U.S. patent application number 12/616311 was filed with the patent office on 2010-03-18 for microwave processing of carbon-based compositions.
This patent application is currently assigned to GLOBAL RESOURCE CORPORATION. Invention is credited to Carl Everleigh, Julian Forthe, Frank G. Pringle.
Application Number | 20100069688 12/616311 |
Document ID | / |
Family ID | 38138200 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100069688 |
Kind Code |
A1 |
Pringle; Frank G. ; et
al. |
March 18, 2010 |
MICROWAVE PROCESSING OF CARBON-BASED COMPOSITIONS
Abstract
The present invention provides methods for decomposing and
extracting compositions for the recovery of petroleum-based
materials from composites comprising those petroleum-based
materials, comprising subjecting the compositions and/or composites
to microwave radiation, wherein the microwave radiation is in the
range of from about 4 GHz to about 18 GHz. The present invention
also provides for products produced by the methods of the present
invention and for apparatuses used to perform the methods of the
present invention.
Inventors: |
Pringle; Frank G.; (Medford,
NJ) ; Everleigh; Carl; (Raleigh, NC) ; Forthe;
Julian; (Lake Park, GA) |
Correspondence
Address: |
WOODCOCK WASHBURN LLP
CIRA CENTRE, 12TH FLOOR, 2929 ARCH STREET
PHILADELPHIA
PA
19104-2891
US
|
Assignee: |
GLOBAL RESOURCE CORPORATION
Mount Laurel
NJ
|
Family ID: |
38138200 |
Appl. No.: |
12/616311 |
Filed: |
November 11, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11610823 |
Dec 14, 2006 |
7629497 |
|
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12616311 |
|
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60750098 |
Dec 14, 2005 |
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Current U.S.
Class: |
585/1 ;
204/157.43; 204/158.21; 422/186 |
Current CPC
Class: |
B01J 2219/00006
20130101; C10G 1/04 20130101; B01J 2219/1275 20130101; B01J
2219/1239 20130101; A61B 18/1815 20130101; B01J 2219/0879 20130101;
C10G 15/08 20130101; B01J 19/1825 20130101; B01J 19/126 20130101;
B01J 2219/0877 20130101; B01J 2219/0884 20130101; B01J 2219/089
20130101; C10G 1/10 20130101; H05B 6/802 20130101; B01J 19/20
20130101; B01J 2219/0875 20130101; C10G 1/00 20130101; B01J 19/1818
20130101; B01J 2219/0886 20130101 |
Class at
Publication: |
585/1 ;
204/157.43; 422/186; 204/158.21 |
International
Class: |
B01J 19/08 20060101
B01J019/08; C09K 3/00 20060101 C09K003/00 |
Claims
1. A method for obtaining a carbon-based composition from a
composite, the method comprising: subjecting a composite to
microwave radiation for a time sufficient to convert the composite
into a fluid composition and a carbon-based composition, wherein
said microwave radiation comprises at least one frequency component
in the range of from about 4 GHz to about 18 GHz; and separating
the fluid composition from the carbon-based composition.
2. The method of claim 1 wherein said microwave radiation comprises
one or more pre-selected microwave radiation frequencies.
3. The method of claim 1 wherein the microwave frequency component
is in the range of from about 5.8 GHz to about 12 GHz.
4. The method of claim 1 wherein said microwave radiation comprises
a sweeping range of microwave radiation frequencies.
5. The method of claim 4 wherein the range of microwave radiation
frequencies is about +/-2 GHz of the pre-selected microwave
radiation frequency.
6. The method of claim 1 wherein the microwave frequency component
is in the C-Band frequency range.
7. The method of claim 1 wherein the microwave frequency component
is in the X-Band frequency range.
8. The method of claim 1 wherein said composite is exposed to less
than about 12% oxygen.
9. The method of claim 1 wherein said composite is exposed to an
inert gas atmosphere.
10. The method of claim 1 further comprising exposing said
composite to pressures less than atmospheric pressure.
11. The method of claim 1 wherein the fluid composition comprises a
carbon-based material, a hydrocarbon, or both.
12. The method of claim 1 wherein the temperature of the composite
does not exceed about 600.degree. C.
13. The method of claim 1 wherein the composite comprises
petroleum-based material, tire material, shale rock, drilling
cuttings, tar sands, plastics, polymeric materials, recycled
materials, refuse, or any combination thereof.
14. The method of claim 1, wherein the carbon-based composition
comprises carbon black.
15. The method of claim 14 wherein the carbon black material is
characterized as conforming to ASTM Designation N110 grade, N220
grade, N330 grade, N300 grade, N550 grade, or any combination
thereof.
16. The method of claim 14 wherein the mean particle size of the
carbon black is in the range of from about 20 nm to about 25
nm.
17. The method of claim 14 wherein the geometry of the carbon black
is substantially spherical.
18. The method of claim 14 wherein at least 75% of the carbon black
material originally present in the composite is obtained.
19. A microwave system for obtaining carbon-based material from
composite material, the system comprising an infeed airlock
configured to receive composite material, said infeed airlock being
sealable at a pressure less than one atmosphere, wherein said
infeed airlock is configured to feed composite material into a
microwave reactor coupled to said infeed airlock; said microwave
reactor further comprising a microwave antenna orientable towards
said composite material to irradiate said composite material while
being transported through the microwave reactor; said microwave
reactor further comprising a vacuum port to receive
carbon-containing fluid generated from the composite material being
irradiated with microwave radiation characterized as having at
least one frequency component in the range of from about 4 GHz to
about 18 GHz; a microwave radiation generator operatively coupled
to said microwave antenna via a microwave waveguide, wherein said
microwave radiation generator is capable of generating microwave
radiation characterized as having at least one frequency component
in the range of from about 4 GHz to about 18 GHz; a vacuum
generator operatively coupled to said vacuum port, wherein said
vacuum generator is capable of generating vacuum pressure within
said microwave reactor below one atmosphere; a vessel or conduit
operatively coupled to said vacuum port to receive the
carbon-containing fluid; and a discharge airlock operatively
coupled to the microwave reactor to discharge a composition
comprising carbon-based material from the microwave reactor,
wherein said discharge airlock is capable of discharging the
composition comprising carbon-based material from the microwave
system while maintaining pressure within the microwave reactor at
less than one atmosphere.
20. The system of claim 19, wherein the composite material
comprises tire material.
21. A composition made by subjecting a carbon-based material to
microwave radiation for a time sufficient to convert at least a
portion of the carbon-based material into a fluid composition,
wherein said microwave radiation comprises at least one frequency
component in the range of from about 4 GHz to about 18 GHz; and
removing the fluid composition from the carbon-based material.
22. The composition made according to claim 21, wherein the
composition comprises a carbon-based material.
23. The composition made according to claim 21, wherein the fluid
composition comprises a plurality of hydrocarbons.
24. The composition of claim 23, wherein at least a portion of the
plurality of hydrocarbons comprise hydrocarbon chains each
comprising from 14 to about 25 carbon atoms.
25. A method of cracking heavy oil, comprising: subjecting heavy
oil to microwave radiation for a time sufficient to crack at least
a portion of the heavy oil, wherein said microwave radiation
comprises at least one frequency component in the range of from
about 4 GHz to about 18 GHz.
26. The method of claim 25, wherein the heavy oil comprises an
electron activator.
27. The method of claim 25, wherein the microwave radiation heats
the heavy oil to at least about 250.degree. C.
28. The method of claim 25, wherein the microwave radiation heats
the heavy oil up to about 500.degree. C.
29. The method of claim 25, wherein the microwave radiation heats
the heavy oil to at least about 500.degree. C.
30. The method of claim 25, wherein the heavy oil is preheated.
31. The method of claim 25, wherein the heavy oil is preheated
using microwaves.
32. The method of claim 25, wherein the heavy oil comprises heavy
oil bottoms from a distillation plant, residual oil, slurry oil,
refinery waste oil, oil cuttings, oil sands, a geological carbon
deposit, or any combination thereof.
33. The method of claim 25, wherein the heavy oil is subjected to
microwave radiation at a pressure of less than one atmosphere.
34. The method of claim 25, further comprising recovering cracked
heavy oil fluid.
35. The method of claim 34, wherein the cracked heavy oil fluid is
transported at a pressure less than one atmosphere.
36. The method of claim 34, wherein at least a portion of the
cracked heavy oil is vaporized.
37. The method of claim 36, wherein the vaporized cracked heavy oil
is recovered by cooling and condensing the vaporized cracked heavy
oil.
38. The method of claim 25, wherein said microwave radiation
comprises one or more pre-selected microwave radiation
frequencies.
39. The method of claim 25, wherein the microwave radiation
frequency component is in the range of from about 7.9 to about 8.7
GHz.
40. The method of claim 25, wherein said microwave radiation is a
sweeping range of microwave radiation frequencies.
41. The method of claim 40, wherein the sweeping range of microwave
radiation frequencies encompasses one or more pre-selected
microwave radiation frequencies.
42. The method of claim 41, wherein the range of microwave
radiation frequencies is about +/-2 GHz of the pre-selected
microwave radiation frequency.
43. The method of claim 40, wherein the range of microwave
radiation frequencies comprises a bandwidth of about 4 GHz.
44. The method of claim 25, wherein the frequency component is in
the C-Band frequency range.
45. The method of claim 25, wherein the frequency component is in
the X-Band frequency range.
46. The method of claim 25 wherein the range of frequencies of said
radiation is in the range of from about 7.9 GHz to about 8.7
GHz.
47. The method of claim 25, wherein said heavy oil is exposed to
less than about 12% oxygen.
48. The method of claim 25, further comprising recovering a
carbon-based material at a pressure less than one atmosphere.
49. The method of claim 25, wherein said heavy oil is exposed to an
inert gas atmosphere.
50. A method of removing hydrocarbons from oil cuttings,
comprising: subjecting oil cuttings comprising hydrocarbons to
microwave radiation for a time sufficient to remove at least a
portion of the hydrocarbons, wherein said microwave radiation
comprises at least one frequency component in the range of from
about 4 GHz to about 18 GHz.
51. The method of claim 50, wherein the microwave radiation heats
the oil cuttings to at least about 250.degree. C.
52. The method of claim 50, wherein the microwave radiation heats
the oil cuttings up to about 500.degree. C.
53. The method of claim 50, wherein the microwave radiation heats
the oil cuttings to at least about 500.degree. C.
54. The method of claim 50, wherein the oil cuttings are
preheated.
55. The method of claim 50, wherein the oil cuttings are preheated
using microwaves.
56. The method of claim 50, wherein the oil cuttings are subjected
to microwave radiation at a pressure of less than one
atmosphere.
57. The method of claim 50, wherein the hydrocarbons are removed
from the oil cuttings at a pressure less than one atmosphere.
58. The method of claim 57, wherein at least a portion of the
hydrocarbons are vaporized.
59. The method of claim 58, wherein the vaporized hydrocarbons are
recovered by cooling and condensing the vaporized hydrocarbons.
60. The method of claim 50, wherein said microwave radiation
comprises one or more pre-selected microwave radiation
frequencies.
61. The method of claim 50, wherein the microwave frequency
component in the range of from about 7.9 and about 8.7 GHz.
62. The method of claim 50, wherein said microwave radiation is a
sweeping range of microwave radiation frequencies.
63. The method of claim 62, wherein the sweeping range of microwave
radiation frequencies encompasses one or more pre-selected
microwave radiation frequencies.
64. The method of claim 63, wherein the range of microwave
radiation frequencies is about +/-2 GHz of the pre-selected
microwave radiation frequency.
65. The method of claim 62, wherein the range of microwave
radiation frequencies comprises a bandwidth of about 4 GHz.
66. The method of claim 62, wherein the microwave frequency
component is in the C-Band frequency range.
67. The method of claim 62, wherein the microwave frequency
component is in the X-Band frequency range.
68. The method of claim 50, wherein said composite is exposed to
less than about 12% oxygen.
69. The method of claim 50, further comprising recovering the
hydrocarbons at a pressure less than one atmosphere.
70. The method of claim 50, wherein the oil cuttings are exposed to
an inert gas atmosphere.
71. The method of claim 50, wherein the oil cuttings comprise less
than 1% by weight hydrocarbon content after subjecting the oil
cuttings to the microwave radiation.
