U.S. patent application number 11/043793 was filed with the patent office on 2006-07-27 for method and system for fueling a power/heat generating unit with plastic material.
Invention is credited to David A. Hazlebeck.
Application Number | 20060162242 11/043793 |
Document ID | / |
Family ID | 36695173 |
Filed Date | 2006-07-27 |
United States Patent
Application |
20060162242 |
Kind Code |
A1 |
Hazlebeck; David A. |
July 27, 2006 |
Method and system for fueling a power/heat generating unit with
plastic material
Abstract
A method and system for using plastic material as a fuel
includes dissolving the plastic material in biodiesel to form a
solution. After the solution is created, it is filtered to remove
insoluble contaminants and is then fed to a generator that oxidizes
the solution to create power and/or heat. Heat from the oxidation
of the solution can be utilized to facilitate the further
dissolution of plastic material in biodiesel and to reduce the
viscosity of the resulting solution.
Inventors: |
Hazlebeck; David A.; (El
Cajon, CA) |
Correspondence
Address: |
NEIL K. NYDEGGER;NYDEGGER & ASSOCIATES
348 Olive Street
San Diego
CA
92103
US
|
Family ID: |
36695173 |
Appl. No.: |
11/043793 |
Filed: |
January 26, 2005 |
Current U.S.
Class: |
44/388 |
Current CPC
Class: |
C10L 1/02 20130101; F23G
7/12 20130101; F23G 2201/70 20130101; F23G 2206/10 20130101; C10G
2300/1011 20130101; C10G 1/04 20130101; F23G 5/02 20130101; C10L
1/026 20130101; Y02E 50/13 20130101; Y02P 30/20 20151101; Y02E
50/10 20130101; F23G 2201/60 20130101 |
Class at
Publication: |
044/388 |
International
Class: |
C10L 1/18 20060101
C10L001/18 |
Claims
1. A method of using a plastic material as a fuel comprises the
steps of: providing the plastic material and a biodiesel;
dissolving the plastic material in the biodiesel to form a solution
having a fuel value; and burning the solution in a device to
utilize the fuel value.
2. The method as recited in claim 1 further comprising the step of
filtering out insoluble contaminants from the solution after
dissolving the plastic material in the biodiesel.
3. The method as recited in claim 1 wherein the solution has a
viscosity and further comprising the steps of: heating the solution
to facilitate the dissolving step; and mixing the solution to
facilitate the dissolving step.
4. The method as recited in claim 3 further comprising the step of
using heat created during the burning step to heat the solution to
reduce the viscosity.
5. The method as recited in claim 1 further comprising the step of
heating the biodiesel.
6. The method as recited in claim 1 wherein the plastic material is
waste material.
7. The method as recited in claim 1 wherein the device is selected
from the group consisting of an engine, a turbine, a burner and a
heater.
8. The method as recited in claim 1 wherein the plastic material
comprises a polymer.
9. The method as recited in claim 8 wherein the polymer is selected
from the group consisting of polystyrene, polyethylene and
polypropylene.
10. The method as recited in claim 1 wherein the solution is 20-50
wt. % plastic.
11. A method of reducing a volume of a plastic material comprising
the steps of: providing the plastic material and a biodiesel; and
dissolving the plastic material in the biodiesel to form a solution
for use as a fuel.
12. The method as recited in claim 11 further comprising the steps
of: filtering out insoluble contaminants from the solution after
dissolving the plastic material in the biodiesel; heating the
solution to reduce viscosity; feeding the solution to a device; and
burning the solution in the device.
13. The method as recited in claim 12 wherein the burning step
creates heat and wherein a portion of the heat created from the
burning step is used in the heating step.
14. The method as recited in claim 11 further comprising the step
of increasing the temperature of the biodiesel before the
dissolving step.
15. The method as recited in claim 14 wherein the burning step
creates heat and wherein a portion of the heat created from the
burning step is used in the increasing step.
16. The method as recited in claim 12 further comprising the step
of increasing the temperature of the biodiesel before the
dissolving step wherein the burning step creates heat and wherein
portions of the heat created from the burning step are used in the
heating step and in the increasing step.
