MECO ENVIRONMENTAL LLC (1233 Nw 12th Avenue, Suite 200Portland, OR, 97209, US)
| CLAIMS
What is claimed is:
1. A system for remediation of a waste material is provided, the system comprising: an indirect desorption unit having an inner barrel and an outer chamber; an plurality of platco valves that are pneumatically operated in opposing fashion as to preserve negative airflow; an off-gas conditioning mechanism; a quench mechanism; and a thermal oxidizer;
2. The system of Claim 1 wherein the indirect desorption unit has an inner barrel and an outer chamber wherein the inner barrel has a conveyer system to transport waste materials therein.
3. The system of Claim 1 wherein the indirect desorption unit has an inner barrel and an outer chamber wherein the outer chamber is a heating chamber with a plurality of heating elements.
4. The system of Claim 1 wherein the indirect desorption unit has a inner barrel surrounded by an outer heating chamber wherein the inner barrel may rotate within the surrounding outer heating chamber.
5. The system of Claim 1 wherein gases produced in the inner barrel and kept separate from gases in the outer chamber.
6. The system of Claim 1 wherein the system may accommodate a plurality of different waste products,
7. The system of Claim 1 wherein the system may re-mediate contaminant levels up to 20% hydrocarbons or more.
8. The system of Claim 1 wherein the system minimizes air in-leakage into the system.
9. The system of Claim 1 wherein the platco valves are pneumatically operated and open and close in opposite patterns thereby minimizing air entry into the desorption unit.
10. The system of Claim 1 further comprising: a conditioner having a plurality of spray nozzles therein.
11. The system of Claim 10 wherein the conditioner nozzles are utilized to displace and dislodge particulate from the waste products after exit from the desorption unit.
12. The system of Claim 1 wherein the off-gas system allows for condensation of any gas contaminant for collection of volatized contaminants and polishing of same.
13. The system of Claim 1 wherein the off-gas system collects contaminants but does not destroy them thereby eliminating environmental pollution by the contaminants.
14. The system of Claim 1 further comprising: a cyclone system whereby the cyclone further removes contaminants with the use of velocity and specific gravity.
15. The system of Claim 1 wherein the quench system has a quench chamber whereby off- gasses may be combined with water to cool gases.
16. The system of Claim 1 wherein said quench system separates the incoming products into either a liquid state or a gaseous state.
17. The system of Claim 1 further comprising: a centrifuge system to handle materials exiting the quench system.
18. The system of Claim 11 wherein the centrifuge system may be utilized to treat contaminants and be utilized to feed the desorption unit with a fuel source.
19. The system of claim 1 wherein the thermal oxidizer is located at the end of the remediation system.
20. The system of Claim 1 wherein the thermal oxidizer heats the off-gasses to eliminate any by-products or contaminants.
21. The system of Claim 1 wherein the thermal oxidizer ' returns heated by-products to be used as heating elements in the desorption unit. |
PROCESS FOR THE RECOVERY OF OIL FROM A CATALYST Cross Reference to Related Application
This application claims priority to U.S. Provisional Application No. 61/060,743 filed on June 11, 2008, which is hereby incorporated by reference in its entirety. Field of the Invention
The present invention relates generally to the treatment of waste material to recover a byproduct. More specifically, the present invention relates to a process for treating a waste product to recover waste oils and use same as feed stock.
Background of the Invention In the industry of oil refineries and other petroleum based facilities, one of the many issues faced is the disposal and removal of sometimes hazardous and large quantities of waste material such as oil sludge and other byproducts. These waste materials are typically dumped into lai-ge holding receptacles and taken to a disposal site for evacuation and holding. These waste materials and other by-products are sometimes classified as hazardous wastes, and therefore must be treated with special handling and care. Moreover, because of their special classification, the handling of such materials is often more difficult and costly than other types of non-hazardous materials.