72. The composition of claim 21, wherein the carbon-containing
material further comprises water.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a 35 U.S.C. .sctn.120 continuation of
U.S. patent application Ser. No. 11/610,823, filed Dec. 14, 2006,
now allowed, and it also claims the benefit of U.S. Provisional
Patent Application No. 60/750,098, "Method for Using Microwave
Radiation", filed Dec. 14, 2005, the entirety of each application
is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and apparatuses for
using microwave radiation and more particularly, to methods and
apparatuses for decomposing compositions comprising petroleum-based
materials.
BACKGROUND OF THE INVENTION
[0003] Petroleum-based materials are integral to the world's
economy and demand for such fuels and consumer products is
increasing. As the demand rises, there is a need to efficiently and
economically extract petroleum-based materials to fulfill that
demand. As such, it would be advantageous to not only be able to
extract petroleum-based materials from the earth, but to also
recycle consumer products to recapture those petroleum-based
materials.
[0004] Worldwide oil consumption is estimated at seventy-three
million barrels per day and growing. Thus, there is a need for
sufficient oil supplies. Tar sands, oil sands, oil shales, oil
cuttings, and slurry oil contain large quantities of oil, however,
extraction of oil from these materials is costly and time-consuming
and generally does not yield sufficient quantities of usable
oil.
[0005] Soil contaminated with petroleum products is an
environmental hazard, yet decontamination of petroleum-tainted soil
is time-consuming and expensive.
[0006] Furthermore, it has been estimated that 280 million gallons
of oil-based products such as plastics go into landfills each day
in the United States. It would be desirable to recapture and
recycle the raw materials of these products.
[0007] Scrap vehicle tires are a significant problem worldwide and
their disposal presents significant environmental and safety
hazards, including fires, overflowing landfills, and atmospheric
pollution. While there are a number of existing applications for
these tires, including tire-derived fuels, road construction, and
rubber products, these applications are insufficient to dispose of
all the available scrap tires. The major components of tires are
steel, carbon black, and hydrocarbon gases and oils, which are
commercially desirable. As such, it is advantageous to develop
processes for the recovery of these products from scrap vehicles
tires. Prior art methods of decomposing scrap vehicle tires do not
produce commercial-grade carbon black and require high temperatures
and extended exposure times for recovery of the hydrocarbon
components.
[0008] Efforts to recycle tires using microwave technology has been
described in U.S. Pat. Nos. 5,507,927 and 5,877,395 to Emery.
Efforts to recover petroleum from petroleum-impregnated media has
been described in U.S. Pat. Nos. 4,817,711 and 4,912,971 to
Jeambey. Efforts to decompose plastics using microwave radiation
has been described in U.S. Pat. No. 5,084,140 to Holland. The prior
work has involved the use of single-frequency microwave radiation.
Single-frequency microwave radiation is a slow process that does
not provide uniform heating. Moreover, single-frequency microwave
radiation typically results in arcing on metal components.
[0009] Thus, there is a need for methods and apparatuses for the
recycling of petroleum-based compositions and for the recovery of
petroleum-based materials from composites containing
petroleum-based materials. The invention is directed to these and
other important needs.
SUMMARY OF THE INVENTION
[0010] The present invention provides methods for decomposing
compositions comprising carbon-based materials comprising
subjecting the compositions to microwave radiation for a time
sufficient to at least partially decompose the composition, wherein
the microwave radiation comprises at least one frequency component
in the range of from about 4 GHz to about 18 GHz.
[0011] The present invention provides methods for decomposing
compositions comprising petroleum-based materials comprising
subjecting the compositions to microwave radiation for a time
sufficient to at least partially decompose the composition, wherein
the microwave radiation comprises at least one frequency component
in the range of from about 4 GHz to about 18 GHz.
[0012] The present invention further provides methods for recovery
of petroleum-based materials from composites comprising those
petroleum-based materials. The methods of the present invention
include subjecting the composite to microwave radiation for a time
sufficient to extract the petroleum-based material, wherein the
microwave radiation comprises at least one frequency component in
the range of from about 4 GHz to about 18 GHz.
[0013] The present invention also provides for products produced by
the methods of the present invention.
[0014] The present invention additionally provides apparatuses for
decomposing compositions comprising petroleum-based materials. The
apparatuses of the present invention comprise a microwave radiation
generator, wherein the generator is capable of applying microwave
radiation characterized as having at least one frequency component
in the range of from 4 GHz to about 18 GHz, and at least one
container to collect decomposed components from the compositions.
The present invention further provides apparatuses for extracting
petroleum-based materials from composites comprising the
petroleum-based material. These apparatuses comprise a microwave
radiation generator, wherein the generator is capable of applying
microwave radiation characterized as having at least one frequency
component in the range of from 4 GHz to about 18 GHz, and at least
one container to collect decomposed components from the
composite.
[0015] The general description and the following detailed
description are exemplary and explanatory only and are not
restrictive of the invention, as defined in the appended claims.
Other aspects of the present invention will be apparent to those
skilled in the art in view of the detailed description of the
invention as provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The summary, as well as the following detailed description,
is further understood when read in conjunction with the appended
drawings. For the purpose of illustrating the invention, there are
shown in the drawings exemplary embodiments of the invention;
however, the invention is not limited to the specific methods,
compositions, and devices disclosed. In addition, the drawings are
not necessarily drawn to scale. In the drawings:
[0017] FIGS. 1A-1G illustrate an embodiment of the present
invention directed to processing tire cuttings using microwaves to
recover fuel oil;
[0018] FIG. 2A is an elevation view, axial direction, of a
microwave reactor suitable for processing oil cuttings according to
an aspect of the present invention;
[0019] FIG. 2B illustrates an elevation view of the microwave
reactor of FIG. 2A, longitudinal direction;
[0020] FIG. 2C illustrates an elevation view of the microwave
device and control room suitable for generating microwaves and
propagating the same through waveguides;
[0021] FIGS. 3A-3B illustrate several embodiments of the present
invention for extracting petroleum-based materials from oil
slurry;
[0022] FIG. 4A illustrates an elevation view of a microwave reactor
system suitable for processing shale rock, tar sands, drill
cuttings, and the like;
[0023] FIG. 4B provides a plan view of FIG. 4A;
[0024] FIG. 4C is an elevation view of the microwave reactor system
along the axis 406, the near end being the exit discharge screw
feed system section 416;
[0025] FIG. 4D illustrates a suitable microwave device control
room, waveguides, and vacuum pumps suitable for use with the system
illustrated in FIG. 4A;
[0026] FIG. 4E illustrates an optional hopper elevator for
transporting material into the inlet feed section 402;
[0027] FIGS. 4F and 4G illustrate three horizontal microwave
reactor systems operating in parallel;
[0028] FIG. 4H illustrates additional microwave generators,
waveguides and vacuum pumps for operating the three horizontal
microwave reactors illustrated in FIGS. 4F and 4G;
[0029] FIG. 5A is an illustration of one embodiment of the present
invention for extracting petroleum-based materials from heavy oil
contained in oil wells;
[0030] FIG. 5B is an illustration of one embodiment of the present
invention for extracting petroleum-based materials from oil shale,
in situ;
[0031] FIG. 5C illustrates the separation of crude oil using a
fractionating tower into its component products;
[0032] FIG. 6 is an illustration of one embodiment of the present
invention for extracting petroleum-based materials from tar sands,
oil sands and shale rock;
[0033] FIG. 7 is an schematic of one embodiment of the present
invention for decomposing vehicle tires;
[0034] FIG. 8A is a plan view of an oil platform incorporating a
drill cuttings microwave processing unit;
[0035] FIG. 8B illustrates an elevation view of the oil platform in
FIG. 8A;
[0036] FIG. 8C illustrates a vertical and horizontal configurations
of the drill cuttings microwave processing unit suitable for use in
the oil platform illustrated in FIG. 8A;
[0037] FIG. 9A is a depiction of an electron microscope photograph
of carbon black produced by the method of the present
invention;
[0038] FIG. 9B is a depiction of an electron microscope photograph
of carbon black produced by the method of the present
invention;
[0039] FIG. 9C is a depiction of an electron microscope photograph
of carbon black produced by the method of the present invention;
and
[0040] FIGS. 10A-10E illustrate an additional embodiment of a drum
reactor system for processing materials containing
hydrocarbons.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0041] The present invention may be understood more readily by
reference to the following detailed description taken in connection
with the accompanying figures and examples, which form a part of
this disclosure. It is to be understood that this invention is not
limited to the specific devices, methods, applications, conditions
or parameters described and/or shown herein, and that the
terminology used herein is for the purpose of describing particular
embodiments by way of example only and is not intended to be
limiting of the claimed invention. Also, as used in the
specification including the appended claims, the singular forms
"a," "an," and "the" include the plural, and reference to a
particular numerical value includes at least that particular value,
unless the context clearly dictates otherwise. The term
"plurality", as used herein, means more than one. When a range of
values is expressed, another embodiment includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another embodiment. All ranges are inclusive and
combinable.
[0042] It is to be appreciated that certain features of the
invention which are, for clarity, described herein in the context
of separate embodiments, may also be provided in combination in a
single embodiment. Conversely, various features of the invention
that are, for brevity, described in the context of a single
embodiment, may also be provided separately or in any
subcombination. Further, reference to values stated in ranges
include each and every value within that range.
[0043] "Sweeping," as the term is used herein, is defined as the
application of a plurality of radiation frequencies over a period
of time.
[0044] "Pulsing," as used herein, means subjecting the composition
to microwave radiation for a period of time, followed by periods of
time wherein the composition is not subjected to microwave
radiation.
[0045] "Oil," as used herein, means any hydrocarbon or
petroleum-based oil.
[0046] "Gas," as used herein, includes any hydrocarbon-based
material that is in the gaseous state at atmospheric temperature
and pressure and includes, but is not limited to, methane, ethane,
propane, butane, isobutene, or mixtures thereof.
[0047] "Carbon black," as used herein, includes any grade of
commercially-acceptable carbon black, including, but not limited
to, rubber black.
[0048] "Oil sands," also known as "tar sands," are deposits of
bitumen, a heavy black viscous oil.
[0049] "Oil shale" is sedimentary rock containing a high proportion
of Kerogen, which, when heated, can be converted into oil.
[0050] "Slurry oil" is refinery waste oil.
[0051] "Oil cuttings" are the waste product generated during the
drilling of oil wells. Examples of oil cuttings include, but are
not limited to, bits and pieces of oil-soaked soil and rock.
[0052] "Hydrocarbons" are compositions that comprise carbon and
hydrogen.
[0053] "Carbon-based" refers to matter that comprises carbon.
[0054] "Decompose" and "decomposing" refers to a process whereby
matter is broken down to smaller constituents. For example, solids
can be broken down into particles, liquids, vapors, gases, or any
combination thereof; rubbery materials can be broken down into
liquids, vapors, gases, or any combination thereof; viscous liquids
can be broken down to lower viscosity liquids, vapors, gases, or
any combination thereof; liquids can be broken down to vapors,
gases, or any combination thereof; composite materials comprising
inorganic solids and trapped organic matter can be broken down to
inorganic solids and released organic vapors and gases, and the
like.
1 Torr=1 mm Hg=1 millimeter mercury.
[0055] Methods for decomposing compositions comprising
petroleum-based materials are set forth herein. The compositions
used in the present invention contemplate any composition comprised
of petroleum-based, carbon-based and various hydrocarbon materials.
The petroleum-based materials may be present in the composition in
amounts ranging from about 1% to 100%, by weight, based on the
weight of the composition. Preferably, the composition is a vehicle
tire. In other embodiments, the composition comprises plastic,
which includes, but is not limited to ethylene (co)polymer,
propylene (co)polymer, styrene (co)polymer, butadiene (co)polymer,
polyvinyl chloride, polyvinyl acetate, polycarbonate, polyethylene
terephthalate, (meth)acrylic (co)polymer, or a mixture thereof. A
variety of natural and synthetic resins and rubbers can also be
decomposed according to the methods described herein. Various
carbon-based materials that can also be processed according to the
inventions described herein include coal, such as anthracite coal
and bituminous coal.
[0056] In one embodiment, the composition is subjected to microwave
radiation for a time sufficient to at least partially decompose the
composition. The microwave radiation can be in the range of from
about 4.0 and about 12.0 GHz. Other ranges can also be used, for
example, in the range of from about 4 GHz to about 18 GHz, and more
preferably in the range of from about 12 GHz to about 18 GHz. For
example, coal can be processed at frequencies in the range of from
about 4 GHz to about 18 GHz, and more preferably in the range of
from about 12 GHz to about 18 GHz.
