery, reforming, recycling and manufacturing and producing products, energy and feedstocks the system comprising modules adapted for receiving storage and routing of raw materials;

modules adapted for processing;

modules adapted for separation and recovery;

modules adapted for reforming; and

modules adapted for recycling and manufacturing and producing products, energy and saleable feedstocks.

2. A system according to claim 1, comprising an oil refinery module and one or more recycling and/or manufacturing modules wherein the matrix system is adapted to produce volume refined oil at a cost less than a prior art refinery.

3. The matrix system of claim 1, wherein the one or more modules include:

a power generation module;

metallurgy modules;

a water generation and recycling module;

feedstock vertical integration modules; and

modules adapted for recycling spent oil, batteries, tired, off gases, sulfuric acid or zinc.

4. The matrix system of claim 1, wherein the system comprises a refinery module, at least one recycling module, at least one manufacturing module, at least one processing module and a power generation module.

5. The matrix system of claim 1, wherein at least one module of the matrix system comprises a super reactor system.

6. The matrix system of claim 1, which comprises at least one of a metal recovery process module, a contaminant extraction module, a mercury extraction process module, a clay/acid filtering and regeneration process, a ceramic firing process, a closed loop air and water system, a tank farm sediment collection and bottom tank processing system, a electric power generation module, or a nano plant.

7. The matrix system of claim 1, wherein the system is a closed loop vertically integrated system.

8. The matrix system of claim 1, wherein the system comprises at least one of a processing module, a separation and recovery module, a reforming module, a recycling module, and a manufacturing or production module.

9. The matrix system of claim 1, wherein the system comprises a refinery module and at least one of a receiving and routing module, a tire plant module, a pyrolysis module, a battery plant module, a sulfuric acid plant module, an oil-metal extraction module, an asphalt plant module, a steel foundry module, a least oxide module, a lead smelter module, an aluminum smelter module, a zinc smelter module, a copper smelter module, a sintering module, a precious metals recovery module, a waste water treatment module, a sour water stripper module, or a power generation module, a hydrogen plant module, an oxygen plant module, a nano plant module, a nano processing module or a tank farm module.

10. The matrix system of claim 9, wherein one or more of the modules comprise a super reactor system.

11. The matrix system according to claim 10, wherein the refinery module comprises a super reactor system.

12. A super reactor system adapted for the matrix system according to claim 1, wherein the super reactor system comprises progressive connected thermal conversion chambers which comprise one or more of an autoclave chamber for extraction, a pyrolysis chamber for extraction, a distillation chamber, a cracking and reforming chamber, an atomizing and extraction chamber, a gas and metal vaporization and extraction chamber, a sintering chamber, and a hearth chamber.

13. The super reactor system according to claim 12, wherein materials moving in the super reactor system are moved by a vortex propulsion system moving material from chamber of lower temperatures to the highest temperature chamber.

15. The super reactor system according to claim 12, wherein the super reactor system comprises multiple independent flow streams.

16. The super reactor system according to claim 12, wherein the super reactor system comprises indirect thermal contact flow sections.

17. The super reactor system according to claim 16, wherein indirect thermal contact flow sections in the super reactor system are one or more of infrared heating, microwave heating, convection heating, laser heating, sonic heating or optical heating.

18. The super reactor system according to claim 16, wherein the indirect thermal flow sections of the super reactor system comprise one or more of flash injection, steam, gas and/or fuel combustion or electric arc.

19. The super reactor system according to claim 12, wherein the super reactor system is robotically operated.

20. The super reactor system according to claim 12, wherein the super reactor system is a rotary system having tilt capability.

21. The super reactor system according to claim 12, wherein the super reactor system is bunker enclosed.

22. The super reactor system according to claim 12, wherein the super reactor system is fugitive vapor-proof and is a closed loop system.

23. The matrix system according to claim 1, wherein the system comprises one or more modules adapted for metals extraction.

24. The matrix system according to claim 23, where the metal extraction is from one or more of waste sludge, residues, mattes, slag, ore, spent filters, waste water, gasses, sweepings, coal, spent or waste oil, or soot.

25. The matrix system according to claim 1, wherein one or more modules of the system are adapted for shredding, granulation and/or micronization.

26. The matrix system according to claim 1, wherein the system is adapted for fugitive vapor extraction, capture, containment and reprocessing.

27. The matrix system according to claim 1, wherein the system is adapted for vertically integrated recyclable loped air, water and feedstock self-sufficiency.

