Reforming process and apparatus

• US 5,543,061 A
• Filed: 10/31/1994
• Issued: 08/06/1996
• Est. Priority Date: 09/17/1992
• Status: Expired due to Term

• Current Assignee: AB-Cwt, LLC
• Original Assignee: Paul T. Baskis TDP Trust
• Inventors: Baskis, Paul T.
• Primary Examiner(s): FORTUNA, ANA M
• Application Number:
  US08/332,346
• Time in Patent Office: 645 Days
• Field of Search: 210/774, 210/770, 210/806, 210/180, 210/181, 210/761, 210/769, 201/2.5, 585/240, 48/209, 95/266
• US Class Current: 210/774
• CPC Class Codes: B01J 19/20 in the form of helices, e.g. screw reactors
• CPC Class Codes: B01J 6/008 Pyrolysis reactions of hydrocarbons C10G9/00
• CPC Class Codes: B01J 8/00 Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
• CPC Class Codes: C10B 47/26 with the aid of hot liquids, e.g. molten salts
• CPC Class Codes: C10B 53/00 Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form wet carbonising of peat C10F
• CPC Class Codes: C10G 1/02 by distillation

Abstract

This disclosure relates to a processor comprising means (10,11,12,110,111,112) for mixing a process material with a process liquid (13,113) (such as water) and forming an emulsion or slurry. Means (17,18,21,24,117,120,230,420) is provided for pressuring (16,26,116,126) and heating (61,36,173,227) the slurry, and the slurry is then fed to means (28,128,320,420) for reducing the pressure (27,127) to the slurry or emulsion and for further increasing the temperature (33,227) of the slurry or emulsion. The drop in pressure and increase in temperature causes components of the slurry or emulsion to convert to gases and separate from the remainder of the slurry or emulsion which is removed from the processor in the form of solids (32,132). The gas is fed to one or more condensers (10,63,64,65,177,178) which separate the gas into useful liquids such as various grades of oil.

Claims

1. A process for converting a process material into other useful products, comprising the steps of:

a) mixing the process material with a process liquid to create a flowable slurry,

b) pumping said slurry to a container while preheating said slurry,

c) further reducing the pressure on said slurry in said container while further heating said slurry to separate vapor by-products from solids in said slurry,

d) collecting said vapor by-products, and

e) collecting said separated solids.

2. A process as set forth in claim 1, including the step of increasing said pressure on said separated vapor by-products while cooling said separated vapor by-products to produce separate components.

3. A process for converting a process material into other useful products, comprising the steps of:

a) mixing the process material with a process liquid create flowable slurry;

b) heating said slurry to a first preestablished temperature and applying a first pressure to said slurry;

c) reducing said pressure applied to said slurry from said first pressure to a second pressure while heating said slurry from said first preestablished temperature to a second preestablished temperature and reforming said slurry into a first by-product and at least one-second by-product, said second pressure being less than said first pressure;

e) collecting said first by-product; and

,

f) collecting said second by-product.

4. The process of claim 3 including the step of cooling said second by-product and separating said second by-product into at least one-third by-product and at least one-fourth by-product.

5. A processor for converting a process material into other use products comprising:

a) a mixer means for mixing the process material with a process liquid and for forming a flowable slurry;

b) a system means connected to said mixer means for receiving and (i) heating and increasing the pressure applied to said slurry followed by (ii) reducing said pressure applied to said slurry and further heating and reforming said slurry into a first by-product and at least one-second by-product;

d) a first collection means for receiving said first by-product from said second system means; and

,

e) a second collection means for receiving said second by-product from said second system means.

6. The processor of claim 5 wherein said second collection means includes:

a) a second system means connected to said system means for receiving, cooling and increasing said pressure applied to said second by-product, and for separating said second by-product into at least one-third by-product and at least one-fourth by-product; and

,

b) a third collection means for receiving said fourth by-product from said second system means.

7. The processor of claim 6 wherein said third collection means includes:

a) a third system means connected to said second system means for receiving and separating said third by-product into at least one-fifth by-product and at least one-sixth by-product;

b) a fourth collection means for receiving said fifth by-product from said third system means; and

,

c) a fifth collection means for receiving said sixth by-product from said third system means.

