US20070022653A1 - Method and system for efficiently disposing of dead animal parts and for converting animal parts and biomass to fuels - Google Patents

Method and system for efficiently disposing of dead animal parts and for converting animal parts and biomass to fuels Download PDF

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US20070022653A1
US20070022653A1 US11/194,393 US19439305A US2007022653A1 US 20070022653 A1 US20070022653 A1 US 20070022653A1 US 19439305 A US19439305 A US 19439305A US 2007022653 A1 US2007022653 A1 US 2007022653A1
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reactor
animal
parts
chemical waste
argon
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US11/194,393
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Dean Gokel
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GOKEL RECON LLC
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GOKEL RECON LLC
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Priority to US11/194,393 priority Critical patent/US20070022653A1/en
Priority to PCT/US2006/029778 priority patent/WO2007016504A2/en
Publication of US20070022653A1 publication Critical patent/US20070022653A1/en
Assigned to GOKEL RECON, LLC reassignment GOKEL RECON, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GOKEL, DEAN EDWARD
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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00Liquid carbonaceous fuels

Definitions

  • the present invention relates to forming combustible fuels from biomass, and more particularly to a system for eliminating waste animal parts by utilizing the animal parts as a feedstock for producing combustible fuels through a distillation process.
  • the present invention entails an efficient method of managing and disposing dead animal parts.
  • the method entails transferring parts of one or more dead animals into a reactor and pressurizing the reactor with an inert gas such as argon, nitrogen or helium.
  • the reactor is heated for a selected period of time and this transforms at least a portion of the dead animal parts into a gaseous composition.
  • the present invention also entails a method of forming a fuel or chemical from animal parts.
  • the animal parts are transferred into a reactor and heated.
  • a portion of the dead animal parts are transformed into a gaseous composition.
  • the gaseous composition is formed it is distilled and in the distillation process one or more combustible fuels is formed.
  • the dead animal parts are mixed with a chemical reactant or a chemical waste.
  • the chemical reactant or chemical waste is mixed with the dead animal parts to form an animal-chemical waste product.
  • This product is transferred to a reactor that is pressurized with an inert gas such as argon, nitrogen or helium.
  • the reactor is heated and at least a portion of the dead animal parts is transformed to a gaseous composition that is directed to a distillation process.
  • the gaseous composition formed from the dead animal parts is cooled and condensed to form a fuel or chemical.
  • FIG. 1 is a schematic illustration of the distillation system of the present invention that can be used to convert animal parts to fuels.
  • FIG. 2 is a flow chart that illustrates basic steps in converting animal parts to a combustible fuel.
  • distillation system 10 can be utilized to convert animal parts and biomass in general to various types of combustible fuels and other chemicals of economic interest. Before discussing the method or process of converting animal parts and biomass to fuels and other combustible chemicals, the distillation system 10 will be described.
  • Feedstock storage tank 12 serves to receive and hold animal parts or other biomass.
  • Storage tank 12 receives and holds various types and forms of organic chemicals or chemical waste that, as will be appreciated from subsequent portions of the disclosure, is mixed with the animal parts and/or biomass to form an animal-chemical waste product.
  • Both feedstock tank 12 and the chemical waste storage tank 14 are communicatively connected to a holding tank or chamber 16 . Also, communicatively connected with the holding chamber 16 is a base storage tank 18 . A conduit is connected between the base storage tank 18 and the holding tank 16 . A control valve 20 is connected between the base storage tank 18 and the holding tank 16 for metering base into the holding tank.
  • a reactor 22 also forms a part of the distillation system 10 .
  • a conduit 17 extends between the holding tank 16 and the reactor 22 .
  • a pump 19 is communicatively connected to the conduit 17 for pumping the animal-chemical waste product or mixture from the holding tank 16 to the reactor 22 .
  • conduit 17 is provided with a shut-off valve 21 for controlling the flow of the animal-chemical waste product from the holding tank 16 to the reactor 22 .
  • Reactor 22 is designed to be pressurized and to heat the contents thereof. Two types of heating provisions are provided in association with the reactor 22 .
  • reactor 22 is provided with an external heating capability. That is, reactor 22 is provided with external heating elements that are disposed within or adjacent an outer jacket 24 .
  • one or more internal heating elements 26 that project into the reactor 22 .
  • the external heating device and the internal heating elements 26 can be controlled during the course of the distillation process to cause the animal-chemical waste product to vaporize and to produce a vapor.
  • reactor 22 is provided with a temperature gauge 30 and a pressure gauge 32 . The temperature gauge can measure the temperature of the animal-chemical waste contained within the reactor 22 , or alternatively, the temperature gauge can reflect the temperature of the inner wall of the reactor 22 .
  • Distillation system 10 is provided with an inert gas storage tank 34 .
  • Gas storage tank 34 is communicatively connected to the reactor 22 .
  • a conduit extends from the gas storage tank 34 to the reactor 22 .
  • control valve 36 Disposed within the conduit is a control valve 36 for metering gas from the gas storage tank 34 to the reactor 22 .
  • reactor 22 includes an outlet 38 formed in the bottom or in the bottom portion thereof.
  • fuel product will accumulate in the bottom of the reactor 22 and from time to time this fuel product can be discharged via the outlet 28 and captured.