One of the most common ways to dispose of waste materials is to use different strains of bacteria which are capable of decomposing the waste materials and leave a by-product that may be reusable. One of the many problems with this type of waste disposal and recovery is that the bacteria is only capable of breaking down certain compounds and will often leave many different compounds behind because of their inability to break down certain materials. For example, many metals are left in the waste material because bacteria is unable to break them down. These metals can still be very dangerous and pose problems in the surrounding environment. Additionally, the recovered by-products are not recovered and recycled, but rather are shipped to another location where they may be stored.
There are several waste material recyclers, many use the refinery waste and recycle oil sludge and the like.
There are many different prior art references that deal with refinery waste and the removal and treatment of oil sludge and the like. For example, United States Patent Number: 3,791,965 issued to Fitzsimons et al., discloses a process for re-fining and treating used petroleum products. The process disclosed in Fitzsimmons et al., utilize a crank case oil and transmission fluid that is collected at specified locations, whereby the process is only capable of handling a raw feed stock of used liquid petroleum products with a viscosity ranging between that of mineral spirits to about SAE 60 weight oil, which is the method used for determining the viscosity of essentially solids-free liquids. The process handles only solids of small particle size and therefore, solids in excess 100 mesh (105 microns) must be removed prior to treating the feed stock.
United States Patent Number: 3,923,643 issued to Lewis et al., discloses a process for purification of specified waste materials, more specifically, used hydrocarbon lubricating oil, and is directed to the removal of suspended lead and other dispersed solids from used lubricating oil. However, the Lewis et al. patent process is not capable of handling feed stocks containing more than minimal amounts of solids and other types of waste products and is limited in its ability to recover any usable by-product.
There are other prior art references that teach processes for treatment of contaminated oil based products, but many are very specific volatilizing light oils and water only, and the organic solids residue removed by filtration from the remaining heavy oil is combusted for reheating oil, treated in the process leaving no unburned matter.
Further, there are several other prior art references such as United States Patent Number: 4,512,878 issued to Reid, et al. that teach reclamation of used lubricating oils and treatment of other types of hydrocarbons. However, all these prior art references are limited in their scope and do not teach a system for treating waste materials such that a significant recovery is made of beneficial by-products. Nor do any of these prior art references teach or suggest a process and system that may recover by-products at the point of original refinery.
However, a need still exists for an improved system and method for treating waste materials for recovery of oil by-products that may be recovered and utilized as feed stock and/or other purposes. Additionally, a need still exists for an improved system and methods for treatment of waste materials which maybe done at the point of recovery of the waste products
instead of shipping the waste product to a remote location. Further, a need still exists for an improved system and method for treatment of waste materials which has limited and/or no effect on the surrounding environment. Still further, a need exists for a system and a method for treatment of waste products whereby the resulting waste products exiting the system are water- free and oil-free solids which may be nonhazardous when tested in accordance with EPA toxicity test procedures, and therefore are suitable for disposal in a conventional sanitary landfill and/or are completely eliminated prior to exiting the system. Additionally, a need exists for a system and method that recycles all the elements such as water used in the process to minimize use of additional materials in the system. Summary of the Invention
The present invention relates to the remediation of contaminated soils and media utilizing a system and a method for producing a waste product. More specifically, the present invention relates to the recovery of secondary materials such as contaminated media, by-products and the like that are generated during refinery process. The by-products are refined, separated and a resulting recovery product is obtained using the proprietary waste recovery system. It is contemplated that the waste products will result in the recovery of oily material that may be collected and/or utilized in feed stock. The present invention utilizes an indirect thermal desorption unit having a unique feed system to separate the contaminates to produce the end product. To this end, in an exemplary embodiment of the present invention, a system for remediation of a waste material is provided. In an exemplary embodiment, the system has an indirect desorption unit having an inner barrel and an outer chamber; an plurality of platco valves that are pneumatically operated in opposing fashion as to preserve negative airflow; an off-gas conditioning mechanism; a quench mechanism; and a thermal oxidizer. In another exemplary embodiment, the system has a indirect desorption unit wherein the indirect desorption unit has an inner barrel and an outer chamber wherein the inner barrel has a conveyer system to transport waste materials therein.