8. A processor for converting a process material into other useful products comprising:

a) blending means adapted for receiving the process material, receiving a process liquid and mixing the process material with said process liquid to form a flowable emulsion, said blending means being a hopper connected to a material input conduit adapted for preheating the process material and a liquid tank connected to a liquid input conduit, a mixer having two input openings, each connected to a one of said material input conduit and said liquid input conduit, and one output opening connected to a first slurry conduit;

b) first system means connected to said blending means adapted for receiving, heating to a first preestablished temperature and applying a first pressure to said emulsion;

c) second system means connected to said first system means for receiving and reducing said pressure applied to said emulsion from said first pressure to a second pressure, for heating said emulsion from said first preestablished temperature to a second preestablished temperature and for reforming said emulsion into a first by-product and at least one-second by-product, said second pressure being less than said first pressure;

f) first collection means for receiving said first by-product from said second system means; and

,

g) second collection means for receiving said second by-product from said second system means, said second collection means including third system means connected to said second system means for receiving and cooling said second by-product and for separating said second by-product into at least one-third by-product and at least one-fourth by-product.

9. A processor for converting a process material into other useful products comprising:

a) blender means adapted for receiving the process material, receiving a process liquid and mixing the process material with said process liquid to form a flowable emulsion or slurry;

b) system means adapted for (i) heating said slurry or emulsion to a first preestablished temperature and applying a first pressure to said slurry or emulsion followed by (ii) reducing said pressure applied to said slurry or emulsion from said first pressure to a second pressure and heating said slurry or emulsion from said first preestablished temperature to a second preestablished temperature so as to reform said slurry or emulsion into a first by-product and at least one-second by-product, said second pressure being less than said first pressure;

c) a first collection means for receiving said first by-product from said system means; and

,

d) a second collection means for receiving said second by-product from said system means.

10. The processor of claim 9 wherein said second collection means includes a condenser connected to said system means adapted for receiving and cooling said second by-product and for separating said second by-product into at least one-third by-product and at least one-fourth by-product.

11. The processor of claim 10 wherein said blender means is a hopper connected to a material input conduit, adapted for preheating the process material and a liquid tank connected to a liquid input conduit, a mixer having two input openings, each connected to a one of said material input conduit and said liquid input conduit, and one output opening connected to a first slurry conduit.

12. A processor for converting a process material into other useful products comprising:

a) a hopper connected to a material input conduit adapted for receiving the process material;

b) a liquid tank connected to a liquid input conduit for receiving a process liquid;

c) a mixer adapted for mixing the process material with said process liquid to form a flowable slurry or emulsion having two input openings, each connected to one of said material input conduit and said liquid input conduit, and one output opening connected to a first slurry conduit, said first slurry conduit being adapted for preheating said slurry or emulsion;

d) a pump adapted means for moving said slurry or emulsion through said first slurry conduit to a reactor,

e) said reactor adapted for (i) receiving, heating to a first preestablished temperature and applying a first pressure to said slurry or emulsion followed by (ii) reducing said pressure applied to said slurry or emulsion to a second pressure, heating said slurry or emulsion from said first preestablished temperature to a second preestablished temperature and reforming said slurry or emulsion into a first by-product and at least one-second by-product, said second pressure being less than said first pressure;

f) a first collection means for receiving said first by-product from said reactor; and

,

g) a condenser connected to said reactor adapted for receiving and cooling said second by-product and for separating said second by-product into at least one-third by-product and at least one-fourth by-product.

13. A processor for converting a process material into other useful products comprising:

a) a hopper connected to a material input conduit adapted for receiving the process material;

b) a liquid tank connected to a liquid input conduit for receiving a process liquid;

c) a mixer adapted for mixing the process material with said process liquid to form a flowable slurry or emulsion having two input openings, each connected to one of said material input conduit and said liquid input conduit, and one output opening connected to a first slurry conduit, said first slurry conduit being adapted for preheating said slurry or emulsion;

d) a pump adapted means for moving said slurry or emulsion through said first slurry conduit to a reactor,

e) said reactor adapted for (i) receiving, heating to a first preestablished temperature and applying a first pressure to said slurry or emulsion followed by (ii) reducing said pressure applied to said slurry or emulsion to a second pressure, heating said slurry or emulsion from said first preestablished temperature to a second preestablished temperature and reforming said slurry or emulsion into a first by-product and at least one-second by-product, said second pressure being less than said first pressure,

f) said reactor being a cylindrical shell and said means for moving said slurry from said input end to said output end being an internal auger having variably spaced blades thereon;

g) a first collection means for receiving said first by-product from said reactor; and

,

h) a condenser connected to said reactor adapted for receiving and cooling said second by-product and for separating said second by-product into at least one-third by-product and at least one-fourth by-product.

14. The processor of claim 13 including a grinder adapted for grinding the process material before the process material is transported to said reactor and a strainer adapted for straining the process material before the process material is transported to said reactor.