  • the fuel product and chemical components discharged through outlet 28 will differ from fuel and chemical products discharged downstream or subsequently in the distillation process.
  • Distillation system 10 also includes a series of distillation tanks and/or evaporation tanks or towers.
  • a first distillation tank 40 Extending between the first distillation tank 40 and the reactor 22 is a conduit 38 .
  • a valve 39 is provided between the distillation tank 40 and the reactor 22 for controlling the passage of vapor or superheated liquid from the reactor 22 to the first distillation tank 40 .
  • Distillation tank 40 includes an outlet 42 .
  • a second fuel product, and component chemicals of economic interest, can be discharged via outlet 42 .
  • the first distillation tank 40 includes a pressure gauge 44 for indicating the pressure within distillation tank 40 .
  • a second distillation tank 50 is provided downstream of the first distillation tank 40 .
  • a transfer conduit 46 extends between the distillation tanks 40 and 50 .
  • a control valve 48 controls the transfer of vapor or other material from the first distillation tank 40 to the second distillation tank 50 .
  • Second distillation tank 50 includes a product outlet 52 .
  • a pressure gauge 54 indicates the pressure within distillation tank 50 . Distillation tank 50 can, and usually does, produce a fuel product, and component chemicals of economic interest, that are different from the fuel products that are discharged via outlets 28 and 42 . This will be further explained subsequently herein.
  • Extending from distillation tank 50 is a conduit 60 .
  • Conduit 60 leads to a cooling tower or evaporation tank, indicated generally by the numeral 70 .
  • the evaporation tank 70 includes a series of outlets numbered 72 , 74 , 76 , 78 , 80 , 82 , 84 and 86 that are vertically spaced along a sidewall of the evaporation tank 70 . Vapor produced in the reactor 22 and ultimately introduced into the lower portion of the evaporation tank, will move upwardly in a conventional fashion. In the process condensation occurs and various types of fuels and chemicals will be captured in the evaporation tank and discharged out through the various outlets 72 - 86 provided therein.
  • a biomass feedstock is utilized.
  • the feedstock comprises animal parts from chickens, turkeys, pigs, cows, dogs, horses and other animals.
  • one source for the feedstock would be animal slaughterhouses which typically produce large amounts of waste body parts, waste sludge, and washed down wastewater that results from slaughterhouse cleaning.
  • animal waste parts and related animal waste compositions are usually subjected to a grinding, chopping, or cutting operation. That is, the animal parts are ground or cut into smaller parts by a meat grinder, hammermill, or other apparatus.
  • the animal feedstock can be augmented with plant organic matter, soybean oils, corn, corn oils, rapeseed oils, palm fruit, and other plant or vegetable stock.
  • the feedstock is held within the feedstock tank 12 .
  • the feedstock tank 12 is sealed so as to control odor and bacteria.
  • a blanket of nitrogen can be confined in the headspace at a pressure of approximately one atmosphere. While the size of the feedstock tank 12 can vary, it should be sized to contain sufficient feedstock to support the process for one day.
  • An organic chemical reactant such as a chemical waste
  • a chemical waste is mixed with the animal feedstock to form an animal-chemical waste product.
  • a range of organic chemicals or chemical waste products can be utilized. Typically they would include industrial organic waste that is produced in commercial and industrial facilities.
  • a suitable chemical waste product would comprise polymer waste that typically contains components such as propanoic acid and its esters, hexanal, etc.
  • other chemical waste suitable for mixing with the animal feedstock includes chemicals such as methacrylates, hexanes, methyl pentanes, ethanol, hexahydrogenzene, etc.
  • Other chemical waste products can be used and various types of chemical waste can be blended.
  • the composition of the chemical reactant or waste utilized will affect the nature and quality of the fuel or chemical produced. It is hypothesized that the more effective chemical reactant or waste products would be characterized in that they will have a relatively high pH and a sufficient carbon content to drive chemical reactions throughout the process to be described subsequently herein. Organic acids, methyl esters, and most non-hazardous chemical and polymer wastes are desirable. Even waste petroleum products such as paint thinners, gasoline, diesel fuel, kerosene, jet fuel, and aviation gasoline that is recovered from contaminated sites can be used as a waste chemical or blended with other waste chemicals for use in this process.
  • the chemical reactant or waste products are conveyed into a receiving tank 14 .
  • the animal feedstock in tank 12 and the chemical waste product held in tank 14 are conveyed into the holding tank 16 .
  • the holding tank may include an agitator or mixer that mixes the animal feedstock with the chemical waste to form the animal-chemical waste product.
  • the pH of the animal-chemical waste mixture should be controlled to a pH of approximately 8 to 12.
  • a base contained within the base storage tank is selectively metered into the holding tank 16 and mixed with the animal-chemical waste mixture. Suitable bases for mixing with the animal-chemical waste mixture are sodium hydroxide, potassium hydroxide, etc. Any strong base will work with this system.
  • the reactor is cleaned by a gas purging procedure.
  • an inert gas from tank 34 is directed into the reactor 22 .
  • gases such as nitrogen, helium and argon can be used. Argon maybe preferred.