In another exemplary embodiment, the system has a indirect desorption unit wherein the indirect desorption unit has an inner barrel and an outer chamber wherein the outer chamber is a heating chamber with a plurality of heating elements.
In another exemplary embodiment, the system has a indirect desorption unit wherein the indirect desorption unit has a inner barrel surrounded by an outer heating chamber wherein the inner barrel may rotate within the surrounding outer heating chamber.
In another exemplary embodiment, the system has a indirect desorption unit having an inner barrel and an outer chamber wherein gases produced in the inner barrel and kept separate from gases in the outer chamber.
In an exemplary embodiment, the system may accommodate a plurality of different waste products.
In an exemplary embodiment, the system may re-mediate contaminant levels up to 20% hydrocarbons or more.
In an exemplary embodiment, the system may minimizes air in-leakage into the system.
In an exemplary embodiment, the system may have valves wherein the platco valves are pneumatically operated and open and close in opposite patterns thereby minimizing air entry into the desorption unit. In an exemplary embodiment, the system may further have a conditioner having a plurality of spray nozzles therein.
In an exemplary embodiment, the system may have a conditioner wherein the conditioner nozzles are utilized to displace and dislodge particulate from the waste products after exit from the desorption unit. In an exemplary embodiment, the system may an off-gas system wherein the off-gas system allows for condensation of any gas contaminant for collection of volatized contaminants and polishing of same.
In an exemplary embodiment, the system may have an off-gas system wherein the off-gas system collects contaminants but does not destroy them thereby eliminating environmental pollution by the contaminants.
In an exemplary embodiment, the system may have a cyclone system whereby the cyclone further removes contaminants with the use of velocity and specific gravity.
In an exemplary embodiment, the system may a quench system wherein the quench system has a quench chamber whereby off-gasses may be combined with water to cool gases.
In an exemplary embodiment, the system may have a quench system wherein said quench system separates the incoming products into either a liquid state or a gaseous state. In an exemplary embodiment, the system may have a centrifuge system to handle materials exiting the quench system.
In an exemplary embodiment, the system may have a centrifuge system wherein the centrifuge system may be utilized to treat contaminants and be utilized to feed the desorption unit with a fuel source. In an exemplary embodiment, the system may have a thermal oxidizer that is located at the end of the remediation system.
In an exemplary embodiment, the system may have a thermal oxidizer that heats the off- gasses to eliminate any by-products or contaminants.
In an exemplary embodiment, the system may have a thermal oxidizer that returns heated by-products to be used as heating elements in the desorption unit.
It is therefore an objective of the present invention to provide an end product whereby the end product is retrieved through the process of separating secondary materials from a contaminate.
In another exemplary embodiment of the present invention, an end product is produced whereby the end product is at least an oily material.
In still a further exemplary embodiment of the present invention, an end product is produced whereby the end product is at least a refinery oil and/or at least an oil and/or grease component.
Yet another exemplary embodiment of the present invention is to provide a product which is retrieved from a refinery process secondary material.
Still another exemplary embodiment of the present invention is to provide an end product whereby the end product is at least an oil and further wherein the oil product is accumulated and used as feed stock.
In a further exemplary embodiment of the present invention, an indirect fired thermal unit is provided whereby the unit has at least a heating chamber whereby material is fed into the heating chamber to desorb the contaminates placed therein.
Another exemplary embodiment of the present invention is to provide an end product whereby the product is produced by utilizing a heating chamber whereby the heating chamber exhausts gases and off-gases that do not contact the contaminated material contained within the chamber.
In another exemplary embodiment of the present invention, an end product is provided whereby the end product may be organic contaminants including all regulated compounds, ranging from PAHs to Volatile organic compounds (known as VOCs) as well as oils and petroleum products.