17. A system for using a plastic material for fuel, the system
comprising: a dissolution chamber for receiving a biodiesel and the
plastic material, with the biodiesel dissolving the plastic
material to form a solution having a fuel value; and a device for
burning the solution, with the device receiving the solution from
the dissolution chamber, and with the device providing heat to the
dissolution chamber.
18. The system as recited in claim 17 wherein the device is
selected from the group consisting of an engine, a turbine, a
burner and a heater.
19. The system as recited in claim 17 further comprising a means
for heating the solution in the dissolution chamber.
20. The system as recited in claim 17 further comprising a filter
for removing insoluble contaminants from the solution.
Description
FIELD OF THE INVENTION
[0001] The present invention pertains generally to systems and
methods for using plastics. More particularly, the present
invention pertains to the use of plastics in fuel for power/heat
generating units. The present invention is particularly, but not
exclusively, useful in methods or systems that dissolve plastic
material in biodiesel for use as fuel.
BACKGROUND OF THE INVENTION
[0002] The world's annual consumption of plastic materials has
increased from around 5 million tons in the 1950s to nearly 100
million tons today. While recycling efforts have been made to
reduce the amount of plastic waste landfilled, applications or
markets for recycled plastics are often limited. Additionally, the
costs involved in collecting, transporting, and separating plastic
waste often result in recycled plastic products that are more
expensive than new plastic products. This is particularly true for
situations in which special storage and transport of the waste is
required. For instance, shipboard waste or waste at remote forward
military bases may require special disposal procedures.
[0003] As with the concerns for handling waste, the storage and
transport of fuel incurs high costs for many operations, such as on
ships and military bases. Therefore, a reduction in the need for
fuel can significantly reduce costs. One fuel source that can be
used in such operations is biodiesel. Biodiesel, i.e. fatty acid
alkyl esters, is a fuel made from fatty acids and oils from animals
and plants, particularly soybeans. It is fully renewable and can be
used in many diesel engines. Its high cost, however, currently
prevents it from competing with traditional diesel fuel.
Nevertheless, by somehow increasing the output from the oxidation
of biodiesel, it can be made more cost competitive.
[0004] With the above in mind, consideration is given here for
dissolving plastic material in biodiesel before using it as fuel.
As a result, the amount of plastic material that must be
transported for landfilling or other recycling is reduced.
Additionally, the plastic material that is transported (in fuel
form) is far less bulky and far easier to ship. Furthermore, the
heating value of the plastic material can make the biodiesel cost
competitive as a fuel.
[0005] In light of the above, it is an object of the present
invention to provide methods and systems for using plastic material
dissolved in biodiesel as fuel. Another object of the invention is
to provide methods and systems for recycling plastic waste as a
component of a fuel. Another object of the present invention is to
provide methods and systems for increasing the output of biodiesel
as fuel. It is yet another object of the present invention to
provide methods and systems for reducing the volume of plastic
material, particularly plastic waste. Still another object of the
present invention is to provide systems for using plastic material
as a fuel, and methods of using the systems, that are relatively
easy to create, simple to use and comparatively cost effective.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, a system and
method are presented for dissolving plastic material in a fuel for
the purpose of increasing the heating value of the fuel.
Specifically, the system includes a holding tank for storing a
biodiesel fuel, and the holding tank is connected in fluid
communication with a dissolution chamber. Biodiesel can then be
selectively transferred from the holding tank to the dissolution
chamber. Additionally, the dissolution chamber is provided with an
access port for dumping plastics and other plastic-type wastes into
the dissolution chamber. The purpose here is to dissolve the
plastics in the biodiesel to thereby create a supplemented
biodiesel fuel.
[0007] A tube is provided that leads from the dissolution chamber
to a filter where insoluble products are removed from the
supplemented biodiesel. Once the insoluble products are removed,
the supplemented biodiesel can then be transferred via a storage
inlet tube to a storage container. Outlet pipes from the storage
container and the filter are also provided to selectively transfer
the supplemented biodiesel from the storage container, or directly
from the filter, for use by a heat or power-generating device
(generator) such as an engine, turbine, heater or burner.
[0008] Another aspect of the present invention is that the output
heat from the generator can be provided to other systems or devices
as desired. For instance, the heat can be provided back to the
holding tank or the dissolution chamber, or both, to heat the
biodiesel to assist in dissolving the plastics that are introduced
into the dissolution chamber to create the supplemented biodiesel.