  • the reactor 22 is vented. During this purging operation it is contemplated that reactor 22 would be slightly pressurized with the argon gas with the pressure being in the range of 5-6 psi.
  • the purging gas can also be directed through the reactor 22 and through tanks 40 and 50 as well as through the evaporation tank 70 . This will effectively clean the reactor and tanks and will contribute to efficient and effective chemical reactions during the entire process.
  • the reactor 22 is closed and pressurized to a level of approximately 40-80 psi with argon gas. Thereafter the animal-chemical waste mixture is pumped by pump 19 from the holding tank 16 through line 17 and valve 21 into the reactor 22 . Because the animal parts have been chopped, cut or ground, the animal-chemical waste mixture typically assumes a slurry consistency.
  • the animal-chemical waste mixture in the reactor 22 will be held in a pressurized argon or inert gas environment.
  • argon it is believed that the argon functions as a medium for various reactants to mix, and provides consistency and predictability in the various chemical reactions that will take place in the reactor 22 .
  • the argon will increase the boiling point of the animal-chemical waste mixture.
  • the reactor is heated.
  • Reactor 22 has two sources of heat.
  • the reactor is provided with an external heating system or device that is incorporated into the jacket 24 of the heater.
  • the animal-chemical waste mixture is first heated by the external heating system or device.
  • the external heating system will be utilized to raise the temperature of the reactor to a temperature of 200° C. to 290° C.
  • the pressure in the reactor It is contemplated that with a temperature increase in the range of 200° C. to 290° C. that the pressure within the reactor 22 will increase to approximately 90-350 psi. Upon reaching 350 psi, or thereabouts, it is contemplated that the reactor would be vented so as to reduce the pressure within the reactor to a pressure of 350 psi or below.
  • the internal pressure within the reactor 22 will increase. Once the internal pressure begins to increase within the range of 90-350 psi, then the internal heating element or elements 26 can be actuated. Internal heating element or elements 26 are preferably intermittently utilized to heat the animal-chemical waste mixture. As shown in FIG. 1 the internal heating element or elements 26 project into the mixture. In one typical operation, the internal heating element or elements 26 would be switched on and off with the ON time constituting approximately 30% of the time and the OFF time constituting approximately 70% of the time.
  • the reactor 22 reaches a temperature of 200° C. to 290° C. then a multitude of reactions will begin taking place. As the animal-chemical waste mixture is heated in the presence of argon and under the pressure of 90-350 psi, a series of reactions will take place and these reactions will produce a gaseous composition or vapor along with a super hot liquid. It is contemplated that the residency time of the animal-chemical waste product within the reactor at a temperature of 200° C. to 290° C. and at a pressure of 90-350 psi will be in the range of 1 to 5 hours.
  • the valve 39 disposed between the reactor 22 and the first distillation tank 40 is open.
  • the gaseous composition produced in the reactor 22 is permitted to flow from the reactor 22 through the conduit 38 into the distillation tank 40 .
  • Details of the distillation tanks are not shown herein in detail because such is not per se material to the present invention, and further, such distillation tanks are well known and widely used for condensing gaseous compositions.
  • portions of the gaseous composition will condense and the condensed portion will be directed to outlet 42 . While the precise chemical composition of the distillate will vary depending upon the feedstock, the chemical waste, the inert or noble gas used, and certain other operating parameters of the reactor, the distillate will comprise a combustible fuel and other chemicals.
  • the gaseous composition entering the evaporation tank 70 will be directed into the bottom thereof.
  • the gaseous composition will spiral upwardly through the evaporation tank. At certain points along the way portions of the vapor or gaseous composition will condense.
  • the evaporation tank at various height intervals, is provided with plates to catch the various distillates. As illustrated in FIG. 1 , at various height intervals along the evaporation tank 70 , there is provided a series of discharge outlets 74 - 86 . As the vapor or gaseous composition moves upwardly through the evaporation tank 70 , at certain points along the way certain distillates will be produced and discharged from the respective outlets 74 - 86 .
  • the quality of the distillates produced by this distillation process will vary depending upon the location where the distillate is discharged from the system.
  • the product discharged from the outlet 28 associated with the reactor will differ substantially in quality from the distillate produced at the outlet 86 of the evaporation tank 70 .
  • the more refined and lighter fuel oils and chemical compositions will be formed later on in the distillation process.
  • fuel means a conventional fuel or a flammable chemical.

Abstract

A method and system utilizes animal parts as a feedstock to produce one or more combustible fuels or chemicals. The animal parts are mixed with a chemical waste to form an animal-chemical waste product. This animal-chemical waste product is transferred to a reactor and heated under pressure to form a gaseous composition. The gaseous composition is distilled to form one or more combustible fuels.

Description

    FIELD OF THE INVENTION
  • The present invention relates to forming combustible fuels from biomass, and more particularly to a system for eliminating waste animal parts by utilizing the animal parts as a feedstock for producing combustible fuels through a distillation process.
  • BACKGROUND OF THE INVENTION
  • The management and disposal of animal parts is a huge problem throughout the world. It is a particular problem for chicken and turkey processors as well as swine and cattle slaughterhouses. In the process of slaughtering animals and preparing them for market, there is a great deal of waste parts such as blood, bones, organs, and skin that must be disposed. Efficiently dealing with the sheer magnitude of animal parts is problematic, but doing so in compliance with local, state and federal regulations is even more challenging.