[0057] In one embodiment, the composition is subjected to one or
more pre-selected microwave radiation frequencies. Preferably, the
pre-selected microwave radiation frequency will be the resonating
microwave frequency, i.e, the microwave radiation frequency at
which the composition absorbs a maximum amount of microwave
radiation. It has been determined that different compositions of
the present invention will absorb more or less microwave radiation,
depending on the frequency of the microwave radiation applied. It
has also been determined that the frequency at which maximum
microwave radiation is absorbed differs by composition. By using
methods known in the art, a composition of the present invention
can be subjected to different frequencies of microwave radiation
and the relative amounts of microwave radiation absorbed can be
determined. Preferably, the microwave radiation selected is the
frequency that comparatively results in the greatest amount of
microwave radiation absorption. In one embodiment, microwave
radiation frequency resulting in a comparative maximum absorption
of microwave radiation by the compositions of the present invention
is in the range of from about 4.0 and about 12.0 GHz. In others,
particularly with respect to vehicle tires, the microwave radiation
frequency resulting in a comparative maximum absorption of
microwave radiation by the compositions of the present invention is
in the range of from about 4.0 and about 7.2 GHz. In yet others,
the microwave radiation frequency resulting in a comparative
maximum absorption of microwave radiation by the compositions of
the present invention is in the range of from about 4.0 and about
6.0 GHz.
[0058] The present invention also provides methods for subjecting a
composition to a sweeping range of microwave radiation frequencies
for a time sufficient to at least partially decompose the
composition. Preferably, variable frequency microwave ("VFM") is
used to sweep the compositions. VFM is described in U.S. Pat. No.
5,321,222 to Bible, et al. and U.S. Pat. No. 5,521,360 to Johnson,
et al., incorporated herein by reference in their entireties.
Unlike single frequency microwave radiation, VFM produces a
bandwidth of microwave radiation frequencies that are applied
sequentially to the composition. Consequentially, the field
distribution with VFM is substantially more uniform than the field
distribution of single microwave frequency radiation. The more
uniform field distribution of VFM produces fewer hot spots,
resulting in more uniform heating of the composition. Moreover,
generally, no single frequency is applied for longer than about 25
.mu.s. The short duration of each applied frequency produces no
build-up of charge, thus eliminating discharge, or arcing,
typically observed during single frequency microwave
irradiation.
[0059] In some embodiments, particularly with respect to vehicle
tires, the range of microwave radiation frequencies swept is in the
range of from about 4.0 GHz to about 12.0 GHz. In certain
embodiments, the range of microwave radiation frequencies swept is
in the range of from about 5.8 GHz to about 7.0 GHz. In still
others, the range of microwave radiation frequencies swept is in
the range of from about 7.9 GHz and 8.7 GHz. In some embodiments,
range of microwave radiation frequencies is in the C-Band frequency
range, the C-Band frequency range encompassing microwave
frequencies in the range of from about 4.0 GHz to about 8.0 GHz. In
other embodiments, the range of microwave radiation frequencies is
in the X-Band frequency range, the X-band frequency range
encompassing microwave frequencies in the range of from about 8.0
GHz to about 12.0 GHz.
[0060] Preferably, the sweeping of the range of microwave radiation
frequencies encompasses a pre-selected, resonating microwave
radiation frequency characterized as having at least one frequency
component in the range of from about 4.0 GHz to about 12.0 GHz.
This frequency can be selected by using the methods described
herein and techniques known in the art. Preferably, the bandwidth
of the sweeping range of microwave radiation is about 4.0 GHz. More
preferably, the range of microwave frequencies with which the
composition is swept, is about +/-2 GHz of the pre-selected
microwave radiation frequency. For example, if the pre-selected
microwave radiation frequency is 7.2 GHz, the composition would be
swept with the range of microwave radiation frequencies
encompassing from about 5.2 to about 9.2 GHz. The microwave
frequencies can also be swept at about +/-1.5 GHz, or even +/-1.0
GHz, or even +/-0.5 GHz of the preselected microwave frequency.
[0061] Upon decomposition of the compositions subjected to the
methods and apparatuses of the invention, flammable
hydrocarbon-based gases are released. To reduce the risk of
ignition, it is preferred that the method be performed in an
oxygen-deprived atmosphere. Preferably, the composition is exposed
to less than about 12% oxygen. More preferably, the composition is
exposed to less than about 8% oxygen. Even more preferably, the
composition is exposed to less than about 5% oxygen.
[0062] In one embodiment, the composition is exposed an inert gas
atmosphere. Preferably, the inert gas is nitrogen, argon, or
mixtures thereof.
[0063] In some embodiments, the composition is exposed to less than
atmospheric pressure. Preferably, the composition is exposed to
less than about 40 Torr. More preferably, the composition is
exposed to less than about 20 Torr. Even more preferably, the
composition is exposed to less than about 5 Torr. Without being
bound by any particular theory or operation, it is believed that
operating at sub-atmospheric pressures helps to recover
hydrocarbon-based gases and prevents over-heating.
[0064] In one embodiment, the composition of the present invention
forms a vehicle tire. Using the methods of the present invention,
the tire can be decomposed to produce at least one of oil, gas,
steel, sulfur, and carbon black.
[0065] Over-exposure to microwave radiation and over-heating of the
composition of the present invention may result in the recovery of
non-commercially-acceptable carbon black. Controlling the
temperature of the composition during microwave irradiation
prevents such over-exposure and over-heating to produce
commercially-acceptable carbon black. Preferably, the temperature
of the composition does not exceed about 700.degree. F. More
preferably, the temperature of the composition does not exceed
about 500.degree. F. Even more preferably, the temperature of the
composition does not exceed about 465.degree. F.
[0066] In one embodiment, the temperature of the composition can be
controlled while performing the method of the present invention by
pulsing the microwave radiation subjection. For example, microwave
radiation can be applied until the composition temperature reaches
about 465.degree. F., at which time, the application of microwave
radiation can be stopped for a time sufficient for the composition
to cool between about 5 to 25 degrees. Once the composition has
cooled, the application of microwave radiation can be resumed. This
process can be repeated, as necessary, until the composition is
sufficiently decomposed.
[0067] Decomposition products obtained from the compositions using
the methods of the present invention may be refined and/or purified
using techniques known in the art.
[0068] The present invention also provides methods for extracting
petroleum-based materials from composites comprising the
petroleum-based materials by subjecting the composites to microwave
radiation for a time sufficient to extract the petroleum-based
material. Preferably, the microwave radiation is in the range of
from about 4.0 and about 12.0 GHz.
[0069] The composites are any material comprising petroleum-based
materials, including, but not limited to, at least one of oil
sands, oil shale, slurry oil, oil cuttings, and soil or sand
contaminated with petroleum-based materials. As used herein,
"composites" also includes, but is not limited to, oil wells.
[0070] In one embodiment, the composite is subjected to one or more
pre-selected microwave radiation frequencies. Preferably, the
pre-selected microwave radiation frequency will be the resonating
microwave frequency, i.e, the microwave radiation frequency at
which the composite absorbs a maximum amount of microwave
radiation. It has been determined that different composites of the
present invention will absorb more or less microwave radiation,
depending on the frequency of the microwave radiation applied. It
has also been determined that the frequency at which maximum
microwave radiation is absorbed differs by composite. By using
methods known in the art, a composite of the present invention can
be subjected to different frequencies of microwave radiation and
the relative amounts of microwave radiation absorbed can be
determined. Preferably, the microwave radiation selected is the
frequency that comparatively results in the greatest amount of
microwave radiation absorption. In one embodiment, microwave
radiation frequency resulting in a comparative maximum absorption
of microwave radiation by the composite of the present invention is
in the range of from about 4.0 and about 12.0 GHz. In others, the
microwave radiation frequency resulting in a comparative maximum
absorption of microwave radiation by the composite of the present
invention is in the range of from about 7.9 and about 12.0 GHz. In
yet others, the microwave radiation frequency resulting in a
comparative maximum absorption of microwave radiation by the
composite of the present invention is in the range of from about
7.9 and about 8.7 GHz.
[0071] The present invention also provides methods for recovery of
petroleum-based materials from composites comprising those
petroleum-based materials, by subjecting the composite to a
sweeping range of microwave radiation frequencies for a time
sufficient to extract the petroleum-based material, and wherein the
range of frequencies of the microwave radiation is in the range of
from about 4.0 GHz to about 12.0 GHz. The composites are any
material comprising petroleum-based materials, including, but not
limited to, at least one of oil sands, oil shale, slurry oil, oil
cuttings and soil or sand contaminated with petroleum-based
materials.
[0072] Preferably, variable frequency microwave ("VFM") is used to
sweep the composites. VFM is described in U.S. Pat. No. 5,321,222
to Bible, et al. and U.S. Pat. No. 5,521,360 to Johnson, et al.,
incorporated herein by reference in their entireties. Unlike single
frequency microwave radiation, VFM produces a bandwidth of
microwave radiation frequencies that are applied sequentially to
the composite. Consequentially, the field distribution with VFM is
substantially more uniform than the field distribution of single
microwave frequency radiation. The more uniform field distribution
of VFM produces fewer hot spots, resulting in more uniform heating
of the composite. Moreover, generally, no single frequency is
applied for longer than about 25 .mu.sr, or no longer than about 20
.mu.s, or no longer than about 15 .mu.s, or even no longer than
about 10 .mu.s. The short duration of each applied frequency
produces no build-up of charge, thus eliminating discharge, or
arcing, typically observed during single frequency microwave
irradiation.
[0073] In certain embodiments, the range of microwave radiation
frequencies is in the range of from about 7.9 GHz to about 12.0
GHz. In still others, the range of microwave radiation frequencies
is in the range of from about 7.9 GHz and 8.7 GHz. In some
embodiments, range of microwave radiation frequencies is in the
C-Band frequency range, the C-Band frequency range encompassing
microwave frequencies in the range of from about 4.0 GHz to about
8.0 GHz. In other embodiments, the range of microwave radiation
frequencies is in the X-Band frequency range, the X-band frequency
range encompassing microwave frequencies in the range of from about
8.0 GHz to about 12.0 GHz.
[0074] Preferably, the sweeping of the range of microwave radiation
frequencies encompasses one or more pre-selected microwave
radiation frequencies in the range of from about 4.0 GHz to about
12.0 GHz. This frequency can be selected by using the methods
described herein and techniques known in the art. In one
embodiment, the pre-selected microwave radiation frequency is in
the range of from about 7.9 and about 8.7 GHz. In other
embodiments, the bandwidth of the sweeping range of microwave
radiation is about 4.0 GHz. More preferably, the range of microwave
frequencies with which the composition is swept, is about +/-2 GHz
of the pre-selected microwave radiation frequency. For example, if
the pre-selected microwave radiation frequency is 7.2 GHz, the
composition would be swept with the range of microwave radiation
frequencies encompassing from about 5.2 to about 9.2 GHz.
[0075] Upon extraction, flammable hydrocarbon-based gases are
released. To reduce the risk of ignition, it is preferred that the
method be performed in an oxygen-deprived atmosphere. Preferably,
the composite is exposed to less than about 12% oxygen. More
preferably, the composite is exposed to less than about 8% oxygen.
Even more preferably, the composite is exposed to less than about
5% oxygen.
[0076] In one embodiment, the composite is exposed to an inert gas
atmosphere. Preferably, the inert gas is nitrogen, argon, or
mixtures thereof.
[0077] In some embodiments, the composite is exposed to less than
atmospheric pressure. Preferably, the composite is exposed to less
than about 40 Torr. More preferably, the composite is exposed to
less than about 20 Torn Even more preferably, the composite is
exposed to less than about 5 Torr.
[0078] In one embodiment, the composite is subjected to microwave
radiation sufficient to heat the petroleum-based material to its
boiling point temperature. Boiling point temperatures of
petroleum-based materials are known in the art. Reducing the
pressure at which the composite is exposed will result in a
decrease in the boiling point temperature of the petroleum-based
material. Those of skill in the art will be able to determine the
boiling point temperatures of petroleum-based materials at
different pressures.
[0079] In some embodiments, the methods of the present invention
may be used in situ to extract petroleum-based materials from
composites located in the field. In other embodiments, inert gases
may be flowed, in situ, onto the composites. In one embodiment, the
pressure surrounding the composite may be reduced to below
atmospheric pressure.
[0080] Using the methods of the present invention, oil and/or gases
can be recovered from the composite.
[0081] The petroleum-based material extracted using the methods of
the present invention may be refined and/or purified using
techniques known in the art.