28. The matrix system according to claim 1, wherein the system is adapted for water creation.

29. The matrix system according to claim 1, which comprises a process to extract and recover metals and to remove mercury.

30. The matrix system according to claim 1, wherein the system comprises flash atmospheric distillation for condensed lube oil fraction removal and/or extraction of residue bottoms, tars, carbon and soot.

31. The matrix system according to claim 1, wherein the system comprising finishing optionally by hydrotreating, clay acid treating, or alkaline hydroxide for rare metal extraction, extraction of halogen reacted with hydrogen, sulfur, oxygen or nitrogen.

32. The matrix system according to claim 1, wherein the system is adapted for metal extraction from spent reforming catalyst, spent isomerization chemicals and for precious metal recovery.

33. The matrix system according to claim 1, wherein the system is adapted for pretreatment and defouling of crude oil, dewatering of crude oil, fraction vacuum distillation of crude oil, atmospheric distillation of crude oil, hydrotreating of crude oil or fluid catalytic cracking of crude oil.

34. The matrix system according to claim 1, wherein the system is adapted for treatment of waste water for metals removal, phosphate removal, mercury removal, volatile organics removal or oil, sludge and residue removal.

35. The matrix system according to claim 1, wherein the system is adapted for the treatment of coal for metals removal, fly-ash and soot extraction, mercury extraction or syngas production.

36. The matrix system according to claim 1, wherein the system is adapted for the processing of spent tires and battery cases by metal belt removal, tire fiber and cord removal, battery sulfuric acid removal, soot extraction, optionally for fullerene production, fly ash removal or plastics gasification.

37. The matrix system according to claim 1, wherein the system is adapted for secondary metal recovery by precious metal removal and recovery, primary recycled metal, optionally lead and carbon steel removal and recovery, secondary melt metal removal and recovery or slag, sludge, matte, residue, sweeps, dross, process filters and skimming removal and recovery.

38. The matrix system according to claim 1, wherein the system comprises a nano reactor module wherein the nano reactor module comprises retractable robotically operated vaporizing heads located in an emissions free vaporizing chamber, an electro-magnetic field in surrounding vaporizing chamber walls for vapor deposition, a catalyst, water, carbon-gas and process-gas feedstock injection system, a freezing thawing compression separating chamber and an atmospherically controlled chemical vapor disposition mixing and processing chamber.

39. The super reactor system according to claim 12, where the super reactor system comprises a vaporization hearth adapted for metal extraction, gas extraction, carbon production or graphite production.

40. The super reactor system according to claim 12, wherein the super reactor system carries out atomizing including fuming and converting which is adapted for powdered metal production, spent clay-acid and/or sludge purification and including a slag-fuming chamber.

41. The super reactor system according to claim 12, wherein the super reactor system comprises a pyrolysis section adapted for coal liquefaction and gasification, crumb rubber to black oil production, crumb rubber to carbon black production, soot extraction to fullerene processing chamber or gas extraction (syngas to power plant).

42. The super reactor system according to claim 12, wherein the super reactor system comprises a sintering section adapted for mercury and/or sulfur removal.

43. The super reactor system according to claim 12, wherein the super reactor system comprises a pre-heat firing chamber adapted for concentrated heat recovery or flare gas recovery.

44. The nano plant module according to claim 6, wherein the nano plant module comprising a nano reactor comprising multiple reactor chambers adapted for micronizing, devilcanization and blending, a cryogenic micro shear chamber, adapted for single tube production, multi-wall production and/or nano-composites, a surround electro-magnetic field, an atmospheric vacuum controlled chamber and/or a fugitive vapor proof chamber.

45. The nano plant module according to claim 6, comprising multiple heads, multiple axis vaporizers, rotating heads, a DC-plasma arc, and/or laser ablation.

46. The nano plant module according to claim 6, wherein the nano plant module utilizes a continuous beam or pulse wave.

47. The nano plant module according to claim 6, wherein the nano plant module utilizes chemical vapor deposition as an aero spray feed or aerogel catalyst.

48. The nano plant module according to claim 6, wherein the nano plant module comprises a tunneled tornado vortex with adjustable fuel/feed gas.

49. The nano plant module according to claim 6, wherein the nano plant module comprises a V-bowl beam/wave concentrator apparatus.

50. The nano plant module according to claim 6, wherein the nano plant module comprises chambers adapted for mixing and forming and waste water purification chambers.