  • In recent years, considerable attention has been given to the conversion of corn and other plant material to liquid fuels. The use of plant material and other biomass offers the potential to replace or supplement dwindling reserves of non-renewable fossil fuels with fuels derived from biomass types of material which contains carbon and are renewable. If, in the case of dead animal parts, it is possible to convert them to fuels and at the same time provide an efficient and effective means of disposal, then the utility and advantages of such are clear.
  • SUMMARY OF THE INVENTION
  • The present invention entails an efficient method of managing and disposing dead animal parts. The method entails transferring parts of one or more dead animals into a reactor and pressurizing the reactor with an inert gas such as argon, nitrogen or helium. The reactor is heated for a selected period of time and this transforms at least a portion of the dead animal parts into a gaseous composition.
  • The present invention also entails a method of forming a fuel or chemical from animal parts. The animal parts are transferred into a reactor and heated. In the process, a portion of the dead animal parts are transformed into a gaseous composition. Once the gaseous composition is formed it is distilled and in the distillation process one or more combustible fuels is formed.
  • In one particular embodiment of the present invention, the dead animal parts are mixed with a chemical reactant or a chemical waste. The chemical reactant or chemical waste is mixed with the dead animal parts to form an animal-chemical waste product. This product is transferred to a reactor that is pressurized with an inert gas such as argon, nitrogen or helium. The reactor is heated and at least a portion of the dead animal parts is transformed to a gaseous composition that is directed to a distillation process. During the course of the distillation process, the gaseous composition formed from the dead animal parts is cooled and condensed to form a fuel or chemical.
  • Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a schematic illustration of the distillation system of the present invention that can be used to convert animal parts to fuels.
  • FIG. 2 is a flow chart that illustrates basic steps in converting animal parts to a combustible fuel.
  • DESCRIPTION OF THE INVENTION
  • With further reference to the drawing, a distillation system is shown therein and indicated generally by the numeral 10. As will be appreciated from subsequent portions of this disclosure, distillation system 10 can be utilized to convert animal parts and biomass in general to various types of combustible fuels and other chemicals of economic interest. Before discussing the method or process of converting animal parts and biomass to fuels and other combustible chemicals, the distillation system 10 will be described.
  • Forming a part of the distillation system 10 is a feedstock storage tank 12 and a chemical reactant storage tank 14. Feedstock storage tank 12 serves to receive and hold animal parts or other biomass. Storage tank 12 receives and holds various types and forms of organic chemicals or chemical waste that, as will be appreciated from subsequent portions of the disclosure, is mixed with the animal parts and/or biomass to form an animal-chemical waste product.
  • Both feedstock tank 12 and the chemical waste storage tank 14 are communicatively connected to a holding tank or chamber 16. Also, communicatively connected with the holding chamber 16 is a base storage tank 18. A conduit is connected between the base storage tank 18 and the holding tank 16. A control valve 20 is connected between the base storage tank 18 and the holding tank 16 for metering base into the holding tank.
  • A reactor 22 also forms a part of the distillation system 10. A conduit 17 extends between the holding tank 16 and the reactor 22. A pump 19 is communicatively connected to the conduit 17 for pumping the animal-chemical waste product or mixture from the holding tank 16 to the reactor 22. In addition, conduit 17 is provided with a shut-off valve 21 for controlling the flow of the animal-chemical waste product from the holding tank 16 to the reactor 22.
  • Reactor 22 is designed to be pressurized and to heat the contents thereof. Two types of heating provisions are provided in association with the reactor 22. First, reactor 22 is provided with an external heating capability. That is, reactor 22 is provided with external heating elements that are disposed within or adjacent an outer jacket 24. In addition, there is provided one or more internal heating elements 26 that project into the reactor 22. As will be appreciated from subsequent portions of the disclosure, the external heating device and the internal heating elements 26 can be controlled during the course of the distillation process to cause the animal-chemical waste product to vaporize and to produce a vapor. Furthermore, reactor 22 is provided with a temperature gauge 30 and a pressure gauge 32. The temperature gauge can measure the temperature of the animal-chemical waste contained within the reactor 22, or alternatively, the temperature gauge can reflect the temperature of the inner wall of the reactor 22.
  • Distillation system 10 is provided with an inert gas storage tank 34. Gas storage tank 34 is communicatively connected to the reactor 22. A conduit extends from the gas storage tank 34 to the reactor 22. Disposed within the conduit is a control valve 36 for metering gas from the gas storage tank 34 to the reactor 22. Further, reactor 22 includes an outlet 38 formed in the bottom or in the bottom portion thereof. During the course of the distillation process fuel product will accumulate in the bottom of the reactor 22 and from time to time this fuel product can be discharged via the outlet 28 and captured. As will be appreciated from subsequent portions of the disclosure, the fuel product and chemical components discharged through outlet 28 will differ from fuel and chemical products discharged downstream or subsequently in the distillation process.