[0082] The present invention also provides for apparatuses for
decomposing a composition comprising a petroleum-based material. In
one embodiment, the apparatuses of the present invention comprise a
microwave radiation generator, wherein the generator is capable of
applying microwave radiation characterized as having at least one
frequency component in the range of from about 4.0 and about 12.0
GHz, and at least one container to collect decomposed components
from the composition. In one embodiment, the microwave radiation
generator is capable of applying a microwave radiation frequency
between about 4.0 and about 12.0 GHz.
[0083] In other embodiments, the apparatuses of the present
invention comprise a microwave radiation generator, wherein the
generator is capable of applying a sweeping range of frequencies of
microwave radiation characterized as having at least one frequency
component in the range of from about 4.0 GHz to about 12.0 GHz, and
at least one container to collect decomposed components from the
composition. In other embodiments, microwave radiation generator is
capable of applying sweeping microwave radiation in the C-Band
frequency range. In yet other embodiments, microwave radiation
generator is capable of applying sweeping microwave radiation in
the X-Band frequency range. In yet other embodiments, microwave
radiation generator is capable of applying sweeping microwave
radiation in the Ku-Band frequency range (about 12 GHz to about 18
GHz). In further embodiments, the microwave radiation generator is
capable of applying sweeping microwave radiation in the range of
about 5.8 GHz to about 7.0 GHz. In yet other embodiments, the
microwave radiation generator is capable of applying sweeping
microwave radiation in the range of about 7.9 GHz to about 8.7
GHz.
[0084] In another embodiment, the chamber is open to the outside
atmospheric conditions. In other embodiments, the chamber is closed
to the outside atmosphere. In yet other embodiments, the chamber
has an internal pressure of less than atmospheric pressure.
Preferably, the chamber is capable of operating at a pressure of
less than about 40 Torr. More preferably, the chamber is capable of
operating at a pressure of less than about 20 Torr. Even more
preferably, the chamber is capable of operating a pressure of less
than about 5 Torr.
[0085] The present invention also provides for apparatuses for
extracting a petroleum-based material from a composite comprising
the petroleum-based material. In one embodiment, the apparatuses of
the present invention comprise a microwave radiation generator,
wherein the generator is capable of applying microwave radiation
characterized as having at least one frequency component in the
range of from about 4.0 GHz to about 12.0 GHz, and at least one
container to collect the extracted petroleum-based material. In
some embodiments, the microwave radiation generator is capable of
applying a microwave radiation frequency of characterized as having
at least one frequency component in the range of from about 4.0 and
about 12.0 GHz.
[0086] In other embodiments, the apparatuses of the present
invention comprise a microwave radiation generator, wherein the
generator is capable of applying a sweeping range of frequencies of
microwave radiation characterized as having at least one frequency
component in the range of from about 4.0 GHz to about 12.0 GHz, and
at least one container to collect the extracted petroleum-based
material. In some embodiments, the microwave radiation generator is
capable of applying sweeping microwave radiation in the C-Band
frequency range. In yet other embodiments, microwave radiation
generator is capable of applying sweeping microwave radiation in
the X-Band frequency range. In further embodiments, the microwave
radiation generator is capable of applying sweeping microwave
radiation in the range of about 5.8 GHz to about 7.0 GHz. In yet
other embodiments, the microwave radiation generator is capable of
applying sweeping microwave radiation in the range of about 7.9 GHz
to about 8.7 GHz.
[0087] In some embodiments, the apparatuses of the present
invention may be used in situ to extracted petroleum-based
materials from composites located in the field.
[0088] In other embodiments, the apparatuses further comprise at
least one chamber for holding the composite. In another embodiment,
the chamber is open to the outside atmospheric conditions. In other
embodiments, the chamber is closed to the outside atmosphere. In
yet other embodiments, the chamber has an internal pressure of less
than atmospheric pressure. Preferably, the chamber is capable of
operating at a pressure of less than about 40 Torr. More
preferably, the chamber is capable of operating at a pressure of
less than about 20 Torr. Even more preferably, the chamber is
capable of operating at a pressure of less than about 5 Torr.
[0089] In other embodiments, the apparatuses further comprise at
least one chamber for holding the composition. The volume of the
compositions of the present invention may reduce during
decomposition. In some embodiments, the chamber may have a conveyor
having a perforated bottom such that decomposed materials may fall
out of the chamber once reaching a particular size, so as not to
over-expose the materials to microwave radiation. The conveyor may
be adapted to be oscillated.
[0090] An exemplary embodiment of the present invention is depicted
in FIGS. 1A-1G. FIGS. 1A-1G demonstrates one apparatus wherein tire
fragments are placed on a first conveyor belt that carries the tire
pieces through three, differently-sized chambers of the apparatus.
In a first chamber, the tire pieces are exposed to microwave
radiation using the methods described herein. As the tire fragments
decompose, the smaller pieces will fall through perforations in the
first conveyor and drop to a second conveyor. The second conveyor
is not exposed to microwave radiation in the first chamber. The
second conveyor carries the pieces to a second chamber, wherein
they are exposed to microwave radiation using the methods described
herein. As the pieces decompose, the smaller pieces fall through
the perforations in the second conveyor to a third conveyor. The
perforations in the second conveyor are smaller than the
perforations in the first conveyor. The third conveyor is not
exposed to microwave radiation in the second chamber. The third
conveyor carries the pieces to a third chamber, wherein they are
exposed to microwave radiation using the methods described herein.
As the pieces decompose, the smaller pieces fall through the
perforations in the third conveyor to a fourth conveyor. The
perforations in the third conveyor are smaller than the
perforations in the second conveyor. Decomposition will be
essentially complete after exposure in the third chamber and the
material remaining on the fourth conveyor will be mainly steel,
carbon black, and ash, which can be further processed using
techniques known in the art.
[0091] FIG. 1 comprises FIGS. 1A-1F, along with inset FIG. 1G. The
orientation of FIGS. 1A through FIG. 1F are set forth in the inset
in FIG. 1. Referring to FIGS. 1A-1G, there is provided an
embodiment of the present invention directed to processing tire
cuttings using microwaves to recover fuel oil. The processing
equipment described herein is commercially available from one or
more process equipment manufacturing companies.
[0092] FIG. 1A illustrates an elevation view of the beginning
section of a tire cuttings plant layout according to an aspect of
the present invention. This illustration shows two tire processing
lines side-by-side in a parallel configuration. Tires from
automobiles and trucks are first cut into suitable chips, e.g.,
4.times.4 or 5.times.5 chips (not shown). The tire chips are
transported using incline belt conveyor 120 to accumulation silos
102. The tire chips are then conveyed from the accumulation silos
102 to a pre-washer screw wash section 122. Tire chips are then
conveyed to a pressure washer hot water sonic washer 105. Dirt,
stones, gravel and other debris is cleaned off of the tire chips to
minimize contamination of the process further downstream. The tire
chips are then dried using forced air dryer system 106. FIG. 1B is
a plan view of the beginning section of a tire cuttings plant
layout corresponding to FIG. 1A. Cleaned and dried tire chips are
then conveyed up another conveyor 120, as set forth in FIGS. 1C and
1D, below.
[0093] FIG. 1C is an elevation view of the midsection of the tire
cuttings plant layout described here. Cleaned and dried chips are
transported to accumulation silo 112, which are then transported
along transport conveyor 120 to microwave room 124. The details of
the microwave room 124 or further described in FIG. 1G below. In
this elevation view, a dual wall tank with enclosed high
high-capacity heat exchanger 118 is shown in dotted lines. This
high-capacity heat exchanger receives hydrocarbon vapor produced by
the microwave reactors residing within the microwave room 124. The
position of the dual wall tank with enclosed high-capacity heat
exchanger 118 is illustrated further in FIG. 1D.
[0094] FIG. 1D is a plan view of the midsection of the tire
cuttings plant layout described here. Accumulation silos 112 feed
tire chips via incline belt conveyor 120 and screw feed in-feed
section 117 to a series of microwave reactors within hermetically
sealed reactor room 116 with filtration system and vacuum pumps.
Tire chips in the screw feed in-feed section 117 are fed into a
first microwave reactor 150 (see FIG. 1G) residing within the
microwave room 116. The microwave room is depicted in FIG. 1D
containing two sets of microwave reactors side-by-side. Additional
microwave reactors and additional lines can also be added.
Hydrocarbon vapors generated in the microwave reactors from the
irradiated tire chips are collected out of the top of each of the
microwave reactors. The hydrocarbon vapors are then transported,
under vacuum (e.g. at a pressure less than ambient) to heat
exchanger 118. The heat exchanger is capable of further separating
hydrocarbon vapors to oil and high carbon gases by cooling to a
liquid or a vapor, depending on the vaporization temperature of the
hydrocarbon vapors.
[0095] The microwave reactor room 116 is also depicted having
refrigeration equipment 123 for maintaining constant room
temperature. Processed tire chips exit the microwave reactor 154
(FIG. 1G) by a screw feed discharge section 115. Processed tire
chips exit the final microwave room hot and are subsequently cooled
using cooler 114. The cooled processed tire chips (below about
110.degree. F.) then enter a pregrader grinder system 113, where
processed carbon containing materials are separated from metallic
materials (e.g., metal tire cords). Metal materials are separated
using a suitable magnetic conveyor take away system, as shown in
121 in FIGS. 1E and 1F. Organic particles (e.g. carbon black) can
further be shipped to bulk feed trucks equipped to handle fine
particles, other packaging, as well as rail cars. The resulting
organic particles are composed primarily of carbon. In some
embodiments, the organic particles can be used as electronic
activators, as described herein.
[0096] FIGS. 1E and 1F illustrate the magnetic conveyor take away
system 121 for separating metal particles from nonmagnetic organic
matter. Metal is stored in a metal storage unit 140 while
nonmagnetic organic matter (e.g., carbon particles) is transported
via incline belt conveyor 120 to silo and grinder 130. Carbon
particles prepared according to the processes of the present
invention are suitable for use as electron activators for the
microwave processing of heavy residual refinery oil and other
materials (e.g., residual oil from the bottom of a hydrocarbon
distillation apparatus that is traditionally unable to be further
processed). In one embodiment, the tire sidewalls can be separated
from the tire treads. Tire treads typically have a greater amount
of carbon black than the sidewalls. Accordingly, the amount of
carbon black recovered from the treads is greater than that of the
sidewalls. In one aspect, carbon black can be accumulated to form
electron activator by processing the treads. Electron activator
that can be further used in processing heavy viscous oil
feedstocks. Also present is a sifter system with grinder return 111
for preparing controlled particle size carbon material. The matter
in the silo and grinder 130 is transported by a pneumatic tube
conveyor system 119 and auxiliary pump 136 toward sifter 132, and
then to sorter 134, and finally to a super sack gantry system 138.
The super sack entry system 109 is suitable for loading and
unloading using forklift delivery. Also shown is electrical
enclosure 108 containing control panels, a centrifugal
feeder/sorter system 110 for managing fine particles.
[0097] As shown in FIGS. 1D and 1G, the microwave reactor room
contains two series of three reactors each (one series is
illustrated in FIG. 1G). Tire pieces enter first reactor 150 via
screw feed infeed section 117. This reactor is the largest reactor
of the series. 4.times.4 or 5.times.5 inch tire chips are first
exposed to microwaves in the first reactor 150 by operation of the
microwave antennas in the first microwave chamber 161. In this
first stage, the tire pieces "pop" or explode into smaller pieces
when exposed to the microwaves. The smaller pieces are separated
through a mesh belt 170, and then transported onto another
transportation mesh belt 172. The mesh is designed to keep the
microwaves in the first reactor from getting through and over
heating the tire chips. Typically, the temperature of the tire
chips is maintained at about 465.degree. F. or less. The mesh size
in the larger reactor will have an opening of approximately 2
inches, the mesh size in the midsized reactor is approximately 0.5
inches, and the mesh size opening for the smallest reactor is
approximately 1/16''.
[0098] Microwaves are generally generated outside of the microwave
room and transported into the microwave room by a suitable
microwave conduit, e.g. stainless steel wire. The design and
interconnection of the three microwave reactors in series is
provided so that the location of the tire chips in the microwave
radiation zone is maintained so that the tire chips do not exceed
465.degree. F. Initially, "popping" of the tire begins in the first
reactor 150 when the temperature of the tire chips is in the range
of from about 300.degree. F. to about 450.degree. F. It has been
surprisingly found that once the temperature exceeds about
450.degree. F., the carbon black residing within the tires can be
charred and overcooked and the efficiency of the process for
recovering hydrocarbon fuel oils diminishes drastically.