Additionally, the heat can be provided back to the dissolution
chamber or storage container, or both, to heat the supplemented
biodiesel. Heating the supplemented biodiesel reduces its viscosity
and allows it to be more easily fed to, and burned by, the
generator.
[0009] In operation, biodiesel is released from the holding tank to
the dissolution chamber. Plastic waste material can then be added
to the dissolution chamber. Additives or heat may also be added to
the dissolution chamber to facilitate dissolution of the plastic
material within the biodiesel. The consequence of this addition is
that as the soluble plastic material dissolves, the biodiesel and
plastic material form a supplemented biodiesel solution. If
insoluble plastic material or other non-plastic materials
(nonsoluble materials) are included within the supplemented
biodiesel solution, the solution and nonsoluble materials form a
slurry which needs to be filtered.
[0010] After dissolution is completed, the slurry is pumped out of
the dissolution chamber through the chamber exit tube. The slurry
then passes through a filter which separates the nonsoluble
materials from the supplemented biodiesel solution. From the
filter, the solution is fed to the generator which burns the
solution as a fuel to create heat and/or power. For immediate use
of the solution as fuel, a generator feed conduit delivers the
solution directly from the filter to the generator. In other cases,
the solution may be piped to containers for storage or transport.
When needed, the solution is fed from the storage containers to the
generator.
[0011] Depending on the composition of the filtered solution, i.e.,
the ratio of plastic to biodiesel, the solution may be too viscous
to be used as a fuel. In such cases, the solution is heated to
reduce its viscosity. Alternatively, solvents or additives may be
utilized to lower the solution viscosity. In order to maximize
efficiency of the system, at least a portion of the heat output of
the generator is directed to the dissolution chamber or storage
containers to reduce the viscosity of the solution. Furthermore,
heat may be provided to the dissolution chamber to facilitate
dissolution of the plastic waste.
[0012] While the invention has been described as using plastic
waste material, it is contemplated that non-waste plastic material
may also be used.
BRIEF DESCRIPTION OF THE DRAWING
[0013] The novel features of this invention, as well as the
invention itself, both as to its structure and its operation, will
be best understood from the accompanying drawing, taken in
conjunction with the accompanying description, in which the FIGURE
is a process flow diagram of a system for using plastic material as
fuel in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to the FIGURE, a system for using plastic material
as fuel in accordance with the present invention is shown and
generally designated 10. As shown, the system 10 includes a holding
tank 12 that stores biodiesel 14. A biodiesel conduit 16 provides
fluid communication between the holding tank 12 and a dissolution
chamber 18. Additionally, an additive hose 20 provides fluid
communication between the dissolution chamber 18 and an additive
reservoir 22 that holds additives 24 such as solvents. Further, the
dissolution chamber 18 includes a port 26 for receiving the plastic
material 28.
[0015] As shown in the FIGURE, a chamber exit tube 30 provides an
outlet to the dissolution chamber 18 and leads to a filter 32. The
filter 32 includes a sieve, grate or other filtering mechanism.
Downstream of the filter 32 is a generator 34, which may be an
engine, turbine, heater or burner. A generator feed conduit 36
provides direct fluid communication between the filter 32 and the
generator 34. Alternatively, a storage container 38 may be
positioned between the filter 32 and generator 34. In such a case,
a storage inlet pipe 40 leads from the filter 32 to the storage
container 38 and a storage outlet pipe 42 leads from the storage
container 38 to the generator 34.
[0016] The output 44 of the generator 34 includes power and/or
process heat 46. Additionally, the output 44 may include recyclable
heat 48. As shown in the FIGURE, the recyclable heat 48 is directed
to system components to provide heat where desired. Specifically, a
tank heating conduit 50 connects the recyclable heat 48 to the
holding tank 12, a chamber heating conduit 52 connects the
recyclable heat 48 to the dissolution chamber 18, and a container
heating conduit 54 connects the recyclable heat 48 to the storage
container 38.
