The present invention relates to a device for transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains.

In the field of transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains it is known that elastomers and polymers are not efficient as heat conductors and therefore it has been necessary to operate directly within the mass so that the outermost region does not need to be heated a lot beyond the limit in order for the core to reach the minimum temperature for dissolution of molecular bonds.

In greater detail, the energy required to break the bonds of the long molecular chains is applied by acting mechanically directly on the matter to be degraded, so as to achieve the dual effect of limiting the thermal energy and of containing the temperature rise below a set threshold by integrating the thermal energy required to complete the process.

Thermomechanical apparatuses of the known type suitable for the transformation of organic matter are not free from drawbacks, which include the fact that they do not produce in constant quantities and with constant quality.

One of the important factors is also, but not exclusively, the loss of viscosity of high molecular weight matter, which results in an energy loss since it is necessary to supply additional energy that is not exclusively mechanical, and produces an unwanted rise in operating temperature as a side effect.

A further drawback of thermomechanical apparatuses of the known type resides in that by operating at high temperatures they are unable to produce high-quality intermediate products (hydrocarbons).

In fact, once a specific temperature threshold is exceeded, the amount of condensable hydrocarbon is reduced in favor of low molecular weight compounds (gaseous in standard conditions) with a concomitant deterioration in the quality of condensables (where double and triple bonds are widely present) that have a high specific gravity (up to 0.98 kg/1) that is unfavorable for subsequent uses.

A final drawback of thermomechanical apparatuses of the known type resides in that they are unable to vary in real time, while the process is in progress, all and/or individually the operating parameters; in fact, they cannot manage the relative dimensions and/or positions of the components that are active in the process, i.e., it is not possible to modulate the operating conditions of the system by acting on each component independently, seamlessly, during the molecular dissociation process.

The aim of the present invention is to provide an apparatus for transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains that can overcome the drawbacks noted above.

Within this aim, an object of the present invention is to provide a device capable of converting solid matter with high molecular weight or with long/complex molecular chains into liquid and gaseous hydrocarbons or into organic matter with low molecular weight in addition to a possible carbon-containing solid, reaching the energy threshold required to complete the degradation process of all of the matter to be degraded, by providing the device, for the same or greater quantities and better quality of degraded matter, with less energy than that used in the background art.

Another object of the present invention is to provide an apparatus that is capable of giving the greatest assurances of reliability and safety in use.

A further object of the present invention is to provide an apparatus that can be provided with per se known technologies and thus has low provision costs and economical operation on the basis of the lower energy consumption for an equal result.

This aim, as well as the objects mentioned and others that will become better apparent hereinafter, are achieved by a device for transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains, characterized in that it comprises:

- one or more feeders adapted to receive granulated organic matter from a densification station;

- an intake chamber which operatively communicates with said one or more feeders in order to receive said organic matter, said intake chamber being provided with first means for the compression and advancement of said organic matter along a predefined advancement direction;

- a conveyance tunnel which operatively communicates with said intake chamber in order to receive said organic matter and is provided with second means for the compression and advancement of said organic matter along said predefined advancement direction;

- a degradation chamber which operatively communicates with said conveyance tunnel and is delimited by two mutually opposite rotors for the degradation of said organic matter.

Further characteristics and advantages of the invention will become better apparent from the description of a preferred but not exclusive embodiment of a device for transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains, illustrated by way of non-limiting example with the aid of the accompanying drawing, wherein the only figure is a schematic view of the apparatus according to the invention.

With reference to Figure 1, the device for transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains, generally designated by the reference numeral 1, can be inserted in an apparatus for transformation by degradation of solid organic matter with long molecular chains into fluid and/or solid organic matter with short molecular chains.

In greater detail, the apparatus can comprise a plurality of sections as follows:

- a first section for the selection and mixing of organic matter, optionally heterogeneous in terms of chemical composition, density and size;

- a second section for volumetric reduction and mixing of the filler;

- a third section for densification at a medium temperature of the matter, which is integrated with, but optionally separable from, the mixer;

- a fourth section for volumetric homogenization/granulation of the densified matter;

- a fifth section for the accumulation and cooling of the granulate;

- a sixth section for the mixing of the granulated organic matter, of the mechanically dosed additives and the feeding of the degradation station;

- a seventh section for thermomechanical degradation of the organic substance, provided with the device according to the present invention;

- an eighth section for separation of the fluid and solid fractions that derive from the degradation process;

- a ninth section for cooling the obtained solid fraction and the solid additive;

- a tenth section for the separation/recovery of the additive and its bagging;

- an eleventh section for bagging the solid intermediate product derived from the degradation of the organic matter;

- a twelfth section for the condensation of the organic fluid with short molecular chains derived from the dissociation;

- a thirteenth section for the separation of the gaseous and liquid fractions in standard conditions.