Yet another exemplary embodiment of the present invention is to provide an end product from a refinery process whereby the invention provides at least a thermal desorption unit having at least an inner chamber containing the contaminants and an external chamber whereby the external chamber is heated, and further whereby the burners in the external chamber are utilized to desorb contaminants.
In still another exemplary embodiment of the present invention, an end product is produced utilizing the system embodied herein, the thermal desorption utilizes a feed system.
Still another exemplary embodiment of the present invention is to provide an end product whereby the system utilizes a thermal desorption unit and the unit utilizes a feed system whereby the feed system may be a conveyer belt, a shaker unit and a centrifuge process.
Another exemplary embodiment of the present invention is to provide an end product whereby the system utilizes a heating system whereby the materials entering the heating system may be moist and an auger system may be utilized. The thermal heat system may also have a recovery capability and emissions control devices.
In another exemplary embodiment of the present invention, a system for remediation of contaminates is provided whereby an oven and/or rotating barrel may be set up whereby material is fed into the oven. The oven may rotate depending on the retention time necessary for the materials input into the system.
Yet another exemplary embodiment of the present invention is to provide a system for retrieval of waste products, the system including at least a heating system having an inner rotating barrel which may be constructed of nickel-chromium alloy that can support temperatures in excess of 2000F. In another exemplary embodiment of the present invention, a system and method for retrieval of waste products is provided, the system having a rotating heating barrel, the barrel may be operated under negative pressure to ensure that volatilized contaminants are not released as emissions.
Still another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having a burner system inside the heating barrel.
Another exemplary embodiment of the present invention is to provide a system and a method for retrieval of waste products, the system having an adjustable burner system that provides heat to the outside rotating barrel by a bank of burners in the surrounding heating chamber.
Yet another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having a conditioner unit whereby the material that exits the heating barrel is subjected to a conditioner which sprays away dust and contaminants from the waste material traveling therethrough. Yet a further exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having an exhaust fan to create negative airflow throughout the entire system.
Still another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having an off-gas conditioning system whereby particulate is removed from the material exiting the heating barrel.
A further exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system further having an off-gas treatment system which is a recovery style system whereby gases recovered are not destroyed, but rather recycled and used within the system.
Another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having seals and mechanical airlocks that are utilized to minimize the amount of air leakage.
In another exemplary embodiment of the present invention, it is contemplated that a system and method for retrieval of waste products may be provided whereby the system may have a cyclone system whereby particulate from the waste products may be separated in the cyclone and evacuated from the system.
A further exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system providing a quench chamber. Yet another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having a quench chamber whereby the quench chamber is where the off-gas and water combine for cooling. The off-gas entering the quench chamber is combined with water and cooled to turn back into its original state.
Still another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having a quench chamber whereby upon exiting the quench chamber, two liquid streams and one solid stream is provided, including at least one being an oil material.
In yet another exemplary embodiment of the present invention, a system and method for retrieval of waste products, the system having an oil and water separator unit which separates the liquid from the quench chamber into a water portion and an oil portion.
Still a further exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system having at least a centrifuge system that is installed downstream of the oil and water separator. The centrifuge maybe utilized to centrifuge oil, water and solids from one another. According to another aspect, the present invention comprises a system and method for retrieval of waste products, the system may have a secondary water treatment system.
In another exemplary embodiment of the present invention, a system and method for retrieval of waste products may be provided, whereby the system may have a secondary water
treatment system whereby the water that exits the oil and water separator is relatively clean but may be polished to enter back into the quench chamber to be reused in that system.
Still another exemplary embodiment of the present invention is to provide a system and method for retrieval of waste products, the system may have a packed bed that removes off-gases that survive the quench chamber. The packed bed is a secondary treatment for the off-gases that leave the heating chamber/barrel.
Yet another exemplary embodiment of the present invention is to provide a system and a method for retrieval of waste products, the system having a demister which cools the air stream and removes most of the moisture from the waste product material. Another exemplary embodiment of the present invention is to provide a system and a method for retrieval of waste products, the system having a thermal oxidizer that may destroy any remaining off-gasses to control emissions from the system.
Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
Brief Description of the Drawings
Figure l is a flow chart showing one exemplary method of a production cycle of indirect oily waste plant of the present invention. Figure 2 is a flow chart showing one exemplary method of a production cycle of direct fired calciner PFD of the present invention.
Detailed Description
As illustrated in the figures, according to at least one aspect of the present invention, a system for retrieval of an end material from waste products is provided. The system 1 comprises a plurality of sublayers and sub-systems which may act in accord to provide the desired end product. It is contemplated that the end product is an oily material, such as refined oil. However, it should be contemplated that the desired end product may be a catalyst, sludge, oily material and the like. As illustrated in Figure 1, the system may have at least an indirect fire thermal desorption unit (TDU). The TDU 3 unit may have at least a first inner rotating barrel 5 which
may be enclosed by a heating chamber 7. In an exemplary embodiment, the inner rotating barrel 5 may be completely enclosed by the heating chamber 7 and the heating chamber 7 may also be a fully contained receptacle whereby the inner rotating barrel 5 is not viewable by an outside user. Instead, the user would only see the heating chamber 7 unit. A waste material 9 which may be produced during normal refinery or other production may be discarded by the user. However, it may be desirable to recovery and recycle at least a portion of the waste material 9. In an exemplary embodiment, the waste material 9 may be continuously fed into the rotating inner barrel 5, which is indirectly heated by burners 11 in the surrounding heating chamber 7 to desorb contaminants 13 that may be contained on the waste material 9. The waste material 9 is typically inserted into the inner rotating barrel 5 where the heating of the waste material 9 causes many of the contaminants to be converted into gas. It should be understood that the heating chamber 7 exhaust gases are kept separate from the off-gases from the inner rotating barrel 5. These heating gases do not come in contact with the waste material 9 being processed by the system 1.
It should be understood that the indirect TDU unit 3 may be utilized by a plurality of different waste products. In an exemplary embodiment, organic contaminants amenable to processing in an indirect TDU 3 may include essentially all regulated compounds, ranging from PAHs to volatile organic compounds (VOCs), as well as oils and petroleum products. However, it should be understood that any potential waste product may be introduced into the system if a recovery product is available. The indirect TDU unit 3 is ideal for contaminated soils and cleanup residues because high production rates can be achieved regardless of the high contaminant levels in these waste materials 9. Contaminant concentration levels of up to 20% hydrocarbons or more can be processed. Because the indirect TDU 3 operates under an inert atmosphere and combustion of the waste is not contemplated, a high concentration of contaminants may be safely processed by the system 1 from waste materials 9. It is further contemplated that a plurality of different waste materials 9 may be processed and input into the indirect TDU unit 3. The waste materials 9 that may be contemplated include such materials as: soils, sediments, sludge, filter cake, debris, filter media, catalysts and similar solids. The feeding of waste material 9 into the indirect TDU 3 should optimally be controlled both prior to and during feeding of the waste material 3 into the TDU unit 3. Not only should the feed rate of the waste material 9 into the TDU 3 be controlled, but it would be advantageous to
the system 1 for air in-leakage to the system 1 to be minimized. Minimizing the air in-leakage may prevent burning of desorbed hydrocarbons from the waste materials 9.
Therefore, a specialized feed system 15 may be utilized that maybe used for a plurality of different waste materials 9 ranging from sand and gravel, cohesive "gumbo" clay to high viscosity oily sludge. It is contemplated that the control rate of the feed system 15 may be maintained without unsafe air in-leakage by the system 1. In an exemplary embodiment, it is contemplated that the feed system 15 may include at least a first feed subsystem 17, a second feed subsystem 19, and a third feed subsystem 21. The indirect TDU 3 may be fed utilizing any of the first, second or third feed subsystems 17, 19, and 21. The determination of the feed method is determined by the waste material 9 that is being fed into the system 1. In an exemplary embodiment, a conveyer belt 27 may be utilized to feed waste material 9 into the TDU unit 9 since the indirect TDU 3 may more easily accept a wide variety of different waste material 9 whereby the waste material 9 typically inserted into the TDU unit 3 is relatively dry and can easily travel upward on a belt. If the materials are moist and do not have high clay content, an auger system may be utilized (not shown). If the waste materials 9 are extremely wet, a pump (not shown) may be utilized to dry out the waste material 9 prior to entrance into the TDU unit 3. No matter what feed mechanism is utilized, all feed systems are totally enclosed and may have vapor recovery capabilities and emissions control devices.