51. The nano plant module according to claim 50, wherein the purification chambers comprise an atomizer adapted for a waste separation process, a vaporization section adapted for metal extraction, an organic incineration and gas extraction section, and a filtration section adapted for filtration of activated charcoal, nano materials, carbon black and/or clay.

52. A power reactor module according to claim 6, comprising a section adapted for coal liquefaction and gasification and wherein fly ash and/or soot from the power module is forwarded to the nano plant module and wherein carbon black from the power module is forwarded to the water plant module for filtration and to the pyrolysis module for black oil conversion.

53. The power reactor module according to claim 6, wherein the power reactor module comprises a fuel Cell and reactor for combined power distribution.

54. The refining reactor module of claim 6, wherein the refining module comprises a distillation chamber and a reforming chamber adapted for thermal catalytic cracking and deasphalting.

55. The feedstock preparation module according to claim 6, wherein the feedstock preparation module is adapted for the preparation of coal, slag, tires or battery cases comprises one or more of a cryogenic chamber, a hammermill, a screen-separator unit, a ball mull and/or a stirred ball milling unit, a micronizer and a vacuum transport and feed system.

56. The feedstock preparation system according to claim 6, wherein the feedstock preparation module is adapted for treating crude oil and/or waste or spent oil and comprises a desalting unit, a chemical treatment unit for solvent mixing and/or solvent extraction, clay-acid filtration and/or wiped film evaporator unit and filter press residues.

57. The feedstock preparation module according to claim 6, wherein the feedstock preparation module is adapted for nano and/or graphite utilities comprises one or more units adapted for oxidation, acid treatment, annealing, ultrasonication, microfiltration, ferromagnetic separation, cutting, fractionation, mechanical milling, chromatography and/or polymerization.

58. The super reactor module according to 6, further comprising a separate or integrated filtration reactor module wherein the filtration module comprises a top chamber in a vacuum atmosphere of hydrogen and a layered system of chalcogel-based composite filters wherein the pores of the filters have pore diameters and shapes adapted to match a target contaminant

59. The super reactor module according to claim 58, wherein the pore diameters and shape allow for total micelles absorption and containment.

60. The super reactor module according to claim 58, wherein the chalcogel-based filter layers are located such that the filter with the largest pore size is on top and subsequent filers have placed in descending pore size order.

61. The super reactor module according to claim 60, wherein the chalcogel-based filters are separated by a sieved metal plated adapted for easy filter extraction and replacement.

62. The super reactor module according to claim 60, wherein the chalcogel-based filter layers are treated with at least one solvent so as to filtration by gas injection, liquid spray mist and/or prccoated substrate.

63. The matrix system according to claim 1, wherein a filter reaction module comprises a top chamber in a vacuum atmosphere of hydrogen and a layered system of chalcogel-based composite filters wherein the pores of the filters have pore diameters and shapes adapted to match a target contaminant can be utilized as part of or along with any module of the matrix system.

64. The filtration reaction module according to claim 63, wherein the target contaminants to be separated from a stream flowing through the filtration modules comprise one or more of oxygen compounds, nitrogen compounds, halogens and halogen compounds, metals, aromatics, alcohol and/or ether-bases fuel/oil additives, automotive fuels, benzene, toluene, hexane, mercaptans, and hydrocarbons.

65. The filtration reaction module according to claim 63, where the filtration material is injected and/or layered onto reactor packing in the module of the matrix.

66. A module adapted for use in the receiving, storing, dispensing and routing of materials from numerous locations to processing locations.

67. The module of claim 66, further comprising a pre-atomization or size reduction processes and apparatus configured to process larger materials for final product manufacture within matrix cells at processing locations.

68. The module of claim 66, wherein the module can be located at major consuming market locations being typically interconnected through a direct system of land, sea and air access media both nationally and internationally.

69. A tire plant method or system for processing used and wasted tires to produce useful products such as oil or grease, crumb rubbers, and fluff rayon nylon and polyester, the method and system being adapted to be integrated with other processes and methods to further process said useful products wherein the tire plant method or system comprises processes for cleaning used tires, reduction of the used tires, separation of various components of the reduced used tires and providing for processing uniformity of cleaned and reduced materials.

70. (canceled)

71. A nano plant adapted to receive raw or processed materials from other modules of an

integrated module matrix system to further process these raw or processed materials so as to provide useful nano products including single-wall and multi-wall nano tubes.