[0017] During operation of the system 10, a desired amount of
biodiesel 14 is fed from the holding tank 12 through the biodiesel
conduit 16 to the dissolution chamber 18. Then, the plastic
material 28 is added to the biodiesel 14 in the dissolution chamber
18. Preferably, the plastic material 28 is polymeric and may
comprise polystyrene, polyethylene, polypropylene or other
thermopolymers.
[0018] Once the plastic material 28 is received within the
dissolution chamber 18, the biodiesel 14 begins to dissolve at
least a portion of the plastic material 28 to form a supplemented
biodiesel solution 56. In certain cases, particularly for
polyethylene and polypropylene, the biodiesel 14 may require
heating to over 120.degree. C. to facilitate dissolution of the
plastic material 28. For polyethylene, the biodiesel 14 should be
heated to about 130.degree. C. to prompt dissolution. For
polypropylene, the biodiesel 14 needs to be heated to about
160.degree. C. to prompt dissolution. Some polymers, however, such
as polystyrene, may be dissolved by biodiesel 14 at ambient
temperature.
[0019] In addition to the biodiesel 14 and plastic material 28,
additives 24 including solvents may also be introduced to the
dissolution chamber 18. The additives 24 may facilitate dissolution
of the plastic material 28 or provide desired characteristics to
the resulting supplemented biodiesel solution 56. If the plastic
material 28 includes any nonsoluble material 58, such as
non-plastic material or insoluble plastics, then a slurry 60 of the
supplemented biodiesel solution 56 and nonsoluble material 58 is
formed in the dissolution chamber 18.
[0020] As shown in the FIGURE, the slurry 60 is fed from the
dissolution chamber 18 to the filter 32 by the chamber exit tube
30. The filter 32 removes the nonsoluble material 58 from the
supplemented biodiesel solution 56. While a static filter 32 is
shown in the FIGURE, it is contemplated that a movable filter can
be used to remove the nonsoluble material 58 from the dissolution
chamber 18 or from the slurry exit tube 30.
[0021] After removal of the non-soluble material 58, the
supplemented biodiesel solution 56 is fed to the generator 34
through the generator feed conduit 36. Alternatively, the
supplemented biodiesel solution 56 is fed to the storage container
38 through the storage inlet pipe 40. In such a case, the storage
container 38 is filled with supplemented biodiesel solution 56 and
is stored and/or transported. When use of the supplemented
biodiesel solution 56 is desired, fluid connection between the
storage container 38 and the generator 34 is established via a
storage outlet pipe 42. After such connection, the supplemented
biodiesel solution 56 may be fed to the generator 34. If the
supplemented biodiesel solution 56 is too viscous for use as fuel,
it may be heated prior to delivery to the generator 34. Typically,
high viscosity is encountered when the plastic material 28
comprises about 20-50 wt. % of the supplemented biodiesel solution
56. Supplemented biodiesel solutions 56 comprising less plastic
material 28, such as a solution 56 comprising 90 wt. % biodiesel
and 10 wt. % polystyrene, may exhibit a lower viscosity and not
require heating.
[0022] The generator 34 burns the supplemented biodiesel solution
56 upon receiving it from the generator feed conduit 36 or the
storage outlet pipe 42. Due to the increased energy value of the
supplemented biodiesel solution 56, as compared to the original
biodiesel 14, the generator 34 creates an increased output 44. The
output 44 comprises process heat and/or power 46 in addition to
recyclable heat 48. As shown, the recyclable heat 48 may be
communicated to other system components. For instance, the
recyclable heat 48 may be communicated to the holding tank 12 via
the tank heating conduit 50 to heat the biodiesel 14. Further, the
recyclable heat 48 may be communicated to the dissolution chamber
18 via the chamber heating conduit 52 to heat the biodiesel 14 or
the supplemented biodiesel solution 56 or slurry 60 formed therein.
Finally, the recyclable heat 48 may be communicated to the storage
container 38 to heat the supplemented biodiesel solution 56.
[0023] While the particular system for using a plastic material as
fuel as herein shown and disclosed in detail is fully capable of
obtaining the objects and providing the advantages herein before
stated, it is to be understood that it is merely illustrative of
the presently preferred embodiments of the invention and that no
limitations are intended to the details of construction or design
herein shown other than as described in the appended claims.
* * * * *