Process and reactor for microwave cracking of plastic materials

• US 6,184,427 B1
• Filed: 03/19/1999
• Issued: 02/06/2001
• Est. Priority Date: 03/19/1999
• Status: Expired due to Term

• Current Assignee: Highwave Acquisition, LLC
• Original Assignee: Invitri Incorporated
• Inventors: Klepfer, James S., Tairova, Gulshen, Honeycutt, Travis W., Sharivker, Viktor
• Primary Examiner(s): Yildirim, Bekir L.
• Application Number:
  US09/273,245
• Time in Patent Office: 690 Days
• Field of Search: 585/241, 201/2.5, 201/25
• US Class Current: 585/241
• CPC Class Codes: C10G 1/10 from rubber or rubber waste

Abstract

A process of activated cracking of high molecular organic waste material which includes confining the organic waste material in a reactor space as a mixture with a pulverized electrically conducting material (sensitizer) and/or catalysts and/or “upgrading agents” and treating this mixture by microwave or radio frequency electro-magnetic radiation. Organic waste materials include hydrocarbons or their derivatives, polymers or plastic materials and shredded rubber. The shredded rubber can be the source of the sensitizer and/or catalyst material as it is rich in carbon and other metallic species. This sensitizer can also consist of pulverized coke or pyrolytically carbonized organic feedstock and/or highly dispersed metals and/or other inorganic materials with high dielectric loss which absorb microwave or radio frequency energy.

Claims

1. A method of converting polymer hydrocarbon waste to burnable sources of energy comprising admixing said polymer hydrocarbon waste with a sensitizer and subjecting the polymer hydrocarbon waste-sensitizer combination to exposure to microwave energy.

2. The method of claim 1 wherein said microwave energy exposure is of sufficient duration and power to break down said polymer hydrocarbon waste to reduce its molecular weight and convert at least a portion of it to liquid and gas sources of energy.

3. The method of claim 1 wherein said polymer hydrocarbon waste is exposed to microwave energy in a starved oxygen environment.

4. The method of claim 3 wherein said polymer hydrocarbon waste is exposed to microwave energy in an environment having less than approximately 2% by weight oxygen.

5. The method of claim 1 wherein said polymer hydrocarbon waste comprises hydrocarbon sludges, waste plastics and automobile tires.

6. The method of claim 1 wherein said sensitizer comprises a member selected from the group consisting of amorphous carbon, amorphous and highly dispersed metals, transition metal oxides and salts.

7. The method of claim 6 wherein said sensitizers comprise amorphous metals supported by porous substrates.

8. The method of claim 7 wherein said porous substrates comprise a member selected from the group consisting of activated carbon, silica and alumina.

9. The method of claim 1 wherein said sensitizer comprises γ

-Al₂O₃ containing approximately 10 to 70 wt % of Fe₃O₄.

10. The method of claim 1 wherein said sensitizer comprises (x) M₂O:

(y) Al₂O₃;

(z) SiO₂, where x=0.2 to 0.5;

y=1.0;

z>

6; and

M comprises an alkali metal cation.

11. The method of claim 1 wherein said sensitizer comprises an exchange product of a sodium zeolate with La to a content of approximately 1 to 5% by weight which has been calcined and exchanged with Sr to a content of approximately 0.3 weight %.

12. The method of claim 1 wherein said sensitizer comprises calcium oxide with approximately 10% by weight of a group VIB metal oxide and mixtures thereof.

13. The method of claim 1 wherein said sensitizer comprises a mixture of clay with approximately 5% by weight magnesia and approximately 3% by weight sodium silicate treated with an approximately 10% solution of NaOH, dried and calcined.

14. The method of claim 1 wherein said sensitizer comprises gamma-alumina pellets impregnated with nickel.

15. The method of claim 1 wherein said microwave energy is supplied by a member selected from the group consisting of single mode, traveling mode and multimode applicators.

16. The method of claim 1 further comprising the application of radio frequency energy together with said microwave energy.

17. The method of claim 1 further comprising the additions of bitumens when said polymer carbon waste is exposed to microwave energy.

18. A method of converting solid polymer hydrocarbon waste to burnable sources of energy comprising heating said solid polymer hydrocarbon waste, admixing a sensitizer with said heated polymer hydrocarbon waste to substantially uniformly disperse said sensitizer therein, extruding said polymer hydrocarbon waste-sensitizer combination and subjecting said extruded polymer hydrocarbon waste-sensitizer combination to microwave energy of sufficient duration and power to break down said polymer hydrocarbon waste to reduce its molecular weight.

19. The method of claim 18 wherein said polymer hydrocarbon waste is heated to a molten state prior to extruding said polymer hydrocarbon waste-sensitizer combination and exposing it to said microwave energy.