Conveniently, the device 1 can receive the organic matter to be degraded treated as just described or by other systems equivalent in performance, from the first section to the fourth section, and dried and cooled in the fifth section.

According to the invention, the device comprises one or more feeders 2, for example variable speed feeders, adapted to receive granulated organic matter from a densification station; an intake chamber 3 operatively communicating with the feeders 2 to receive the organic matter and provided with first means 4 for the compression and advancement of the organic matter along a predefined advancement direction; a conveyance tunnel 5, operatively communicating with the intake chamber 3 to receive the organic matter and provided with second means 6 for the compression and advancement of the organic matter along said predefined advancement direction and a degradation chamber 7 operatively communicating with the conveyance tunnel 5 and delimited by two mutually opposite rotors 8 and 9 for the degradation of said organic matter.

Advantageously, the feeders 2 are provided with means for mixing one or more liquid and/or solid additives and comprise worm screws for advancing the organic matter in the direction of said intake chamber.

Such mixing means allow each additive to be dosed and to distribute the additives evenly within the organic matter to be degraded.

Moreover, the profiles of their worm screws and the machining of their internal chambers are functional to ensure that the mixture reaches the end of conveyance tunnel 5, i.e., at a distribution unit 10, without the organic matter to be degraded and the additives, could segregate or separate from each other.

Thus, the intake chamber 3 collects the flows of long-chain solid organic matter and any additives.

Additionally, the feeders 2 are provided with cooling means to control and manage the temperature of the organic matter and are provided with means for draining humidity, possibly separated in the organic matter compression step, and with extraction means to extract the air retained in the organic matter.

Conveniently, a unit 11 for discharging the air and humidity respectively collected by the extraction and drainage means is provided.

Such discharge unit 11 operatively communicates with the conveyance tunnel 5.

In greater detail, the intake chamber 3, which can be integrated with the conveyance tunnel 5, is shaped and sized so as to prevent interference between the flows arriving from the feeders 2, and there is also a connection to the drainage means and extraction means of the feeders 2 so as to also remove the residual fractions of humidity and air conveyed to the discharge unit 11.

In greater detail, the first compression and advancement means 4 and the second compression and advancement means 6 comprise single- and multiple-start worm screws, respectively.

Moreover, the conveyor 6 can operate at a variable speed and the rotation rate can be varied continuously to be the shaft that is driven independently with respect to any other component of the device, in order to optimize the process of compressing the matter without causing the variation of the feed rate of the matter to be degraded to the decomposition chamber. In fact, the flow rate of the matter to be degraded is delegated to the distribution unit 10.

The specific shape of the interface between the first compression and advancement means 6 and the distribution unit 10 also allows to produce a vibration that the second compression and advancement means 6 transmit to the mass to be degraded without directly affecting other moving parts.

The worm screw forming the second compression and advancement means 6 can have an increasing number of starts (or even a decreasing one, in the sections that compose it); the rotation rate is variable and a pulse of modulable amplitude and intensity can be imparted.

The purpose is to achieve uniform compression of the organic matter in order to allow optimal feeding of the distribution unit 10 and to eliminate any interstitial air and humidity that might still be present/residual and will be extracted and conveyed into the discharge unit 11, where they will be collected and separated for subsequent handling and treatment.

Conveniently, there is a radial distribution pre-chamber 12, fed by the distribution unit 10, which communicates with the degradation chamber 7 and is located upstream of the latter along the predefined advancement direction.

The distribution unit 10 is provided with a frustum- shaped sector 13 which is integral with the stator of the degradation chamber and comprises third compression and advancement means 14, constituted by a single- or multiple-start worm screw with a frustum-shaped profile, which is integral in rotation with the rotor 9.

Advantageously, the third compression and advancement means 14 of the distribution unit 10 also operate by rotating in the opposite direction with respect to the second compression and advancement means 6 of the conveyance tunnel 5 in order to facilitate the introduction of the organic matter in the distribution pre-chamber 12 and determine the amount of organic matter to be introduced in the degradation chamber 7.

In greater detail, the long-chain molecular structure of the organic matter, up to the output of the distribution unit 10, is essentially unchanged chemically but has undergone a first temperature increase, resulting in softening by losing up to 75 % of viscosity.

The organic matter is then introduced in the degradation chamber 7 delimited by the two mutually opposite rotors 8 and 9, which can also rotate in phase opposition, i.e., in a mutually counter-rotating manner. In the degradation chamber 7 the organic matter is first subjected to a combined mechanical energy transfer action of compression of the substance and friction performed by the moving parts as well as the substance on itself, resulting in the sudden increase in temperature and the loss of residual viscosity.