As further illustrated in Figures 1 and 2, the waste material 9 that is fed into the TDU unit 3 is inserted into an inner heating chamber 7 or oven. The inner heating chamber 7 or oven has at least two functions. The housing 31 of the oven 7 is fit with the burner head attachments 33 with which the burners 35 are operated. The housing 31 also includes the stack 41 which exits the excess temperature created while heating the inner rotating drum 43. However, it should be understood that the system 1 may recycle the heat/temperature created during heating of the inner rotating drum 43. It is further contemplated that the stack 41 may be directed to other components in the processing system 1 to add heating value to those systems and/or may be redirected into the TDU unit 3 for use in heating the waste materials 9. It is contemplated that in an exemplary embodiment of the present invention, an indirect TDU 3 may have a plurality of burners 35. In another exemplary embodiment, it is contemplated that at least four to six burners 35 may be attached to the housing 31 and each burner 35 may have from 2.5 to 5 million BTU per hour capability. An example unit will operate with four burners 35 each at 2.5 million BTU's.
A burner train 51 may be indirectly connected to the housing 31 of the inner heating chamber 7 because the final step in the burner train 51 is the burner heads 53. The burner train 51 includes all safety devices, valves and piping necessary to operate the burners 35. The housing 31 may also has several thermal couple probes 53 located throughout in order to monitor the temperature within the housing 31 and the TDU 3.
The inner rotating barrel 7 may be constructed from a high nickel-chromium alloy that can operate in furnace temperatures approaching 2,000 0 F. The inner rotating barrel 7 may rotate between 0.5 and 3 revolutions per minute depending upon the required retention time. The retention time of a solid waste material 9 in the TDU 3 may be variable from 30 minutes to 105 minutes via a variable speed rotating barrel drive system. Retention times can also be varied through the use of different flight configurations within the rotating barrel. To increase heat transfer to the solids inside the barrel, there are mixing and turning flights that turn the bed of material within the drum and increase the heat transfer surface area. The housing 31 of the indirect TDU unit unite 3 is insulated with an insulation material 59 to save energy and to ensure the exposed housing 31 is safe for an end user working with the unit 3.
The inner rotating barrel 7 may also be operated under constant negative pressure to ensure that volatilized waste material 9 contaminants may not be released as fugitive emissions. Volatilized contaminants and other off-gases are directed through an off-gas conditioning system 61 to condense and collect volatilized hydrocarbons and other contaminants. As illustrated in Figures 1 and 2, the heat used on the inner rotating barrel 7 may be supplied to the outside portion 63 of the inner rotating barrel 7 by a bank of burners 35 in the surrounding heating chamber 65. The burners 35 are contemplated to be perpendicular to the inner rotating barrel 7, and the firing rate of the burners 35 may be adjusted individually and/or together in a group. This allows the operator to create either a fixed or stratified heating profile in the inner rotating barrel 35, depending upon the application.