Accordingly temperature is desirably maintained below about
465.degree. F., or even below about 550.degree. F. Without being
bound by any particular theory of operation, it appears that the
tire chips pop because the reactors are under vacuum and a lot of
gas within the tire chips is being released suddenly upon
irradiation with microwaves.
[0099] Suitable operating pressures are the range of up to about 20
mm of mercury, or even up to about 40 mm of mercury, or even up to
about 100 mm of mercury. Accordingly, tire chips processed in the
first microwave reactor 150 are then transported to the second
microwave reactor 152, where the processed chips are further
irradiated under vacuum using microwave antennas 162. The tire
chips are further reduced in size, and fall through mesh 174, and
then transported to the third microwave reactor 154. In the third
microwave reactor 154, the processed chips are further irradiated
using microwave antenna 164. Processed chips are finally
transported by a screw feed discharge section 118 and exit the
microwave reactors from screw feed discharge section 166, and
through airlock (not shown) and onto conveyor 156.
[0100] Each of the microwave reactors are fed with microwave
conduits terminating in a suitable cone or nozzle. The first
microwave reactor has more microwave nozzles 160 as it is larger
than the other two microwave reactors. The second microwave reactor
is shown with microwave nozzles 162, and the third microwave
reactor is shown with microwave nozzles 164. Each of the microwave
reactors contains vacuum lines 180 to transport the resulting
hydrocarbon gases to the high-capacity heat exchanger 118 (shown in
dotted lines). Also shown in the microwave room 124 are
refrigeration equipment 123 to maintain the temperature of the
ambient conditions in the microwave room, and support structures
158 for supporting the microwave reactors.
[0101] Suitable microwave ranges for the processing of tire chips
includes using X-band microwave radiation generators (not shown)
transmitted via conduit in tubes at various frequencies to each of
the reactors. Microwave frequencies for tire processing varies from
X-band down towards C-Band radiation. X-band is 5.2 to 10.9 GHz;
C-band is 3.9 to 6.2 GHz. K-band radiation is also useful in some
embodiments. K-band is 10.9 GHz to 35 GHz, which includes the
sub-bands Ku (15.35 GHz to 17.25 GHz) and Ka (33.0 GHz to 36.0
GHz). Typically separate microwave antenna tubes are separated in
frequency by approximately 0.2 gigahertz. In the embodiment shown
in FIG. 1G, a total of approximately 36 microwave antenna tubes are
transported from a microwave source (not shown) to the microwave
reactors. The largest microwave reactor 150 has the greatest number
of tubes, for example about 18. The second microwave reactor 152
has fewer tubes, approximately 12. The third microwave reactor 154
has the fewest number of tubes, approximately 60. Each of the tubes
are capable of operating at different frequencies, which
frequencies in certain preferred embodiments varies between about
7.0 and 6.4 GHz. The ends of the microwave antenna from which the
microwave radiation exits into the reactor chambers are fitted with
a suitable cone antenna. Each of the cone antennae emits microwave
radiation at a separate frequency, which is typically about 0.2 GHz
different than the others that irradiate into each of the microwave
reactors. Microwaves are typically fixed in frequency but they may
also be capable of being swept in a varying frequency manner, for
example, by using a variable frequency microwave generator. A
number of different frequency combinations are envisioned, for
example each of the cone antennas may be fixed in frequency, vary
in frequency, or any combination thereof. As the tire chips are
irradiated, volatile hydrocarbon vapors are emitted from the tire
chips and collected by vacuum tubing. Hydrocarbon vapors are then
transported to a heat exchanger condenser. Highly volatile gases
and vapors that are not conveniently liquefied can be separately
recovered as a high BTU gas product.
[0102] The plant layout described in FIGS. 1A-1G is operated at a
product speed (per line) of approximately 30 tires per minute on
average. Hourly production rate is approximately 36000 pounds per
hour or approximately 1300 ft..sup.3 per hour. This is based upon a
used automobile tire weight of approximately 20 pounds (9.1 kg). Or
alternatively a used truck tire about 40 pounds (18.2 kg). The
shredded tire chip sizes can be in the range of from about 3 to
about 5 inches. Average loose density of the chips is approximately
24 pounds per cubic foot to about 33 pounds per cubic foot. Heat
values generated at atmospheric pressure range from approximately
12,000 BTUs per pound to about 15,000 BTUs per pound.
[0103] FIG. 2A is an elevation view, axial direction, of a
microwave reactor suitable for processing oil cuttings according to
an aspect of the present invention. Oil cuttings comprise dirt,
rock, water, carbon deposits, and the like, which oil cuttings are
obtained during drilling operations. Drilling operations include
drilling from an oil rig, drilling from a deep-sea oil platform, as
well as mining of shale rock and coal deposits. During drilling,
rock that is rich in hydrocarbons is typically reached prior to
hitting a pocket of oil. This hydrocarbon rich rock is transported
up to the surface and can comprise up to 15% oil, and even up to
25% oil. The consistency can also be similar to oil shale.
Hydrocarbon rich rock can be considered hazardous waste and would
need to be disposed of properly. It cannot be sent to a landfill,
and accordingly it has traditionally been handled by combustion.
This is particularly a problem on an oil rig in the middle of the
ocean, where it may be forbidden to dump oil drillings comprising
greater than 1% hydrocarbon content. Accordingly, the process of
the present invention can also be used to recover hydrocarbons from
drill cuttings, thereby permitting the drill cuttings to be placed
back in the environment after the hydrocarbons have been
substantially removed. As used herein the term "substantially
removed" refers to a composition comprising less than 1% by weight
hydrocarbon content. Oil drill cuttings having less than 0.01% by
weight hydrocarbon has been produced using the processes described
herein. Accordingly, the methods suitably provide drill cuttings
that comprise less than 1 percent, or even less than 0.5 percent,
or even less than 0.2 percent, or even less than 0.1 percent, or
even less than 0.05 percent, or even less than 0.02 percent, or
even less than 0.01 percent by weight hydrocarbons based on weight
oil cuttings. Suitable oil cuttings enter into the system through
in-feed grinder system 201. Oil cuttings are ground to a suitable
size, then fed into the microwave reactor chamber (vacuum sealed
reactor tank 216) via in feed screw 202. The vacuum sealed reactor
tank 216 contains a helical mixer element 203 for mixing and
stirring the ground oil cuttings. The reactor tank is typically
filled to about 40% of its total volume. The microwaves irradiate
the contents of the reactor via antennas that are oriented in an
orbital arrangement emanating from the top of the reactor. The
microwave antennas are desirably flexible and irradiate from
several slides from the top the reactor towards the mixing material
below. A helical mixer element is turned using a motor 210.
Microwaves emanating from a cone antenna or a plurality of cone
antennas (not shown) irradiate the oil cuttings with suitable
microwave radiation. Hydrocarbon gases and oil vapor exit towards
the top vacuum tubing towards vacuum pump and collected in a
suitable heat exchanger vapor condensing unit. Hydrocarbon vapor
gases produced by the process of irradiating the oil cuttings with
microwaves exit via a vacuum discharge tube (not shown). Residual
geologic material and unreacted carbon deposits settled towards the
bottom of the reactor. The unvaporized matter is discharged from
the microwave reactor 216 via screw feed discharge section 204, and
exits the system via discharge system 206. Material exiting the
system is suitably clean of hydrocarbons so as to be considered
nonhazardous waste. For example, material exiting the reactor can
be returned to the ocean after drilling, or can be returned to the
land after drilling. Also shown is reactor support structure 205
for holding the components as set forth in the system.
[0104] FIG. 2B illustrates an elevation view of the microwave
reactor of FIG. 2A, longitudinal direction. Oil cuttings are added
to the system as in-feed via an airlock at 201, which oil cuttings
are then transported to the reactor 216 via in-feed screw 202.
Depicted in this diagram is conduit 214 for pulling vacuum on the
airlock, and on the vacuum sealed reactor tank 216, using vacuum
pumps 207. Microwave waveguides 212 are shown entering the vacuum
sealed reactor tank 216. Microwaves emanating from a suitable
microwave cone antenna radiates the oil cuttings within the reactor
tank. A helical mixer element 203 rotates to mix the oil cuttings,
convey the oil cuttings, and reflects microwaves throughout the
volume of the chamber. After suitable microwave processing at a
particular residence time, the reacted oil cuttings exits the
reactor through screw feed discharge section 204 and exits via a
suitable airlock 206 of the discharge system. Also shown is reactor
support structure 205.
[0105] FIG. 2C illustrates an elevation view of the microwave
device and control room suitable for generating microwaves and
propagating the same through waveguides. The microwave device and
control room 208 is depicted as comprising an electrical panel and
a series of six individual microwave generators (222, 226, 230,
234, 238, and 242) each connected to a series of microwave antennas
(220, 224, 228, 232, 236, and 240). The antennas are combined into
a combined antenna conduit 212 which exits the microwave device
control room 208 and leads towards the vacuum sealed reactor tank
216 as shown in FIG. 2B. Suitable microwaves for processing oil
drill cuttings have frequencies in the range of about 11.2 to about
11.8 GHz, typically about 11.5 GHz. Oil shale can also be processed
using the equipment and processes described herein at a microwave
frequency in the range of from about 10.6 to about 11.2 GHz, and
typically about 10.9 GHz. Tar sands can be appropriately processed
using microwaves 4 to about 12 GHz. Tar sands can also be processed
in the K-band, preferably in the Ku band. Anthracite coal deposits
can also be processed in the KU band as well. A vacuum is
maintained within the microwave reactor chamber using suitable
vacuum and hydrocarbon vapor condensation equipment, for example at
pressures less than about 100 mm of mercury, and even at pressures
of less than about 40 mm of mercury, or even at pressures of less
than about 20 mm of mercury. Maintaining such low operating
pressures helps to keep the overall process temperatures below
about 465.degree. F. or even a temperatures less than about
450.degree. F. so as to prevent overheating and efficient recovery
of hydrocarbon vapors. A large proportion of the hydrocarbon vapors
can be condensed into liquid fuel oil at ambient temperatures.
[0106] The system described in FIGS. 2A-2C can be suitably adapted
and scaled to process oil cuttings at a throughput of up to about 2
tons per hour to even up to about 10 tons per hour. It should be
readily apparent to the skilled person how to increase the size and
power of the microwave reactor chamber to yield higher
throughputs.
[0107] The system described in FIGS. 2A-2C can also be suitably
adapted in scale to process oil shale rock. The processing of oil
shale rock includes irradiating it with suitable microwaves at
power sufficient to increase the temperature of the oil shale rock
to within a range of from about 500.degree. C. to about 600.degree.
C. Without being bound by any theory of operation, it is believed
that these processing temperatures are considerably hotter than
compared to tire cuttings for the reason that more energy needs to
be applied to the rocks to volatile lies the hydrocarbons. This is
in contrast to softer, substantially higher concentration
hydrocarbon, tires that readily absorb the microwave energy.
Suitable shale rocks are broken down into small pieces after being
mined For example, shale rock pieces are suitably smaller than an
inch cube, even smaller than a half inch cube, or even smaller than
about 3/8'' cube, even smaller than about a half inch cube, or even
smaller than about 1/4'' cube. The hydrocarbon content of the oil
shale rock typically comprises hydrocarbons comprising from about
C10 to about C25, or even from about C14 to about C22. Oil shale
rock can contain up to about 5% by weight hydrocarbons, or even up
to about 15% by weight hydrocarbons, or even up to about 25% by
weight hydrocarbons. In some cases, shale rock can contain up to
about 70% by weight hydrocarbons.