  • Distillation system 10 also includes a series of distillation tanks and/or evaporation tanks or towers. In the case of the distillation system disclosed in FIG. 1, there is provided a first distillation tank 40. Extending between the first distillation tank 40 and the reactor 22 is a conduit 38. A valve 39 is provided between the distillation tank 40 and the reactor 22 for controlling the passage of vapor or superheated liquid from the reactor 22 to the first distillation tank 40. Distillation tank 40 includes an outlet 42. A second fuel product, and component chemicals of economic interest, can be discharged via outlet 42. Additionally the first distillation tank 40 includes a pressure gauge 44 for indicating the pressure within distillation tank 40.
  • A second distillation tank 50 is provided downstream of the first distillation tank 40. A transfer conduit 46 extends between the distillation tanks 40 and 50. A control valve 48 controls the transfer of vapor or other material from the first distillation tank 40 to the second distillation tank 50. Second distillation tank 50 includes a product outlet 52. A pressure gauge 54 indicates the pressure within distillation tank 50. Distillation tank 50 can, and usually does, produce a fuel product, and component chemicals of economic interest, that are different from the fuel products that are discharged via outlets 28 and 42. This will be further explained subsequently herein.
  • Extending from distillation tank 50 is a conduit 60. Disposed within the conduit 60 is a control valve 62 for controlling the flow of vapor or superheated liquid from the distillation tank 50 into and through the conduit 60. Conduit 60 leads to a cooling tower or evaporation tank, indicated generally by the numeral 70. As will be appreciated from subsequent portions of this disclosure, the evaporation tank 70 includes a series of outlets numbered 72, 74, 76, 78, 80, 82, 84 and 86 that are vertically spaced along a sidewall of the evaporation tank 70. Vapor produced in the reactor 22 and ultimately introduced into the lower portion of the evaporation tank, will move upwardly in a conventional fashion. In the process condensation occurs and various types of fuels and chemicals will be captured in the evaporation tank and discharged out through the various outlets 72-86 provided therein.
  • Turning to the process of the present invention, a biomass feedstock is utilized. In a preferred process the feedstock comprises animal parts from chickens, turkeys, pigs, cows, dogs, horses and other animals. It is contemplated that one source for the feedstock would be animal slaughterhouses which typically produce large amounts of waste body parts, waste sludge, and washed down wastewater that results from slaughterhouse cleaning. These animal waste parts and related animal waste compositions are usually subjected to a grinding, chopping, or cutting operation. That is, the animal parts are ground or cut into smaller parts by a meat grinder, hammermill, or other apparatus.
  • The animal feedstock can be augmented with plant organic matter, soybean oils, corn, corn oils, rapeseed oils, palm fruit, and other plant or vegetable stock. In any event, the feedstock is held within the feedstock tank 12. Preferably the feedstock tank 12 is sealed so as to control odor and bacteria. A blanket of nitrogen can be confined in the headspace at a pressure of approximately one atmosphere. While the size of the feedstock tank 12 can vary, it should be sized to contain sufficient feedstock to support the process for one day.
  • An organic chemical reactant, such as a chemical waste, is mixed with the animal feedstock to form an animal-chemical waste product. A range of organic chemicals or chemical waste products can be utilized. Typically they would include industrial organic waste that is produced in commercial and industrial facilities. For example, a suitable chemical waste product would comprise polymer waste that typically contains components such as propanoic acid and its esters, hexanal, etc. In addition, other chemical waste suitable for mixing with the animal feedstock includes chemicals such as methacrylates, hexanes, methyl pentanes, ethanol, hexahydrogenzene, etc. Other chemical waste products can be used and various types of chemical waste can be blended. As will be discussed subsequently herein, the composition of the chemical reactant or waste utilized will affect the nature and quality of the fuel or chemical produced. It is hypothesized that the more effective chemical reactant or waste products would be characterized in that they will have a relatively high pH and a sufficient carbon content to drive chemical reactions throughout the process to be described subsequently herein. Organic acids, methyl esters, and most non-hazardous chemical and polymer wastes are desirable. Even waste petroleum products such as paint thinners, gasoline, diesel fuel, kerosene, jet fuel, and aviation gasoline that is recovered from contaminated sites can be used as a waste chemical or blended with other waste chemicals for use in this process.
  • In two tests conducted, two batches of chemical waste products were used. In one test, a mixture of propenoic acid and guaiccol were used. The proportions of the components of the waste are not deemed critical to the basic process. It is acknowledged that the resulting fuels and chemicals can be varied based on the selection and amounts of the particular waste components utilized. In another test a mixture of acetic acid, butyl ester, hexahydrobenzene, cyclopentane, methyl-formamide, N, N-dimethyl and oxolane was used as a chemical waste product.
  • The chemical reactant or waste products are conveyed into a receiving tank 14. From time to time, the animal feedstock in tank 12 and the chemical waste product held in tank 14 are conveyed into the holding tank 16. The holding tank may include an agitator or mixer that mixes the animal feedstock with the chemical waste to form the animal-chemical waste product. To facilitate reactions in the distillation system 10 it is believed that the pH of the animal-chemical waste mixture should be controlled to a pH of approximately 8 to 12. To control the pH to a desired level, a base contained within the base storage tank is selectively metered into the holding tank 16 and mixed with the animal-chemical waste mixture. Suitable bases for mixing with the animal-chemical waste mixture are sodium hydroxide, potassium hydroxide, etc. Any strong base will work with this system.