Figure 2 also illustrates the waste material 9 exiting the TDU unit 3. When the waste material 9 exits the inner rotating barrel 7, the waste material 9 is discharged into a series of Platco valves 67. Platco valves 67 are valves that are pneumatically operated and open and close in opposite patterns so there is no air allowed into the inner rotary barrel 7. From the Platco valves 67 the waste material 9 enters into a conditioner 69 which is a large auger system with
several engineered spray nozzles 71 placed therein. It is contemplated in an exemplary embodiment, that the spray nozzles 71 may be placed every 14 inches from one another. The initial nozzles are engineered to knock down any dust from the exiting waste material 9 that have been remediated, and the nozzles 71 downstream are engineered to cool the waste material 9 prior to exiting the TDU unit 3. The conditioner 67 may be built with a heavy steel casing that encompasses the auger and also contains thermal couple slots 73 in order to monitor temperature. Additionally, an exhaust fan 75 may be utilized on the TDU unit 3 to create negative airflow throughout the entire system 1. The exhaust fan 75 may be located just after the quench chamber 79 and begins at the inner rotating barrel 7. There are several segments of ducting 81 that connect the exhaust fan 75 to the system 1 as illustrated in Figures 1 and 2. The exhaust fan 75 has a damper 85 which is controlled by the operator in the control room (not shown). The advantage of using the exhaust fan 75 is to pull air flow towards it which makes the entire system 1 negative airflow. hi an exemplary embodiment, the contaminants that may be volatilized from the waste material 9 that is processed in the inner rotating barrel 7 of the TDU unit 3 are then transferred to an off-gas conditioning system 91 where particulate from the waste material 9 may be removed. Additionally, the off-gas conditioning system 91 may allow condensation of any gas contaminant for collection of volatized contaminants and polishing of same prior to further processing. The off-gas treatment system 91 is a "recovery- style" air pollution control system, whereby the contaminants and particulate collected are not destroyed. It is contemplated that the off-gas treatment system 91 may be operated under constant negative pressure with the use of the exhaust fan 75 to ensure that volatilized contaminants are not released as fugitive emissions from the system 1. It is therefore contemplated that the system 1 may utilize a series of seals (not shown) and mechanical airlocks (not shown) to minimize the amount of leakage of any contaminants and/or gasses from the waste material 9 into the environment. The gas oxygen level in the system 1 may be monitored and maintained below a set criteria which is determined by the individual users. Once the contaminants have been recovered from the off-gas treatment system 91, the process gas stream is vented into the atmosphere below the required emission standard. As illustrated in Figures 1 and 2, after any particulate has exited the off- gas treatment system 91, any additional gases that exit the inner rotating barrel 7 may still have traces of
particulate included in the stream. The particulate may create separation difficulties if it is not removed prior to the quench system 79. The gas stream is then directed into a cyclone system 93 whereby it is removed by a combination of velocity and specific gravity. Particulates fall to the bottom of the cyclone system 93 and enter into a Platco system 68 which includes Platco valves 67 which as enumerated above, are a system of pneumatic valves that open and close on opposite strokes to ensure no outside air is brought into the system 1. The particulate exits the Platco system 68 and enters an auger system for evacuation. The waste material 9 may then be placed with the processed material for testing. While the particulate is dropping to the bottom of the cyclone system 93, the off-gas is continuing the path of the negative air pull. The cyclone system 93 may also act as a mechanism to begin cooling the off-gas air stream. It is contemplated that the air stream entering the cyclone system 93 may be roughly 900 degrees F. It is also contemplated that the gas air stream leaving the cyclone system 93 will be significantly cooler than when it entered the cyclone system 93.
As illustrated in the figures, the next phase of the off-gas conditioning system 71 is the quench system 79. The quench system 79 may consist of a quench chamber 95 whereby the off- gasses may be combined with water to cool the gas. As the gas entering the quench chamber 96 may still be at a high temperature, the elements may be in a vapor state. However, when the off- gases are combined with water, the effect of the water is to cool the gases and turn back the elements contained within the gas stream into their natural and/or original states. It is contemplated that the quench chamber 95 may combine a higher rate of water and the water is recycled water that was originally part of the off-gas stream. At the exit of the quench chamber 95, the off-gas becomes two liquid streams and one solid stream. In an exemplary embodiment, the first liquid stream 97 is from the contaminated product that was in the material and the second liquid stream 99 is moisture that was in the waste material 9, and the third stream 101 is the solids that were not removed in the cyclone system 93. The three streams 97, 99, 101 exit from the quench system 79 utilizing a diaphragm pump 103 and are moved to the next phase of separation.