The surface shape and the dimensions of the degradation chamber 7 produce the transition of the organic matter from the solid phase to the fluid phase due to the combined effect of the rise in temperature of the mass caused by friction and the incremental peripheral velocity of the counterrotating flat disks and the entrainment effect (friction by the mechanical effect of the sliding of the mass against the mutually opposite flat surfaces of the disks and of the matter on itself).

Advantageously, there is a toroidal flow deflector 15, which delimits peripherally the degradation chamber 7 together with the mutually opposite rotors 8 and 9.

More specifically, the flow deflector 15 is accommodated in a compensation chamber 16 interposed between the degradation chamber 7 and a subsequent decompression and collection chamber 17 for the degraded matter.

In the present embodiment, the degradation chamber 7 is composed of two successive areas that have a cross-sections that is variable and decreases, optionally seamlessly, up to the outer perimeter where the flow deflector 15 is located.

Such deflector, which depending on the embodiments may have a profile that is fixed or variable in the radial, transverse or radial and transverse dimensions simultaneously, separates the degradation chamber 7 from the compensation chamber 16.

Conveniently, the deflector 15 can be provided with a toroidal shape, even with a variable transverse cross-section to reduce the kinetic energy of the degrading matter.

The two mutually opposite rotors 8 and 9 are provided with a contoured disc geometry and have profiles and surfaces that are machined to maximize the process of friction for thermal energy production (first section) and propulsion (second section) to impart to the organic matter to be degraded the kinetic energy necessary for the complete degradation of the long carbon chains into short chains.

The substance in the fluid phase allows the system of mutually opposite rotors 8 and 9 to supply new energy, significantly increasing the velocity of the fluid and causing its impact against the moving and stationary elements.

The increase in energy results in a further significant temperature rise in the organic matter, but this is localized and does not increase significantly the temperature of the entire degraded mass, so as to comply with the threshold limit set at 400°C while ensuring completion of the degradation process.

The energy is released into the fluid mass - which is already close to the degradation temperature and largely degraded - by the impact with the surfaces of the impellers of the mutually opposite rotors 8 and 9 but especially against the flow deflector 15; the energy generated in the mass of the substance to be degraded by the high-speed impact against the deflector allows to complete the degradation of the thermomechanical process extended to the entire mass of substance to be degraded, containing the temperature of the apparatus and of the substance, overcoming the limitations of viscosity loss, which in known systems is an unresolved or severely limiting condition.

The rotation rate, the direction of rotation, the distance between the mutually opposite rotors 8 and 9, the profile and the dimensions of the deflector 15, or the axial size of the degradation chamber 7, and other operating parameters, such as the amount of matter to be degraded fed into the degradation chamber, can be varied "continuously", i.e., without interrupting the degradation process or the feeding of the substance to be degraded, which, as mentioned above, is performed without discontinuities.

The profile of the degradation chamber 7, the shape of the surfaces and the calibration of the speed allow to saturate the entire chamber and accelerate the matter to be degraded in the central and peripheral portion of the surface of the mutually opposite rotors 8 and 9.

The rise of the temperature of the mass to the expected level, achieved by friction and supplemented by the transformation of the kinetic energy resulting from the laminar motion imparted to the fluid substance, i.e., by its impact against the surfaces of the rotating disks 8 and 9 and against the deflector 15, produces the fractioning of the solid matter with long molecular chains into fluid matter with short molecular chains and solid carbon-containing compound.

The degradation process is controlled by continuously adapting three operating parameters that allow to minimize the retention time of the matter in the degradation chamber 7 : relative rotation direction and rotation rate of the mutually opposite rotors 8 and 9, degradation chamber width (i.e., wall distance between the mutually opposite rotors 8 and 9), and flow rate adjustment by combining the feed flow of the feeder 10 and the flow of short molecular chain fluid matter through the flow deflector 15.

The fully degraded matter transits in the compensation chamber 16, where the velocity of the fluid is reduced due to the concomitant increase in cross section and the lack of further energy input, and is thus collected in the decompression chamber 17, which due to the shape, dimensions and characteristics of the surface allows to perform an already differentiated - though still not contamination-free - collection of the solid and fluid fractions.

In other words, the device 1 subverts the problem of viscosity loss, which is still a point of extreme criticality for known type apparatuses, by seeking acceleration of viscosity loss to rapidly obtain fluid matter and allow laminar motion induced by the rotating disks. The shape of the mutually opposite rotors 8 and 9 (which advantageously can be rotating flat disks), whose surfaces are machined with profiles and cavities that allow to maximize the transfer of mechanical energy and impart high velocity to the partially or totally degraded matter, associated with the possibility to vary dynamically and independently its direction of rotation, rotation rate and interstitial distance, allows to apply energy to a reduced mass with respect to the surface unit.