  • After transferring the animal-chemical waste to the reactor 22, the reactor is cleaned by a gas purging procedure. By opening valve 36, an inert gas from tank 34 is directed into the reactor 22. Various gases such as nitrogen, helium and argon can be used. Argon maybe preferred. During a portion of the purging operation, the reactor 22 is vented. During this purging operation it is contemplated that reactor 22 would be slightly pressurized with the argon gas with the pressure being in the range of 5-6 psi. The purging gas can also be directed through the reactor 22 and through tanks 40 and 50 as well as through the evaporation tank 70. This will effectively clean the reactor and tanks and will contribute to efficient and effective chemical reactions during the entire process. After purging, the reactor 22 is closed and pressurized to a level of approximately 40-80 psi with argon gas. Thereafter the animal-chemical waste mixture is pumped by pump 19 from the holding tank 16 through line 17 and valve 21 into the reactor 22. Because the animal parts have been chopped, cut or ground, the animal-chemical waste mixture typically assumes a slurry consistency.
  • Thus, the animal-chemical waste mixture in the reactor 22 will be held in a pressurized argon or inert gas environment. In the case of argon, it is believed that the argon functions as a medium for various reactants to mix, and provides consistency and predictability in the various chemical reactions that will take place in the reactor 22. In addition, the argon will increase the boiling point of the animal-chemical waste mixture.
  • Once the animal-chemical waste mixture has been directed into the reactor 22, and the reactor is pressurized with an inert gas, the reactor is heated. Reactor 22, as discussed above, has two sources of heat. First, the reactor is provided with an external heating system or device that is incorporated into the jacket 24 of the heater. The animal-chemical waste mixture is first heated by the external heating system or device. The external heating system will be utilized to raise the temperature of the reactor to a temperature of 200° C. to 290° C. As the temperature of the reactor 22 is increased, so will the pressure in the reactor. It is contemplated that with a temperature increase in the range of 200° C. to 290° C. that the pressure within the reactor 22 will increase to approximately 90-350 psi. Upon reaching 350 psi, or thereabouts, it is contemplated that the reactor would be vented so as to reduce the pressure within the reactor to a pressure of 350 psi or below.
  • During the course of heating the reactor 22 by the external heat source, as noted above, the internal pressure within the reactor 22 will increase. Once the internal pressure begins to increase within the range of 90-350 psi, then the internal heating element or elements 26 can be actuated. Internal heating element or elements 26 are preferably intermittently utilized to heat the animal-chemical waste mixture. As shown in FIG. 1 the internal heating element or elements 26 project into the mixture. In one typical operation, the internal heating element or elements 26 would be switched on and off with the ON time constituting approximately 30% of the time and the OFF time constituting approximately 70% of the time.
  • Once the reactor 22 reaches a temperature of 200° C. to 290° C. then a multitude of reactions will begin taking place. As the animal-chemical waste mixture is heated in the presence of argon and under the pressure of 90-350 psi, a series of reactions will take place and these reactions will produce a gaseous composition or vapor along with a super hot liquid. It is contemplated that the residency time of the animal-chemical waste product within the reactor at a temperature of 200° C. to 290° C. and at a pressure of 90-350 psi will be in the range of 1 to 5 hours.
  • After a selected residency time, the valve 39 disposed between the reactor 22 and the first distillation tank 40 is open. The gaseous composition produced in the reactor 22 is permitted to flow from the reactor 22 through the conduit 38 into the distillation tank 40. Details of the distillation tanks are not shown herein in detail because such is not per se material to the present invention, and further, such distillation tanks are well known and widely used for condensing gaseous compositions. In any event, as the gaseous composition from the reactor 22 moves vertically and upward through the distillation tank 40, portions of the gaseous composition will condense and the condensed portion will be directed to outlet 42. While the precise chemical composition of the distillate will vary depending upon the feedstock, the chemical waste, the inert or noble gas used, and certain other operating parameters of the reactor, the distillate will comprise a combustible fuel and other chemicals.
  • In a typical distillation process of the type described in FIG. 1, all of the gaseous composition passing through distillation tank 40 may not be condensed. Thus, some of the gaseous composition passing through distillation tank 40 can be directed through conduit 46 and valve 48 into the second distillation tank 50. Here, as the gaseous composition moves vertically and upwardly through the distillation tank 50, portions of the gaseous composition will condense to form a distillate, which is discharged from outlet 52. Again, while the precise composition of the distillate discharged from outlet 52 will vary based on the factors discussed above, the distillate produced will again be a combustible fuel and other chemicals of economic value.
  • In some cases there may remain an uncondensed gaseous composition in the second distillation tank 50. In that case the remaining gaseous composition is directed through conduit 60, control valve 62 to the evaporation tank or tower 70. Again, details of the evaporation tank 70 are not dealt with herein because such is not per se material to the present invention, and further, such structures are commonly used and well understood by those skilled in the art. In any event, the gaseous composition entering the evaporation tank 70 will be directed into the bottom thereof. Upon entry to the evaporation tank 70, the gaseous composition will spiral upwardly through the evaporation tank. At certain points along the way portions of the vapor or gaseous composition will condense. The evaporation tank, at various height intervals, is provided with plates to catch the various distillates. As illustrated in FIG. 1, at various height intervals along the evaporation tank 70, there is provided a series of discharge outlets 74-86. As the vapor or gaseous composition moves upwardly through the evaporation tank 70, at certain points along the way certain distillates will be produced and discharged from the respective outlets 74-86.