Upon exiting the quench chamber 95, the three new streams that have been recycled to their natural states enter into a liquid separator 105. The liquid separator 105 is complete with a de-sludge unit 107, a skimmer 109 and an agitation unit 111. The first liquid stream 97 and
second liquid stream 99 enter mixed and then begin separating due to a series of screens and agitation. The first stream 97 floats to the top and the second liquid stream 99 remains on the bottom as the two liquid streams 97 and 99 have different viscosities. The first liquid stream 97 is skimmed as it floats to the top of the system 1 and then transferred to a nearby tank 113. The second liquid stream 99 and particulate that remains is transferred to another chamber 115 where the particulate is removed from the second liquid stream 99. The liquid separator 105 may be configured to handle large streams of liquids and may also be configured to handle solid streams 101 and the removal of same.
In an exemplary embodiment, it is contemplated that it may be advantageous to install a centrifuge 117 into the system 1. The centrifuge 117 may be inserted into the system 1 after the liquid separator 105. It is contemplated that a centrifuge 117 may be utilized when the TDU 1 is to be heated using recycled fuel or the fuel is to be sent to an outside source. The centrifuge 117 may have a three phase consistency, in which a First liquid 97, a second liquid 99 and a solid 101 may be separated and segregated through G-Forces. The second liquid stream 99 and/or the first liquid stream 97 may be directed to a liquid treatment system 119, and the separated first and/or second liquid stream 97, 99 maybe directed back to the liquid separator 105 where any solid 101 may be removed.
The second liquid stream 99 that exits the liquid separator 105 may be relatively clean, but has to be polished prior to entry as a liquid to be used in the quench chamber 75. The second liquid stream 99 is pumped from the liquid separator 105 into a high pressure pod 121 that contains organophilic clay. Organophilic clay has 75% higher hydrocarbon absorption than activated carbon and is hydrophobic so it does not swell with a large water stream. The organophilic clay will remove 99% of the hydrocarbons that remain in the second liquid stream 99. Once the second liquid stream 99 exits the Organophilic clay pod, it is pumped into an activated carbon pod to be polished. It is contemplated that the activated carbon will remove the remainder of the hydrocarbons from the second liquid stream 99. Once the second liquid stream 99 is released from the activated carbon pod, it is re-circulated back into the quench chamber 75.
There is still a minimal amount of off-gases that may survive the quench chamber 75, so a second treatment system 123 may be provided that works together with the liquid separator 105. Once the remaining off-gas exits the quench system 79, it is vacuumed through the exhaust
damper 125 and it is at that point that airflow in the system moves from negative to positive. The positive airflow containing the remaining off- gas is pushed through a packed bed 127. The packed bed 127 is full of activated carbon that begins to polish the air stream. Because the air stream is at a higher temperature, the stream running through the packed bed 127 will turn to liquid and that liquid may be pumped from the packed bed into the liquid separator 105 whereby the liquid may be separated again. Once the off-gas air stream is pushed through the packed bed 127, it may then exit to a demister 129 which cools the air stream and removes the remainder of any moisture. The moisture removed by the demister 129 is pumped back and makes its way back to the liquid separator 105. hi an exemplary embodiment, the last component involved in the system 1 is a thermal oxidizer 131. By this point, most off-gasses have been converted into a liquid and/or solid streams as enumerated above. However, to eliminate any by-products or contaminants, the stream is sent to the thermal oxidizer 131. The oxidizer 131 is heated to a temperature that is capable of destroying any off-gasses that may remain in the air stream. The thermal oxidizer 131 may also have a stack 135 which releases any clean gasses into the surrounding atmosphere.
However, it is contemplated that the exiting gasses may be reused by the system 1 as fuel and the like.
Thus, specific embodiments and applications of the release agent of the present invention have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context, hi particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.