The reduced ratio of mass to active surface area makes it possible to reduce the energy applied to the moving elements (exogenous energy) without altering the amount of energy transferred by the rotors 8 and 9 to the matter to be degraded.

The favorable surface-to-mass ratio ensures a sudden and, above all, homogeneous temperature rise of the entire mass of the substance to be degraded, improving the homogeneity of the intermediates obtained from degradation and reducing the exogenous energy required by the device. The kinetic energy is complementary to the thermal energy induced by friction and is necessary for the complete degradation of the high molecular weight matter; the kinetic energy is imparted by the interaction of the surfaces of the mutually opposite rotors 8 and 9, shaped for this purpose, with the fluid matter and leads to propel it toward the flow deflector 15 and the decompression and collection chamber 17.

The significant outputs of this process are:

- hydrocarbon rich gas with up to six carbon atoms;

- fuel oil;

- solid carbon-containing residue.

In essence, the device according to the present invention associates the mechanical energy, necessary to induce temperature rise and loss of viscosity (a condition which is sought and not suffered), with the kinetic energy that on impact (with the deflector or other surface), provides in a localized manner (i.e., not applied to the entire mass to be degraded) the energy necessary for the completion of the degradation process, limiting the temperature in the matter and in the device.

In practice it has been found that the device according to the present invention fully achieves the intended aim and objects, in that it enables the transformation of solid organic matter with long molecular chains/high molecular weight into organic matter of lower molecular weight by performing the degradation by thermomechanical means in an adiabatic system, without external thermal inputs, feeding the degradation station with a flow of matter without discontinuities; moreover, degradation is achieved without emissions, i.e., in the absence of contamination of the environment.

In fact, the device according to the invention consists in supplying the matter to be degraded with thermal energy by means of the combined processes of friction and kinetic energy, where the latter translates into thermal energy due to the impact of said matter with the mechanical elements; producing a "turbulent" motion is essential to make even that fraction of matter that has not decomposed "by friction" reach the energy threshold; without "impacts", the mechanical elements are less effective in transferring energy when loss of viscosity of organic matter occurs; the invention overcomes the limitation inherent in previous solutions that use the thermomechanical method for the degradation of organic matter; known systems lose efficiency and effectiveness upon the sudden loss of viscosity as the temperature of the matter being degraded increases and cannot rely on the contribution provided by the sudden dissipation of kinetic energy.

Another advantage of the device according to the present invention is to perform a transformation method in a confined environment and in the absence of air, in order to limit the formation of oxidized oxygen and nitrogen compounds by extracting upstream all the air and humidity that might, at the decomposition temperatures, interact and form unwanted compounds; the elimination of air and humidity also prevents the dilution of the non-condensable fraction, i.e., of the gaseous fraction of the hydrocarbon produced.

Moreover, other advantages of the device according to the present invention consist of being able to:

- perform molecular dissociation by operating at a temperature of about 400 °C or lower,

- operate in the absence of thermo-oxidative processes (direct combustion or combustion for energy support to the process),

- not produce contamination of the environment.

Moreover, only the degraded fraction is sent to the subsequent condensation/separation/liquefaction (gas)/storage steps; the non-degraded parts are instead sent back to the feeders for a subsequent degradation process.

Unlike the background art, in the present invention the "active" elements are "flat" disks.

The degradation chamber is contained within the rotors 8 and 9 and the deflector 15, and the matter to be degraded does not come into contact with the casing.

The movement of the material occurs due to the application, to the matter to be degraded, of a centrifugal force (the disks 8 and 9 act like the impellers of a pump), so as to impart a high velocity to all of the matter, causing it to impact against the variable-profile deflector 15.

The deflector 15, which like the disks is movable/variable in size, contributes to changing the profile of the decomposition chamber.

Also for the deflector as well as for the discs, the profile/geometry can be varied continuously during operation, in a fully automatic manner; the management of these profile changes is entrusted to a PLC which performs the variations according to the parameters detected by the sensors to maintain optimal operating conditions without process interruption.

The device thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the accompanying claims.

All the details may furthermore be replaced with other technically equivalent elements. In practice, the materials used, so long as they are compatible with the specific use, as well as the contingent shapes and dimensions, may be any according to the requirements and the state of the art.

The disclosures in Italian Patent Application No. 102021000027416, from which this application claims priority, are incorporated herein by reference.

Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.