  • In the example discussed above and shown in FIG. 1, the quality of the distillates produced by this distillation process will vary depending upon the location where the distillate is discharged from the system. For example, the product discharged from the outlet 28 associated with the reactor will differ substantially in quality from the distillate produced at the outlet 86 of the evaporation tank 70. Generally, the more refined and lighter fuel oils and chemical compositions will be formed later on in the distillation process.
  • The range of combustible fuels or chemicals produced by the distillation process discussed above, include crude oil, biogel, biodiesel and other bio fuels, and common industrially used chemicals. As used herein, the term “fuel” means a conventional fuel or a flammable chemical. A series of tests were conducted utilizing ground chicken parts and two general types of chemical waste. In one test the chemical waste included propenoic acid and guaiccol. In another test the chemical waste included a mixture of acetic acid, butyl ester, hexahydrobenzene, cyclopentane, methyl-formamide, N, N-dimethyl oxolane. Listed below is a partial list of the fuel and chemical products collected at various collection sites in the system.
  • Partial List of Products Collected at tank “40”
      • 1-Propanol, 2-methyl-
      • 2- Propanol
      • Camphene
      • Decane, 5- methyl
      • Hexane
      • Pentane,2,3,3-trimethyl
      • Avantin
  • Partial List of Products Collected at tank “39
      • Benzene, 1,2,4- trimethyl
      • O-xylol
      • Benzene,ethyl- Phenylethane
      • Cyclohexanol
      • Dodecanoic acid methyl ester
      • Hexanal
      • Pentane, 3-ethyl-
      • Methacide
  • Partial List of Products Collected at tank “70
      • Benzene, ethyl-
      • Decane
      • Dodecane
      • Heptane, 4-methyl-
      • Octanoic acid, methyl ester
      • Ethanol, 2-propoxy
      • Phenol
      • Ethanol
      • Ethyl Cyclobutane
      • Cyclohexane
      • 2- Propenoic acid, 2- methyl, methyl ester
      • 2,3,3 Trimethyl pentane
      • 2- methyl nonane
      • Undecane
      • Dodecane
      • Butane
      • Camphene
      • Decane
      • 2- Propanol
      • 2,6- Dimethyl octane
      • 2,5 Dimethyl Octane
      • Butane
      • Ethanol
      • Cyclohexane
      • Trimethylpentane
      • Trimethylhexane
      • Pinene
      • Decane
      • Limonene
  • Partial List of Products Collected at tank “26
      • 1- Heptene
      • Acintene A
      • Naxol

Claims (53)

1. A method of forming fuel from animal parts, comprising:
a. utilizing animal parts as a feedstock;
b. mixing a chemical reactant with the animal parts to form an animal-chemical waste product;
c. transferring the animal-chemical waste product to a reactor;
d. heating the animal-chemical waste product in the reactor under pressure to form a gaseous composition; and
e. distilling the gaseous composition to form combustible fuel.
2. The method of claim 1 wherein the feedstock comprises fowl.
3. The method of claim 1 wherein the feedstock further includes plant parts.
4. The method of claim 3 wherein the animal parts and plant parts that comprise the feedstock are taken from the group consisting of fowl, pigs, cows, horses, dogs, coconut shells, husks, palm fruit, rapeseed oil, sunflower seed oil, corn oil and soybean oil extracts.
5. The method of claim 1 including controlling the pH of the animal-chemical waste product.
6. The method of claim 5 wherein controlling the pH includes varying the amount of chemical reactant added to the feedstock.
7. The method of claim 5 including controlling the pH to about 8-12.
8. The method of claim 5 wherein controlling the pH of the animal-chemical waste product includes adding a base to the animal-chemical waste product.
9. The method of claim 1 including pressurizing the reactor with a noble or inert gas.
10. The method of claim 9 wherein the inert gas is taken from the group consisting of argon, nitrogen, and helium.
11. The method of claim 1 including pressurizing the reactor to about 40 to 80 psi with a noble or inert gas taken from the group consisting of argon, nitrogen and helium.
12. The method of claim 11 including pressurizing the reactor with argon.
13. The method of claim 12 including heating the animal-chemical waste product after the reactor has been pressurized.
14. The method of claim 13 including heating the animal-chemical waste product in the reactor to a temperature of approximately 200 to 290° C.
15. The method of claim 1 including heating the animal-chemical waste product to a temperature of approximately 200 to 290° C.
16. The method of claim 1 including a multistage distilling process where the gaseous composition passes into or through a series of distilling or condensing devices.
17. The method of claim 16 including at least three condensing devices arranged in series.
18. The method of claim 1 including grinding or cutting the animal parts to form a ground mixture of animal parts and combining the ground mixture of animal parts with the chemical reactant.
19. The method of claim 1 including purging the reactor by directing a gas selected from the group consisting of argon, nitrogen and helium through the reactor.