[0108] FIGS. 3A and 3B depicts several embodiments of the present
invention for recovering petroleum-based materials and hydrocarbons
from oil slurry. FIGS. 3A and 3B are schematic illustrations of two
embodiments of a microwave assisted system for the distillation and
recovery of heavy oil bottoms, e.g., oil slurry, from a
distillation plant. FIG. 3A shows the following elements of a
traditional hydrocarbon distillation plant: 302 distillation tower
360 unrefined inlet into distillation tower; 304 vapor line; 306
natural gas line; 308 gas separator; 310 pump; 312 LPG line; 314
gasoline lines; 316 jet fuel (kerosene) line; and 318 inset:
close-up view of the liquid vapor contact caps with an a
distillation tower. This distillation system can be modified using
the microwave process of the present invention as follows. An
electron activator 320 is added using an electron activator pump
322 into residual oil 362. Hot residual oil line (e.g., heavy oil)
362 is pumped into the microwave reactor 330 and atomized using an
atomizer 334. Microwave waveguide antenna 336 is powered from the
microwave room and control system 340, which control system
includes microwave generators 342 and microwave waveguides 344. The
microwaves exit the waveguide antenna 336 at cone nozzles within
the microwave reactor so as to radiate the atomized residual oil
above the atomizer 334. Vacuum pumps 350 connected to the vacuum
line 332 maintains pressure of less than about 20 mmHg, or even
less than about 40 mmHg, or even less than about 100 mmHg. The
irradiation of the atomized residual oil gives rise to cracking of
the residual heavy oil, which in turn produces hydrocarbon vapors
such as natural gas 352 and heavier hydrocarbon vapors such as
diesel and heating oil 354. In the microwave reactor 330, residual
oil 362 is removed from the bottom of a distillation tower 302,
combined with electron activator 320 and processed by microwave
after atomization. We have discovered that addition of the electron
activator to the residual oil, for example about 2% by weight based
on residual oil of carbon small particles, gives rise to a much
faster, more efficient absorption of the microwaves to yield more
efficient cracking of the residual oil. Accordingly, electron
activator made using microwave processing of tire chips as
described supra is useful for making electron activator. Suitable
electron activator is provided as a fine powder, for example of
about a hundred mesh, or finer. The electron activator may be
coarser than 100 mesh, depending on the precise application and
handling requirements. Without being limited by any particular
theory of operation, the electron activator enhances the absorption
of microwaves by the residual oil, which gives rise to faster
processing and more efficient processing of the heavy oil. As a
result, the electron activator, which comprises carbon powder
particulates, are capable of absorbing microwave radiation. Solid
particles containing residual hydrocarbons, such as electron
activator, result in popping (as in popcorn) when irradiated.
Without being bound by any particular theory of operation, it is
believed that the popping action of the small electron activator
particles within the residual oil enhances the microwave processing
of the residual oil. In certain embodiments, the electron activator
functions as a catalyst for effectuating the microwave cracking
process.
[0109] Suitable microwave radiation frequency ranges from about 8.0
to about 8.8 GHz, or in the range of from about 8.1 GHz to about
8.7 GHz, or even in the range of from about 8.2 GHz to about 8.6
GHz, or even in the range of from about 8.3 GHz to about 8.5 GHz,
or even about 8.4 GHz. The microwave reactor contains a series of
microwave cone antennas that radiate the atomized residual oil with
microwaves. These microwave cone antennas can each receive the same
or different microwave frequencies. When the frequencies differ,
they typically are separated by increments of about 0.2 GHz. Ranges
of microwave frequencies are typically useful for processing the
atomized residual oil in this manner. Accordingly multiple
microwave antennas 344 receive microwaves generated by a plurality
of microwave generators 342 provided in the microwave control
system 340. Microwaves are transmitted through microwave antennas
344 to the microwave antenna conduit 336. Microwaves then enters
the microwave reactor. Typically the residual oil 362 is pre-heated
to a temperature of about 350.degree. C. so that it is capable of
flowing under pressure and atomized. The use of microwaves has been
demonstrated to effectively crack the hydrocarbon chains in the
heavy residual oil. Atomization helps to increase the surface area
of the residual oil and decrease particle size, thereby
effectuating absorption of the microwaves and cracking of the
hydrocarbon chains. The residual oil is suitably heated to
temperatures sufficient that can flow under pressure and atomized.
Suitable temperatures are at least about 250.degree. C., or even at
least about 300.degree. C., or even at least about 350.degree. C.,
or even at least about 400.degree. C., or even at least about
450.degree. C., or even at least about 500.degree. C. The residual
oil may be preheated using any of a variety of heating methods, for
example convection, conduction, or irradiation, e.g. microwaves.
The heavy residual oil chains crack at least several times.
[0110] Processes according to the present invention are capable of
producing combustible gases. The processes according to the present
invention are also capable of producing at least several different
weights of oils. These oil products range from carbon content of
hydrocarbon chains comprising from 14 carbons up to about 25
carbons. The starting residual oils comprise hydrocarbon chains
having at least 25 carbons or even at least 28 carbons. The
hydrocarbons in the residual oil do not necessarily need to be
linear hydrocarbon chains, for example cyclic and branched
hydrocarbons are also envisioned. Instead of atomization, hot
flowing residual oil can be formed into a thin film and irradiated
with microwaves, or can be ejected into a shooting stream and
irradiated with microwaves, or can be broken into droplets under
force of pressure and irradiated with microwaves. Similar related
processes give rise to narrow dimension residual oil droplets. In
certain embodiments the products of microwave radiation within the
microwave reactor 330 illustrated in FIG. 3A can be recycled back
to the distillation tower 302 for further processing.
[0111] FIG. 3B is a schematic of another embodiment of a microwave
assisted distillation and recovery unit for heavy oil bottoms from
a distillation plant. This embodiment is similar to that described
in FIG. 3B, with the exception that this embodiment further
includes a reboiler 348 for heating the bottoms coming from
distillation tower 302 by a transfer line 370. The reboiler heats
the bottoms which are distilled in vacuum tower 340. Residual oil
346 from the vacuum tower is combined with electron activator 320
using electron activator pump 322 to provide a mixture of residual
oil in electron activator 362. This mixture is then atomized in
microwave reactor in 330. The operation of the microwave reactor is
similar to that discussed supra in FIG. 3A.
[0112] FIG. 4A illustrates an elevation view of a microwave reactor
system suitable for processing shale rock, tar sands, drill
cuttings, and the like. Inlet feed screw 402 is suitable for
transporting shale rock and other hydrocarbon containing cuttings
and the like into microwave reaction chamber 412. Helical screw
mixing flights 408 are mounted to an axle 406 which is rotated
using a motor. Helical screw mixing flights mix and transport the
material, such as shale rock pieces, in the microwave reaction
chamber interior 404. Microwave antennas 410 enter the interior of
the microwave reaction chamber 404. The material within the
microwave reaction chamber interior is stirred and irradiated.
Vapors are removed using a vacuum recovery system and condensing
unit (not shown). Material depleted of hydrocarbon vapor is
discharged through the exit discharged from feed system 416. Also
shown is a support structure 414.
[0113] FIG. 4B provides a plan view of FIG. 4A, wherein the
direction of the material is shown entering the microwave reaction
chamber via onlet feed screw 402 mixing within the microwave
reaction chamber by a helical screw mixing flights 408, and finally
exiting via exit discharge screw feed system 416. FIG. 4C is an
elevation view of the microwave reactor system along the axis 406,
the near end being the exit discharge screw feed system section
416. FIG. 4D illustrates a suitable microwave device control room,
waveguides, and vacuum pumps suitable for use with the system
illustrated in FIG. 4A. FIG. 4E illustrates an optional hopper
elevator for transporting material into the inlet feed section 402.
FIGS. 4F and 4G illustrate three horizontal microwave reactor
systems operating in parallel. FIG. 4H illustrates additional
microwave generators, waveguides and vacuum pumps for operating the
three horizontal microwave reactors illustrated in FIGS. 4F and 4G.
The processing of hydrocarbon containing materials, such as shale
rock, tar sands, drill cuttings and the like, is conducted in a
vacuum environment, less than about 20 mm of mercury, or less than
about 40 mm of mercury, or even about less than 100 mm of mercury.
The hydrocarbon containing materials are subject to heating by the
microwaves and other heating means, up to about 350.degree. C., or
even up to about 450.degree. C., or even up to about 550.degree.
C., or even up to about 600.degree. C. The hydrocarbon containing
materials are removed from the microwave reactor chamber via a
suitable vacuum plumbing system. The hydrocarbons are recovered
using a suitable heat exchange or condensing system (not
shown).
[0114] FIG. 5A depicts an exemplary embodiment of the present
invention for extracting petroleum-based materials, carbon-based
materials and hydrocarbon-based materials in situ. A probe capable
of generating microwave radiation (e.g., cone, antennae or nozzle)
according to the methods of the present invention can be lowered
into drilled oil wells. Using the methods of the present invention,
the petroleum-based materials can be vaporized and collected at
surface-level and processed using techniques known in the art. FIG.
5A illustrates a schematic view of a microwave system for in situ
recovery of oil from geologic deposits. A suitable geologic deposit
526 includes an oil well, a capped oil well, a shale rock deposit,
a tar sand deposit, a coal deposit, and the like. This illustration
depicts a vacuum recovery unit 502 (e.g., a Venturi type system)
for recovering geologic hydrocarbons such as fossil fuels from a
capped oil well. This system comprises casing 504 extending from
the surface of the ground to the geologic carbon deposits at 526. A
microwave waveguide is delivered through the casing to the geologic
carbon deposit 526. A microwave antenna nozzle 510 resides at the
end of the microwave waveguide 506 proximate to the geologic carbon
deposit, into which microwaves radiate. On the ground surface is
illustrated portable electric generator 522, portable pumping
system 524, and portable microwave generation station control unit
520. Hydrocarbon vapors generated by the microwaves in the geologic
carbon deposit 526 are transported under vacuum as vaporized
geologic carbon deposit (e.g., oil vapor) 508 to the vacuum
recovery unit on the surface ground. Capped oil wells contain
hydrocarbons that can be cracked to oil, suitable for use as diesel
fuel. This involves opening up capped oil wells, optionally adding
electron activator into the wells (which aid in absorbing the
microwaves and converting the heavy oil in the wells to hydrocarbon
vapor), and irradiating the heavy hydrocarbons with microwaves.
Once vaporized, the hydrocarbons are readily transported to the
surface using suitable vacuum piping, or other plumbing means 528.
The vacuum recovery unit 502 is also capable of fractionating the
hydrocarbons into other hydrocarbon products. Oils that are
difficult to recover using normal pumping means can be recovered
according to the processes.
[0115] FIG. 5B depicts an apparatus of the present invention for
recovering petroleum-based materials from oil shale, in situ. A
probe capable of generating microwave radiation according to the
methods of the present invention, can be lowered into oil shale
deposits. Using the methods of the present invention, the
petroleum-based materials can be vaporized and collected at surface
level and processed using techniques known in the art. FIG. 5B
illustrates a schematic view of a microwave system for recovering
hydrocarbons below ground. In this embodiment, one or more
microwave antennae are shown capable of traveling horizontally
underground with respect to the ground surface. The microwave
antennae are illustrated comprising one or more microwave nozzles
for vaporizing hydrocarbon geological deposits in a vacuum
environment. FIG. 5B illustrates two conduits (on the left portion
of the figure), each containing a plurality of waveguides that
terminate it into a suitable microwave nozzle or cone emitter.
Suitable microwave cones emitters are commercially available. This
process is adapted for recovering residual oil in capped oil wells,
and can also be adapted to other geological hydrocarbon deposits
such as tar sands and shale rock. If the oil well is "dry" with
mainly heavy viscous hydrocarbon material remaining in the well, a
microwave antenna is transported down into the oil well and the
antenna-end can reside in one or more of the openings. Microwave
radiation is directed towards the geologic material in the vicinity
of the antenna.
[0116] Various hydrocarbon geological deposits can be processed
underground using this technology at various depths. Piping for the
wells can start at a diameter of about 24 inches at the surface,
which diameter is progressively narrower and narrower as sections
of piping are added as the depth increases. At a depth of
approximately 3000 feet, a typical opening (diameter) of the piping
is about 6 inches. For example oil shale deposits in the Western
part of the United States are relatively shallow, i.e., near the
surface. Strip mines are also relatively shallow, and other
deposits may be as deep as 2000 feet or more. Previously pumped oil
wells often have chambers of oil that are not readily accessible
but require opening by an additional explosive or drilling
operation. Certain chambers can also be opened by irradiating the
sealing rock material with microwaves. In a laboratory setting, it
has been discovered that oil shale pops and reduces in size when
irradiated with microwaves. As the oil shale releases hydrocarbons
(i.e. oil), the oil shale "pops" like popcorn. Accordingly,
directionalizing microwaves within the geological chambers can give
rise to breakdown of the geological formation (i.e. the rocks pop,
break apart, and fall down and fill the cavity). Accordingly, the
antennas can be moved around within geological formations to aid in
recovering hydrocarbon material. In some embodiments microwave
antennas are placed down about 5000 feet or more, and then are
directionalized to travel on the order of approximately 100 yards
or so horizontally.