72. A pyrolysis plant module comprising a kiln, an oil separator, a magnetic separator, a condenser, buffer tanks, a precision filter, gas alkaline scrubbers and a desulphurization scrubber.

73. The pyrolysis plant module of claim 72, comprising a pyrolysis section adapted for coal liquefaction and gasification, crumb rubber to black oil production, crumb rubber to carbon black production, and soot extraction to fullerene processing chamber or gas extraction.

74. A battery plant module comprising a heavy hammer mill for rapid bulk loading and mass high impact breakage, a comprehensive separator system to sort the mix of PVC, fiberglass, Nano, carbon, ceramic, graphite and other similar internal battery construction materials from the lead, lead paste, plastics and rubber and electromagnetic sorting of the metal and non-magnetic aluminum case fragments from the spent fuel cells, wherein the separator system is equipped with a closed looped dust and vapor extraction and filtration system.

75. Sensor automated water jet battery case cutters and subsequent draining in an explosion proof work Cell equipped with a high velocity air filtration system to contain fugitive corrosive, toxic vapor emissions.

76. An asphalt plant module comprising an aggregate cold feed bin, a drying and heating process, a graduated screening including a primary screening process and a secondary screening process, a pug mill mixer, mineral filler, hot binder, and a dust collector.

77. A method and system of sulfur recovery which is adapted to use an end-product of an amine processing plant as the input product in a Claus Processing Plant, aiding in the overall extraction of sulfur from sour petroleum.

78. A sour water plant module adapted to remove hydrogen sulfide and ammonia from the water and reuses the water, hydrogen sulfide and ammonia as front-end products in other systems and processes.

79. A system and method for the regeneration of sulfuric acid and sulfur gas wherein a double absorption line mechanism operates in coordination with a waste heat boiler, catalytic converter and combustion furnace to significantly reduce resulting emissions.

80. A system and method for the production of sulfuric acid through chemical processing means designed to utilize a variety of metal inputs.

81. A novel system and method for the conversion of forms of lead into metallic lead while using outflows from other systems and methods as inflows to the system and method.

82. A novel system and method for the production of zinc, wherein all of the resulting byproducts of said intermediate processes are reused as products in other chemical and biological processes.

83. A novel system and method for treating water comprising a closed-loop, eco-friendly system adapted to recycling end-products from other systems and processes to facilitate the efficient treatment of water to yield ultra-pure water.

84. A hydrogen plant module comprising a hydrotreater, a desulfurizer, a chloride guard bed, a zinc oxide drum, a reformer furnace, a steam drum, a shift converter, a CO₂ stripper, a cold condenser separator, a hot condenser separator, a pressure swing absorber, a methanator, and a knock out drum, to perform water-gas shift technologies, advanced hydrogen separation, development of polishing filters and advanced CO₂ separations.

85. The hydrogen plant module according to claim 84, further comprising a hydro reactor with electron beam to perform desulfurization.

86. The hydrogen plant module according to claim 84, further comprising chalcogel filtration.

87. The hydrogen plant module according to claim 84, further comprising an integrated fuel cell reactor.

88. The hydrogen plant module according to claim 84, further comprising an aerogel piping and insulation system.

89. The hydrogen plant module according to claim 84, further comprising a nautilus reactor packing system.

90. An oxygen plant module for oxygen production, wherein the oxygen plant module being utilized as a standalone unit or can be integrated in an operating system which benefits from the presence of an oxygen plant module, to continuously produce oxygen to enable a self-sustaining, closed looped and emission-free processing of recycling by-products from a petroleum refining process.

92. The oxygen plant module according to claim 90, wherein an oxygen feed is generated to be provided to a SCR/SAR plant module, a sulfuric acid plant module, an FCC units/refinery module, a clause unit, a reforming reactor module, a nano reactor module, a steel mill module, a sintering module, a smelter module, a waste water treatment plant module, a water manufacture plant module, a power plant fuel cell, a pyrolysis reactor, a metals leaching and blast furnace, a slurry fuel plant module, an atomizer plant module, a precious metals plant module, for various applications including water production and oil refinery.

91. An oxygen plant module for oxygen production, wherein the oxygen plant module is included in integrated module matrix eco-friendly system methods and processes (EFSMP).

93. An integrated system for a steel foundry for recycling and producing steel by utilizing multiple temperature and atmosphere control zones.