20. The method of claim 1 wherein the chemical reactant includes a chemical waste.
21. The method of claim 20 wherein the chemical waste is taken from the group consisting of propenoic acid, guaiccol, acetic acid, butyl ester, hexahydrobenzene, cyclopentane, methyl-formamide, N, N-dimethyl oxioane.
22. The method of claim 1 including grinding the animal parts to where the animal parts become a fluid slurry.
23. A method of forming fuel from animal parts comprising:
a. utilizing animal parts as a feedstock;
b. transferring the animal parts to a reactor;
c. transferring a gas selected from the group consisting of argon, nitrogen and helium into the reactor;
d. heating the animal parts in the reactor under pressure to form a gaseous composition; and
e. distilling the gaseous composition produced by the animal parts to form combustible fuel.
24. The method of claim 23 wherein the gas transferred into the reactor is argon.
25. The method of claim 23 including pressurizing the gas within the reactor.
26. The method of claim 25 wherein the gas in the reactor is pressurized to about 40 to 80 psi.
27. The method of claim 23 wherein the animal parts are taken from the group consisting of chicken parts, pig parts, and cow parts.
28. The method of claim 23 further including mixing a chemical waste or reactant with the animal parts to form an animal-chemical waste product; and wherein the animal-chemical waste product is transferred into the reactor and after heating produces the gaseous composition that is distilled.
29. The method of claim 28 wherein the chemical waste or reactant is taken from the group consisting of propenoic acid, guaiccol, acetic acid, butyl ester, hexahydrobenzene, cyclopentane, methyl-formamide, N, N-dimethyl oxloane.
30. The method of claim 23 including heating the reactor to a temperature of approximately 200 to 290° C.
31. The method of claim 30 including heating the animal parts in the reactor for a time period of 1 to 5 hours.
32. The method of claim 23 including producing a combustible fuel within the reactor, and after a selected period of heating the animal parts in the reactor, removing the combustible fuel from the reactor.
33. The method of claim 23 wherein the method of forming the fuels from animal parts is carried out in a distilling system including a series of condensing units, and wherein the gaseous composition is directed from the reactor to and through one or more of the condensing units where portions of the gaseous composition condense and form one or more combustible fuels.
34. The method of claim 23 including heating the contents of the reactor with one or more internal heating devices and one or more external heating devices.
35. The method of claim 34 including intermittently actuating the one or more internal heating elements.
36. A method of forming fuel from animal or plant parts comprising:
a. utilizing a biofeed stock that is formed from animal or plant parts;
b. transferring the biofeed stock to a reactor;
c. pressurizing the reactor with argon;
d. heating the biofeed stock in the reactor to produce a gaseous composition; and
e. distilling the gaseous composition to form fuel compositions and chemicals.
37. The method of claim 36 including pressurizing the reactor with argon to a pressure of approximately 40-80 psi.
38. The method of claim 37 including purging and cleaning the reactor by directing argon into or through the reactor and thereafter pressurizing the reactor with argon to a pressure of approximately 40-80 psi.
39. The method of claim 36 wherein the method is carried out in a distilling system having a series of condensing units communicatively connected, directly or indirectly, with the reactor.
40. The method of claim 39 including purging the reactor and at least one of the condensing units with a noble or inert gas selected from the group consisting of argon, nitrogen and helium.
41. The method of claim 40 wherein the purging gas is argon.
42. The method of claim 36 including heating the biofeedstock in the reactor to a temperature of approximately 200 to 290° C.
43. The method of claim 36 including mixing a chemical waste or reactant with the biofeedstock to form a biofeed-chemical waste product that is transferred to the reactor.
44. A method of disposing of parts of dead animals comprising: transferring the parts of the dead animal into a reactor; pressurizing the reactor with an inert gas; and heating the parts of the dead animals and transforming at least a portion of the parts of the dead animals into a gaseous composition.
45. The method of claim 44 including pressurizing the reactor with argon.
46. The method of claim 44 wherein the inert gas is taken from the group consisting of argon, nitrogen, and helium.
47. The method of claim 44 including pressurizing the reactor to about 40 to 80 psi with the inert gas and wherein the inert gas is taken from the group consisting of argon, nitrogen and helium.
48. The method of claim 44 including heating the reactor to a temperature of approximately 200° to 290° C. and controlling the pressure within the reactor such that the pressure does not exceed 350 psi.
49. The method of claim 48 including pressurizing the reactor to about 40 to 80 psi with an inert gas taken from the group consisting of argon, nitrogen and helium, and wherein the reactor is pressurized to about 40 to 80 psi before the reactor is substantially heated.
50. The method of claim 44 including heating the parts of the dead animal to form a gaseous composition and distilling the gaseous composition to form a fuel.
51. The method of claim 44 wherein the parts of the dead animal include parts from dead fowl.
52. The method of claim 50 including mixing a chemical reactant or a chemical waste with the dead animal parts to form an animal-chemical waste product that is heated in the reactor.
53. The method of claim 52 including controlling the pH of the animal-chemical waste product to about 8-12.
US11/194,393 2005-08-01 2005-08-01 Method and system for efficiently disposing of dead animal parts and for converting animal parts and biomass to fuels Abandoned US20070022653A1 (en)

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