[0117] Any type of hydrocarbon material present within the
geological formation can be cracked to gas and recovered at the
surface using fractionalization condensation units. For example,
any carbon suitable for use as diesel fuel can be made by
irradiating oil shale. Resulting diesel fuel is suitably used as
Cat Diesel Engine Oil. Sometimes oil wells are drilled using
directional drilling technologies. Suitable directional drilling
technologies are capable of bending at a rate of a degree a foot to
create an angle. Accordingly, flexible microwave antennas are
suitable for use in such oils. Accordingly, the process includes
uncapping a capped oil well. This can be accomplished by drilling
out a concrete plug used to cap the well, if present.
[0118] The system can include a number of auxiliary equipment
located on the surface of the ground. Such equipment includes, for
example, well drilling equipment, vacuum pump vehicle, fuel tank
vehicles, a generator vehicle, and microwave control vehicle that
includes microwave generators, microwave waveguides, and associated
equipment. The vacuum pump vehicle can contain a vacuum pump that
is capable of applying intermittent vacuum pulse technology to
raise hydrocarbon gases to the surface. The hydrocarbon gases are
recovered and collected in a suitable distillation tower or
fractionation tower that is fitted with heat exchanger and
condensing unit. Suitable oil wells and other hydrocarbon
geological deposits residing in the ground are accessed via a tube
to provide a sealed system with the vacuum pump vehicle for
producing the vacuum environment needed for recovering a
hydrocarbon vapors. Suitable vacuums include absolute pressures of
less than about 20 mm of mercury, or even less than about 40 mm of
mercury, or even less than about 100 mm of mercury. The microwave
control vehicle contains suitable flexible microwave waveguides and
generators. Typically the end of the microwave waveguides (e.g.,
antennas) are fitted with a suitable microwave cone emitter (e.g.,
nozzle). The antennas are placed into the mahogany zone in Earth in
situ and microwaves are used to radiate tar sands, or oil shale, or
other hydrocarbon deposits. The microwaves cause vaporization and
gasification of the otherwise viscous and solid-like hydrocarbon
and carbon geological sources within the ground. One or more
antenna fitted with one or more cone emitter devices can be
used.
[0119] Generated hydrocarbon gases (e.g., take off gases) are
transported to a suitable fractionation tower capable of separating
the gas, as illustrated in FIG. 5C. Geological material such as
sand and rock from which hydrocarbons have been removed remain
within the geological formation. In some embodiments, an in situ
microwave process is provided. Other embodiments do not require in
situ microwave irradiation of the geological formation, e.g.,
geological material containing hydrocarbons that are mined and
provided via separate feed mechanism into a suitable microwave
reactor. Geological material such as sand and rock can be
substantially totally gasified (i.e., depleted of hydrocarbons and
carbons) according to the processes of the present invention, which
geological material is then returned to the environment
substantially free of hydrocarbons. Finally, fuel and other
hydrocarbons recovered form the geological source can be stored in
a suitable tanker vehicle and shipped for delivery, further
processing, and so on. The recovered hydrocarbons may also be
transported by pipeline, rail car, and the like. Optionally, the
hydrocarbon vapor recovered from geological sources may be
fractionalized on-site using a suitable distillation tower, as
illustrated in FIG. 5A. The process of operating a distillation
tower is suitably described in FIG. 5C, which illustration shows
the separation of crude oil using a fractionating tower into its
component products.
[0120] FIG. 6 depicts one embodiment for extracting petroleum-based
materials from shale and tar sands and oil sands. The tar sands can
be loaded into the top of the apparatus, which can be under reduced
pressure. Using gravity and shaking, the tar sands move through the
apparatus while being exposed to microwave radiation as described
herein. Vaporized petroleum-based materials can be captured and
collected in separate vessels and refined using methods known in
the art. After the material has passed through the apparatus, it
will be essentially free of petroleum-based materials. FIG. 6
provides an elevation view of a multiple microwave reactor system
suitable for high volume recovery of petroleum, carbon and
hydrocarbons (e.g. diesel oil) from mined material, e.g., oil
shale, oil sands, coal slag, and tar sands. This system is
illustrated having the following equipment: microwave waveguide
602; microwave antennas 620; vacuum gas line 604; microwave
reactors 606--a total of five connected in series; connecting pipe
608 between microwave reactors 606; top airlock 610 adjacent to
in-feed of surface shale and tar sand material; airlock 612
adjacent to discharge of depleted material; baffles 614 within
vertically oriented microwave reactors 606; support structure 630
to support multiple microwave reactors connected in series and
adjacent to source of surface shale and/or tar sands. Mined
material enters the system at airlock in-feed 610, which minimizes
the amount of air entering the system. The system is also fitted
with a suitable vacuum gas line 604 to maintain a vacuum
environment (vacuum pumping equipment not shown) of up to about 20
mm of mercury, or even up to about 40 mm of mercury, or even up to
about 100 mm of mercury. Material enters the first microwave
reactors 606 adjacent to the airlock, which material is transported
along baffles 614 while being irradiated with microwave radiation
through microwave antennas 620 (as illustrated in the second
through fourth microwave reactors 606). Microwaves irradiate, heat,
and crack the hydrocarbons, which hydrocarbons exit the system via
a vacuum gas line 604 (connections between the microwave reactors
606 in the vacuum gas line 604 not shown). Geological material
leaves the topmost microwave reactor 606 and enters a first
connecting pipe 608, which partially reacted material is
transported to a second microwave reactor 606. The process is
repeated and the material is subsequently transported and
irradiated with microwaves as it progresses along the series of
microwave reactors and connecting tubes. The processed material
eventually arrives at the bottom discharge, where it exits the
system through an airlock 612.
[0121] Another embodiment of an apparatus of the present invention
is depicted in FIG. 7. FIG. 7 is a schematic view of a microwave
reactor chamber and system for recovering fuel oil from a
hydrocarbon-containing source, such as used tires. The system
includes the following equipment and features: nitrogen supply 702;
nitrogen regulator 704; nitrogen flow valve 706; nitrogen inlet 708
to microwave reactor chamber 710; microwave reactor chamber 710;
infrared thermocouple 712 to measure average temperature over
irradiated area; nitrogen flow meter 714 for infrared thermocouple
purge (low flow); microwave scattering reflector 716; motor 718 for
microwave scattering reflector 716; platform 720 for holding
hydrocarbon containing materials; irradiation area 722; vacuum
outlet 724; vacuum gauge 726; opening 728 to microwave antennae;
microwave source 730 (TVT or magnetron); temperature gauge 732;
vapor transfer tube 734; condenser tube 736; cooling coil 740; oil
collector 742; valve drain 744; vacuum bypass valve 746; vacuum
pump 748; flow meter 750 for TWT nitrogen purge (flow); nitrogen
supply lines 752; exhaust 754; exhaust gas flow meter 756; reactor
chamber door 760.
[0122] FIGS. 8A, 8B and 8C illustrate an embodiment of the present
invention for incorporating a microwave processing system to
process drilling cuttings on an oil drilling platform. FIG. 8A is a
plan view of an exemplary oil platform incorporating a drill
cuttings microwave processing unit. A suitable placement of a
microwave processing unit (further illustrated in FIG. 8C) is
provided. FIG. 8B illustrates an elevation view of the oil platform
in FIG. 8A. FIG. 8C illustrates a vertical and horizontal
configurations of the drill cuttings microwave processing unit
suitable for use in the oil platform illustrated in FIG. 8A.
[0123] FIGS. 9A-9C are electron microscope photographs at 60,000
times magnification of pyrolytic carbon black material obtained
according to Example 3 and using the system illustrated in FIG. 7.
The production of this material is further described in Example 3,
below.
[0124] FIGS. 10A-10E illustrate an additional embodiment of a
system for processing materials containing hydrocarbons. Suitable
materials include shale rock, drilling cuttings, tar sands,
plastics, polymeric materials, recycled hydrocarbon-containing
materials, refuse, residual oil, slurry oil, hydrocarbon
distillation bottoms, and the like. These figures illustrate the
following equipment and features: 1001 microwave tubes, amplifier
and waveguides; reactor drum 1004; sealed material in-feed 1002
through reactor drum 1004; in-feed screw 1003; rotating discharge
screw 1005; control panel 1006; vacuum pumps 1007; hydraulic drive
transmission system 1008 for rotating reactor drum 1004; shipping
container 1009; vacuum release support 1010; drum bearing seal
1012; roller bearings 1014; vacuum port 1016; microwave waveguides
1018 entering rotating reactor drum 1004; mixing flight bars 1020
for mixing materials within the rotating reactor drum 1004;
bearings 1022 by which mechanism the drum slidably rotates;
rotating reactor drum axel 1024 by which mechanism the reactor drum
rotates through actuation with the hydraulic drive transmission
center 1008.
[0125] FIG. 10A is an elevation view of a rotating drum reactor
system. Material enters the in-feed 1002 via a suitable source, for
example a hopper for receiving chips or chunks of material. The
material then enters into the in-feed screw 1003, which meters the
material into reactor drum 1004. The material is stirred and mixed
using mixing flight bars 1020. The drum is rotated using the
hydraulic drive system 1008. The drum reactor is maintained under
vacuum by means of vacuum pumps 1007 and vacuum gas line. The
reactor drum is vacuum sealed by means of a drum bearing seal 1012
as shown in the inset of FIG. 10D. Microwaves are generated at 1001
and transmitted by a waveguides 1018 into the drum reactor 1004.
Hydrocarbon vapors are removed through the vacuum gas line and
collected for further processing as described herein above.
[0126] FIG. 10B is a plan view of the rotating drum reactor portion
depicted in FIG. 10A. The rotating drum 1004 is shown comprising a
drum bearing seal 1012, which drum slidably rotates against end
caps comprising ports for microwave antenna and vacuum connections.
The reactor drum slides via roller bearings 1014 in the top and
bottom end caps. The drum reactor 1004 resides within shipping
container 1009. Screw conveyor 1003 conveys material into the drum
reactor 1004. FIG. 10C is a plan view of an alternative embodiment
of a rotating drum reactor system. FIG. 10D is a cross-sectional
view of a drum bearing seal used in the rotating drum reactor
system.
[0127] FIG. 10E is an elevation view of the rotating drum reactor
portion depicted in FIG. 10A. FIG. 10E further illustrates the
in-feed screw 1003 for metering the material into reactor drum
1004, which material is stirred and mixed using mixing flight bars
1020 as the drum is rotated using the hydraulic drive system 1008.
The drum reactor is maintained under vacuum by means of vacuum
pumps 1007 and vacuum gas line. The reactor drum is vacuum sealed
by means of a drum bearing seal 1012 as shown in the inset of FIG.
10D. Microwaves are generated at 1001 and transmitted by waveguides
1018 into the drum reactor 1004. Mixing flight bars 1020 are used
for mixing materials within the rotating reactor drum 1004.
Bearings 1022 are used for slidably rotating the drum while
maintaining the vacuum and microwave antenna connections. The
reactor drum rotates by means of axel 1024 through actuation with
the hydraulic drive transmission center 1008. Hydrocarbon vapors
are removed through the vacuum gas line 1016 and collected for
further processing as described herein above. Spent materials
substantially depleted of hydrocarbons exit to discharge screw
1005.
[0128] As an example, a suitable microwave rotating reactor drum
system for extracting hydrocarbons from materials such as drill
cuttings and fluids can comprise the following equipment:
[0129] A suitable microwave control center includes a number of
hydrocarbon specific modular microwave generators, high power
amplifiers, master controller module, slave driven power modules,
thermal sensors, safety I/O devices for vacuum, interlocks, and
emergency shut down, manifold banked configuration of flexible
waveguides/windows/adapter plates, thermal metrology gear microwave
power measurement instruments and computer control station as per
schedule.
[0130] A suitable 4'-0'' diameter rotating in-feed channel drum
unit with vacuum seal provisions comprises 3/8'' stainless steel
welded frame construction and bolt on stainless steel (replaceable)
hardened steel troughs driven by a direct coupled, 5-hp NEMA-4
variable speed (VFD driven) indexing servo-motor to transfer
metered product into the feed screw.
[0131] A suitable 2'-6'' diameter.times.12'-6'' long in-feed screw
assembly comprises heavy-duty stainless steel 2'' square tubing
frame supporting 3/8'' stainless steel skins with hardened helical
screw driven by a direct coupled, 2-hp NEMA-4 variable speed (VFD)
servo-motor to transfer metered product into the reactor
vessel.