94. A lead oxide plant module for lead oxide production, wherein the lead oxide plant module is included in integrated module matrix eco-friendly system methods and processes.

95. A lead oxide plant module comprising:

a melting furnace, a Barton pot, a settling chamber, a cyclone, a bag house, and a ball mill, wherein red oxide, grey oxide, and litherage are produced to be sorted and packed.

96. The lead oxide plant module according to claim 95, further comprising a distillation reactor having a vacuum distillation chamber section for cyclonic separation.

97. The lead oxide plant module according to claim 96, further comprising chalcogel filtration.

98. The lead oxide plant module according to claim 96, further comprising an aerogel piping and insulation system.

99. The lead oxide plant module according to claim 96, further comprising an integrated fuel cell reactor.

100. An aluminum plant module for aluminum production, the aluminum plant module utilizing an EFSMP Thermal Conversion Atomization Reactor that performs at least one of atomization, electrowinning, Isothermal Melting Processes (ITM), or decoating metals using indirect-fired controlled atmosphere (IDEX) kilns.

101. The aluminum plant module according to claim 100, wherein the aluminum plant module is utilized as a standalone unit or can be integrated module matrix eco-friendly system methods and processes (EFSMP).

102. A copper plant module for copper production, the copper plant module utilizing at least one of a copper ore hydrometallurgical solvent extraction and electrowinning process or a pyrometallurgical process, or a combination thereof.

103. The copper plant module according to claim 102, wherein the copper plant module is utilized as a standalone unit or can be integrated module matrix eco-friendly system methods and processes (EFSMP).

104. A sintering plant module which can be integrated module matrix eco-friendly system methods and processes (EFSMP) in which waste products are processed to produce advanced matrix composites, rare earth magnets, advanced ceramic parts, etc.

105. The sintering plant module according to claim 104, comprising:

input stream of concentrates of bauxite ore, lead ore, iron ore, zinc ore, copper ore, which are processed by a premix tank for mixing the product prior to sintering, wherein the input stream proceeds to a green body preparation pre/sinter machining, pusher tunnel kiln, designed for processes that require precise control of the heat up rate, connective cooling, grind, surface treatment, polishing, and buffing.

106. A sulfuric acid plant module comprising one or more processes of oleum mixing, flue gas scrubbing, absorption, acid circulation, sulfuric acid storage, drying, sulfur burning, waste heat boiling, hot gas filtering, converting, super heating, sulfur melting, flue gas cooling, and filtration.

107. A precious metals recovery plant module comprising one or more processes of smelting, anode bar casting, fire assaying, cooling, reduction, electrowinning, wet electrostatic precipitation, absorption, caustic neutralization, copper precipitation, pressure cyanidation, wash filtration, carbon absorption, and high pressure autoclaving.

108. A Nano-Graphite &

Fullerene plant module comprising one or more processes of xylene extraction, settling and filtration, reduction, anions solution, oxidation, chalcogel filtration, distillation, xylene evaporation, sulfuric acid treatment, water wash and dry process, thermal reactor expansion, ultra-sonication, ball mining, and high energy ultra-sonication.

109. An atomizer plant module comprising an atomizer reactor and one or more processes of atomizing, gas purification, evaporation, ultrasonic sieving, argon liquefying, wire titanium spooling, and gas jet plasma torching, filtration, compressing, vacuum pumping, and waste heat boiling.

110. A slurry fuel refinery module comprising one or more processes of ultrasonic cavitation, Venturi froth tank separation, crushing, ultrasonic wet milling, scrubbing, wet electrostatic precipitation, robotic plate dipping, extraction, metals extraction, electrowinning, plate stripping, Fischer-Tropsch converting, steel belt filtration, dewatering, colloidal jet aeration, floatation, rare earth magnetic separation, Archimedes screw mixing, and surfactant dispersing.

111. A foreign/offsite collection plant module comprising one or more processes of tire shredding, washing, drying, tire processing, tanker offloading, truck or rail unloading, magnetic separation, steel removing, rasping, waste water recycling, palletizing, power generation, and filtration.

112. A high-field flywheel motor propulsion and energy storage system propelled by a combination of MAGLEV induced levitation, a hypersonic speed mode generated by electromagnetic rail gun or coil gun activation and flux trapping High-temperature Superconducting (HTS) adapted for high-power density, high-energy and efficiency electric power generation.

14. The super reactor system according to claim 112, wherein the super reactor system is adapted to comprise outlets along the wall of the super reactor system to allow egress of a separated stream from the materials moving through the super reactor system.

