Biomass and waste plastics to neodiesel and valuable chemicals via supercritical water

• US 8,057,666 B2
• Filed: 06/30/2010
• Issued: 11/15/2011
• Est. Priority Date: 03/11/2008
• Status: Active Grant

• Current Assignee: Xtrudx Technologies, Inc.
• Original Assignee: Xtrudx Technologies, Inc.
• Inventors: Allan, Graham, Loop, Thomas E., Flynn, James D.
• Primary Examiner(s): DRODGE, JOSEPH W
• Application Number:
  US12/828,102
• Publication Number:
  US 20100329938A1
• Time in Patent Office: 503 Days
• Field of Search: 210/175, 210/177, 210180-182, 210/259, 210/511, 210/521, 210/522, 422/138, 422/198, 422/199, 422/208, 422/602, 422/608, 422/618, 422/242, 219/600, 219/618, 219/628, 219/630, 219/635, 446/05, 585/240, 585/241, 585/800, 585/802, 585833-838, 264/12, 264/13
• US Class Current: 210/177
• CPC Class Codes: B01J 19/087 employing electric or magnetic energy
• CPC Class Codes: B01J 2219/0854 employing electromagnets
• CPC Class Codes: B01J 2219/089 Liquid-solid
• CPC Class Codes: B01J 2219/182 horizontal
• CPC Class Codes: B01J 3/008 Processes carried out under supercritical conditions
• CPC Class Codes: B01J 8/0045 by means of a rotary device in the flow channel
• CPC Class Codes: B01J 8/1836 Heating and cooling the reactor B01J8/42 takes precedence
• CPC Class Codes: B01J 8/20 with liquid as a fluidising medium
• CPC Class Codes: B01J 8/42 with fluidised bed subjected to electric current or to radiations this sub-group includes the fluidised bed subjected to electric or magnetic fields
• CPC Class Codes: Y02P 20/54 using solvents, e.g. supercritical solvents or ionic liquids

Abstract

A supercritical fluid polymer depolymerization machine is disclosed herein, which machine is capable of converting a wide range of biomass and/or waste plastic materials into a plurality of reaction products (liquid and gaseous) including fermentable sugars, hydrocarbons, and various aromatic substances that, in turn, are readily convertible into liquid transportation fuel known as “neodiesel.” In one embodiment, a supercritical fluid reaction apparatus for transforming a selected polymeric material flowstream into a plurality of reaction products is disclosed and comprises, in fluidic series: an extruder; a supercritical fluid reaction zone fluidicly connected to the extruder, the supercritical fluid reaction zone being proximate to a circumferentially positioned heater, with the heater being configured to transfer heat to the selected polymeric material flowstream admixed together with water to supercritical conditions to thereby facilitate chemical reaction; and a reaction products separation chamber fluidicly connected to the supercritical fluid reaction zone.

Claims

1. A supercritical fluid reaction apparatus for transforming a selected polymeric material flowstream into a plurality of reaction products, comprising, in fluidic series:

an extruder;

a supercritical fluid reaction zone connected to the extruder and one or more supercritical water flowstreams, the supercritical fluid reaction zone being proximate to a circumferentially positioned heater, with the heater being configured to transfer heat to the selected polymeric material flowstream admixed together with water to supercritical conditions to thereby facilitate chemical reaction so as to yield the plurality of reaction products; and

a reaction products separation chamber connected to the supercritical fluid reaction zone, the reaction products separation chamber containing both an aqueous phase and a non-aqueous phase, and being configured to cool and separate by way of exits portals the plurality of reaction products into two or more reaction product flowstreams, the reaction zone defining a tube extending from the extruder to the chamber, with the water flowstreams connected to the tube separately from the zone and the chamber.

2. The supercritical fluid reaction apparatus of claim 1, further comprising an upstream hopper connected to the extruder, wherein the extruder is configured to continuously convey the selected polymeric material flowstream from the upstream hopper to the supercritical fluid reaction zone while increasing the pressure of the selected polymeric material flowstream admixed together with water from about atmospheric at an upstream hopper to greater than about 22.1 MPa at the supercritical reaction zone.

3. The supercritical fluid reaction apparatus of claim 2 wherein the supercritical fluid reaction zone is contained within a central tube, and wherein the circumferentially positioned heater comprises an electromagnetic induction heating system, the electromagnetic induction heating system including an alternating current power supply electrically connected to an induction coil, with the induction coil being circumferentially positioned about the central tube, and with the induction coil being configured to pass therethrough an alternating electrical current that simultaneously generates a transverse alternating magnetic field, and with the transverse alternating magnetic field being capable of inductively heating the central tube to a selected temperature.

4. The supercritical fluid reaction apparatus of claim 3 wherein the reaction products separation chamber includes therein a plurality of horizontally positioned separation plates.

5. The supercritical fluid reaction apparatus of claim 4 wherein the reaction products separation chamber includes a bottom exit portal for removal of the aqueous phase, and

a top exit portal for removal of the non-aqueous phase.

6. The supercritical fluid reaction apparatus of claim 1 wherein the selected polymeric material flowstream is flowing through the supercritical fluid reaction apparatus, and further comprising a plurality of electrically conductive particles dispersed throughout the selected polymeric material flowstream, with the plurality of electrically conductive particles being capable of being inductively heated.

7. The supercritical fluid reaction apparatus of claim 1 wherein the extruder comprises and elongated conveying zone that contains two or more elongated rotatable shafts having a plurality of flighted screws, and wherein the two or more elongated rotatable shafts are positioned lengthwise within an elongated conveying section housing.