[0132] A suitable 5'-0'' diameter.times.3/8'' horizontal seamlessly
welded stainless steel and jacketed sub-baric vessel is constructed
with internal angular flight bars, (length varies depending on
composition of the intended process to) with two--24''
long.times.3/8'' stainless steel end cap sections, hardened steel
circum-centerline rack & pinion hydraulic transmission driven
by a variable speed gear-head motor. Includes a maintenance access
door, piping as required to heat vessel jacket, microwave antenna
mountings, vacuum port, pressure/flow meters and gauges as
required, power transmission is stainless steel guarded. Reactor
tank and peripheral equipment is supported by heavy duty stainless
steel formed structural channels and heavy duty external bearing
wheels.
[0133] A suitable 2'-6'' diameter.times.12'-6'' long discharge
screw assembly comprises heavy-duty stainless steel 2'' square
tubing frame supporting 3/8'' stainless steel skins with hardened
helical screw driven by a direct coupled, 2-hp NEMA-4 variable
speed (VFD) servo-motor to transfer metered product into the
reactor vessel.
[0134] A suitable NEMA 4 electrical motor control panel, 480v/3
ph/60 Hz--24 volt control circuits controls all motors and devices,
directly mounted to shipping container wall, includes Allen-Bradley
PLC, touch screen diagnostics, VFD drive components, I/O racks,
rigid conduit with all marine wire specs, color coded, tagged and
match-marked for easy identification.
[0135] A suitable vacuum system comprises Dual to Quad (which
varies according to throughput) 1.5-hp oil-lubricated, rotary vane
vacuum pumps system for -20 in.Hg. continuous duty operation. A
vacuum release port system is mounted on the discharge screw
section.
[0136] Electron activator. It has been discovered that microwave
radiation in the frequency range of from about 4 GHz to about 12
GHz is useful for selectively recovering hydrocarbon materials from
geological petroleum and mineral sources, as well as manufactured
materials such as automobile and truck tires. It has further been
found that such materials can comprise carbon particles that absorb
energy when irradiated with microwave radiation. The heat from the
energized carbon particles is released to the adjacent hydrocarbon
materials, and when sufficient heat is released, the hydrocarbons
are reduced in molecular weight, i.e., "cracked", and vaporized.
Unlike the prior art, the present discovery discloses a particular
range of frequencies that is efficacious for the electromagnetic
stimulation and heating of carbon particles for recovering
hydrocarbons, such as diesel fuel, from difficult to recover
hydrocarbon sources.
[0137] Disclosed are methods for microwave treatment of
difficult-to-recover hydrocarbon source materials comprising
contacting the hydrocarbon source material with particles
comprising carbon, and subjecting the hydrocarbon source material
to microwave radiation. Also disclosed are methods for microwave
treatment of hydrocarbon source material comprising contacting the
hydrocarbon source material with material having a resonating
frequency in the range of from about 4 GHz to about 12 GHz, and
subjecting the hydrocarbon source material to microwave radiation
characterized as having at least one frequency component that
corresponds to the resonating frequency of the material. As used
herein, carbon particles or material having a resonating frequency
corresponding to the applied microwave radiation frequency are
collectively referred to as "electron activator".
[0138] In preferred embodiments of the disclosed methods, the
microwave radiation is one or more pre-selected microwave radiation
frequencies. Preferably, the pre-selected microwave radiation
frequency will be the resonating microwave frequency, i.e., the
microwave radiation frequency at which the particles comprising
carbon absorb a maximum amount of microwave radiation. It has been
determined that different compositions of the present invention
will absorb more or less microwave radiation, depending on the
frequency of the microwave radiation applied. It has also been
determined that the frequency at which maximum microwave radiation
is absorbed differs by composition. By using methods known in the
art, a composition of the present invention can be subjected to
different frequencies of microwave radiation and the relative
amounts of microwave radiation absorbed can be determined.
Preferably, the microwave radiation selected is the frequency that
comparatively results in the greatest amount of microwave radiation
absorption. In one embodiment, the pre-selected microwave radiation
frequency is characterized as having at least one frequency
component in the range of from about 4 GHz to about 12 GHz. In
other embodiments, the pre-selected microwave radiation frequency
is characterized as having at least one frequency component in the
range of from about 5 GHz to about 9 GHz, from about 6 GHz to about
8 GHz, or from about 6.5 GHz to about 7.5 GHz.
[0139] The particles comprising carbon are preferably carbon
substances that have a resonating microwave frequency of from about
4 GHz to about 12 GHz. Many forms of carbon are known by those
skilled in the art, and, while not intending to exclude other
carbon types, it is contemplated that any form of carbon having a
resonating microwave frequency of from about 4 GHz to about 12 GHz
will be within the scope of the present invention. For example, the
particles comprising carbon can comprise carbon black. Carbon black
may be described as a mixture of incompletely-burned hydrocarbons,
produced by the partial combustion of natural gas or fossil
fuels.
[0140] Carbon blacks have chemisorbed oxygen complexes (e.g.,
carboxylic, quinonic, lactonic, phenolic groups and others) on
their surfaces to varying degrees depending on the conditions of
manufacture. These surface oxygen groups are collectively referred
to as the volatile content. In preferred embodiments, the present
invention uses carbon black having a moderate volatile content. The
volatile content of the preferred carbon black can be composed of
hydrocarbons having up to about 20 carbon atoms, or even up to
about 30 carbon atoms.
[0141] The constituent parts of the electron activator preferably
have characteristic dimensions in the micrometer range, although
other particle or fragment sizes may also be used. Because carbon
particles or particles comprising another electron activator for
use in the present invention can be present in numerous
configurations, and can be irregular in shape, the term
"characteristic dimensions" is used herein to describe the long
axis in the case of substantially cylindrical or otherwise oblong
particles, and to describe diameter in the case of substantially
spherical particles, etc. In some embodiments wherein the carbon
particles comprise carbon black, the particles can have
characteristic dimensions of about 10 nm to about 250 .mu.m. In
other embodiments, the particles can have characteristic dimensions
of about 100 nm to about 100 .mu.m, or of about 200 nm to about 10
.mu.m.
[0142] Preferred are electron activators having characteristic
dimensions that are conducive to ready dispersion within
hydrocarbon materials that are targeted for vaporization. The
electron activators can be contacted with the hydrocarbon materials
by directly introducing the electron activators into the
hydrocarbon materials environment.
[0143] In the present systems, the electron activator particles can
comprise any material that is capable of absorbing at least a
portion of the transmitted microwave radiation generated by the
microwave generator. In preferred embodiments the material
comprises carbon. The particles comprising carbon are preferably
carbon substances that have a resonating microwave frequency of
from about 4 GHz to about 12 GHz. Many forms of carbon are known by
those skilled in the art, and, while not intending to exclude other
carbon types, it is contemplated that any form of carbon having a
resonating microwave frequency of from about 4 GHz to about 12 GHz
will be within the scope of the present invention. For example, the
particles comprising carbon can comprise carbon black. Carbon
blacks have chemisorbed oxygen complexes (e.g., carboxylic,
quinonic, lactonic, phenolic groups and others) on their surfaces
to varying degrees depending on the conditions of manufacture.
These surface oxygen groups are collectively referred to as the
volatile content. In preferred embodiments, the present invention
uses carbon black having a moderate volatile content prepared by
processing tire chips using microwave radiation as described herein
above.
[0144] The constituent parts of the particles preferably have
characteristic dimensions in the micrometer range, although other
particle or fragment sizes may also be used. Because carbon
particles or particles comprising another electron activator for
use in the present invention can be present in numerous
configurations, and can be irregular in shape, the term
"characteristic dimensions" is used herein to describe the long
axis in the case of substantially cylindrical or otherwise oblong
particles, and to describe diameter in the case of substantially
spherical particles, etc. In some embodiments wherein the carbon
particles comprise carbon black, the particles can have
characteristic dimensions of about 100 .mu.m.
EXAMPLES
[0145] The following examples are provided to further describe the
present invention. They are not to be construed to limit the scope
of the invention described in the claims. Many of the examples make
use of the apparatus substantially illustrated and described in
FIG. 7.
Example 1
[0146] A chamber capable of being subjected to between 4.0 to 12.0
GHz of microwave radiation frequencies and rated to withstand
reduced atmospheric pressure, was equipped with a 700 W, 5.8 to 7.0
GHz VFM microwave tube (Lambda Technologies, Morrisville, N.C.).
The chamber was outfitted with a nitrogen gas inlet tube, a vacuum
inlet tube, and an outlet tube connected to a heat exchanger and
collection vessel. The chamber was also equipped with an infrared
thermocouple temperature probe.
Example 2
[0147] A chamber capable of being subjected to between 4.0 to 12.0
GHz of microwave radiation frequencies and rated to withstand
reduced atmospheric pressure, was equipped with a 1800 W, 7.3 to
8.7 GHz VFM microwave tube (Lambda Technologies, Morrisville,
N.C.). The chamber was outfitted with an nitrogen gas inlet tube, a
vacuum inlet tube, and an outlet tube connected to a heat exchanger
and collection vessel. The chamber was also equipped with an
infrared thermocouple temperature probe.
Example 3
[0148] A 20 lb automobile tire was cut into approximately
4''.times.4'' pieces. These pieces were washed and dried. The
pieces were placed on a tray and loaded into the chamber of Example
1. Twenty psi of N.sub.2 was introduced into the chamber. The VFM
microwave radiation was initiated (700 W, 5.8-7.0 GHz). When the
temperature of the tire pieces reached 465.degree. F., the
microwave radiation was halted and the tire pieces allowed to cool
about 5-25.degree. F. Microwave radiation was resumed. This process
was repeated an additional three times. Total experiment run time
was approximately twelve minutes. The decomposition products were
then analyzed.
[0149] This experiment produced 1.2 gallons of #4 oil (see Tables 1
and 2), 7.5 lbs of carbon black, 50 cu. ft. of combustible gases
(including methane, ethane, propane, butane, and isobutene), and 2
lbs of steel. FIGS. 9A-9C depict electron microscope photographs of
samples of carbon black produced using this method. FIG. 9C
demonstrates that the carbon black produced by this method is
comparable to commercial-grade rubber black.
TABLE-US-00001 TABLE 1 Analysis of Oil Produced by Example 3. TEST
RESULT Gross Heat of Combustion 18308 BTU/lb Gross Heat of
Combustion 144688 BTU/gal Sulfur 0.931 wt. % Kinematic Viscosity @
122.degree. F. 9.773 cSt Saybolt Furol Viscosity @ 122.degree. F.
78.9 sus Sediment by Extraction 0.02 wt. % Ash @ 775.degree. C.
0.024 wt. % Nitrogen 0.43 wt. % Samples were tested by ITS Caleb
Brett, Deer Park, TX. Samples were filtered through a 100 mesh
filter prior to testing.
TABLE-US-00002 TABLE 2 Analysis of Oil Produced by Example 3 TEST
RESULT Corrected Flash Point 92.degree. C. Corrected Flash Point
198.degree. F. API Gravity 15.56.degree. C., 60.degree. F.
13.7.degree. API Samples were tested by ITS Caleb Brett, Deer Park,
TX.
Example 4
[0150] A sample of oil cuttings, oil shale, tar sands, oil sands,
slurry oil, and/or a material contaminated with petroleum-based
materials, is placed in the apparatus of Example 2. The pressure is
reduced to 20 Torr. Microwave radiation is applied to the sample
for a time sufficient to vaporize all the petroleum-based material
in the sample. At 20 Torr, the petroleum-based materials vaporize
between about 400 and 520.degree. F. The vaporized petroleum-based
materials are cooled and collected in a collection vessel. The
material remaining in the chamber is substantially free of
petroleum-based material.
Example 5
[0151] A plastic bottle was placed in the apparatus of Example 1
and exposed to microwave radiation. The exposure to microwave
radiation resulted in complete vaporization of the bottle and
recovery of petroleum-based materials.
[0152] When ranges are used herein for physical properties, such as
molecular weight, or chemical properties, such as chemical
formulae, all combinations, and subcombinations of ranges for
specific embodiments therein are intended to be included.
[0153] The disclosures of each patent, patent application, and
publication cited or described in this document are hereby
incorporated herein by reference, in its entirety.
[0154] Those skilled in the art will appreciate that numerous
changes and modifications can be made to the preferred embodiments
of the invention and that such changes and modifications can be
made without departing from the spirit of the invention. It is,
therefore, intended that the appended claims cover all such
equivalent variations as fall within the true spirit and scope of
the invention.
* * * * *