113. The energy and storage system according to claim 112 comprising guidance coils affixed to inner surfaces of opposing side rails and high-strength composite matrix flywheel construction materials to ensure rotational stability when in rail gun acceleration mode.

114. The energy and storage system according to claim 112 wherein nesting of multiple two rotor variants rotating in opposite directions helps to eliminate the net angular movement of the total operating system thus allowing for the hypersonic speeds.

115. The energy and storage system according to claim 112 further comprising a third rotor assembly and modifying the inner apparatus'"'"'s height, width and thickness dimensions or wherein the 2-inner rotors are rotated in the same direction and the outer rotor in the opposite direction.

116. The energy and storage system according to claim 112 wherein a dual set of composite constructed MAGLEV flywheel motors rotate in unison to provide the kinetic energy to drive horizontally attached electric power generator drum(s) nested between them.

117. The energy and storage system according to claim 112 wherein the rotating flywheel/generator drum apparatus collectively comprises a system'"'"'s shaftless induction levitated rotor assembly.

118. The energy and storage system according to claim 112 wherein the electric power generator mode creates voltage according to Faraday'"'"'s law as the magnetic flux of the rotating permanent magnets (PM) passes the stator coils.

119. The energy and storage system according to claim 112 wherein the stator assembly is comprised of a flux trapping high-temperature superconducting (HTS) levitated YBCO (yttrium-barium-copper oxide or other materials where Y is replaced with other Rare Earth elements such as Nd, Eu, Gd) bearing assembly with an;

armored sealed outer shell housing, an energy absorbing inner liner, an Inductrack II Hallbach array of permanent magnets and the independent MAGLEV stator Guideway rails.

120. The energy and storage system according to claim 112 wherein each of the independent electrically conductive rails has an internal vacuum-vented duct spanning the entire radius of the rail being designed to capture the arcing sparks created by the rail gun sabot and the highly ionized trailing plasma safely channeling them out of the reactor to an ancillary vortex tube reactor feed inlet.

121. The energy and storage system according to claim 112 wherein the inner rail wall includes a grooved Guideway for the winged sabot to complete the circuit and drive the flywheels to a hypersonic speed for maximum power output.

122. The energy and storage system according to claim 112 wherein the guideway channel or “

barrel”

may include intermittent injection ports for injection into the channel gap of a plasma, electrically conductive liquid metal of or other armature/guiderail support friction reduction solid, liquid, gas or supercritical material.

123. The energy and storage system according to claim 112 wherein the injection can be timed to be near the rear of the armature as it travels in the forward rotational direction.

124. The energy and storage system according to claim 112 wherein the flywheel connected drum apparatus is mated to the armored outer shell'"'"'s inner energy absorbing liner being separated only by a uniform but adjustable levitation gap.

125. The energy and storage system according to claim 112 wherein an Inductrack of permanent magnets is affixed to the inner liner over the drum apparatus in a manner to allow centrifugal forced heat to flow between the magnets into the liner which then directs the flow into an internally mounted Cryocooler for recycle thereby forming a looped cooling system.

126. The energy and storage system according to claim 112 wherein the external cryogenic system can further comprise an advanced type of vortex tube with a hypersonic scramjet feed of high pressure air created by a pulse detonation compression apparatus.

127. The energy and storage system according to claim 112 wherein the nested rotor drums are levitated with flux trapping high-temperature superconducting bearings and the flywheels are levitated by MAGLEV Inductrack induction and accelerated to hypersonic speed by rail gun pulsed inductive and resistive primary rail commutation.

128. The energy and storage system according to claim 112 wherein an open-core flywheel architecture enables both high energy flux-field density and flywheel power storage ability to optimize output demand and store power between low and peak hours.

129. The energy and storage system according to claim 112 wherein the system comprises a rotor drum between each set of MAGLEV flywheels to which subsequent independently rotating sets are nested within to form a multilayered space saving high-output variable speed generator.

130. The energy and storage system according to claim 112 wherein to meet the peak power demands of a large grid system a type of railgun accelerator drives the flywheels into a hypersonic speed.

131. The energy and storage system according to claim 112 wherein the entire generator apparatus is housed in an outer armored housing with an inner energy absorbing containment liner sealed to contain a cryogenic vacuum atmosphere (cryostat or envelope) with both an external and internal cryogenic system of cooling.