AU2018200824A1

AU2018200824A1 - Valuable materials from solid organic waste (vmw)

Info

Publication number: AU2018200824A1
Application number: AU2018200824A
Authority: AU
Inventors: Jamil Rima
Original assignee: Jihany Pty Ltd; Waste Diamond Solutions Pty Ltd
Current assignee: Jihany Pty Ltd; Waste Diamond Solutions Pty Ltd
Priority date: 2017-02-09
Filing date: 2018-02-04
Publication date: 2018-08-30
Also published as: AU2021202520A1

Abstract

An apparatus working continuously for transforming organic waste into coal, carbon dioxide into sodium carbonate and steam into purified water by adequate cooling system, was invented. The invention relates to an apparatus for transforming waste into carbon in a reactor, said method comprising, a) drying the waste under pressure of at least 3 bar, and temperature of at least 2500C; b) releasing the steam out, and cooling it thereby obtaining water; c) carbonizing at least partially the waste by maintaining pressure of at least 3 Bar for 5 minutes, and a temperature of at least 250 OC, thereby obtaining carbon; and d) optionally separating non-organic material from the obtained carbon. The invention relies on the combination of heat, nitrogen pressure for avoiding combustion and rapid heat transfer by using of stainless steel agitator equipped with blades close to the wall of the reactor. Figure 9 En Output Water Input Waste Output Na2CO3 Valves Output Carbon So ium Carbonate Outpt CabonTank

Description

The invention relates to an apparatus for transforming waste into carbon in a reactor, said method comprising, a) drying the waste under pressure of at least 3 bar, and temperature of at least 250°C; b) releasing the steam out, and cooling it thereby obtaining water; c) carbonizing at least partially the waste by maintaining pressure of at least 3 Bar for 5 minutes, and a temperature of at least 250 °C, thereby obtaining carbon; and d) optionally separating non-organic material from the obtained carbon.

The invention relies on the combination of heat, nitrogen pressure for avoiding combustion and rapid heat transfer by using of stainless steel agitator equipped with blades close to the wall of the reactor.

9/8

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Figure 9

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VALUABLE MATERIALS FROM SOLID ORGANIC WASTE (VMW)

FIELD OF THE INVENTION [0001] Technical field relates to a process and apparatus which are working continuously and transforming organic waste into three valuable materials which are the coal by cracking process of organic molecules, sodium carbonate by trapping the carbon dioxide into sodium hydroxide aqueous solution and purified water by adequate cooling system of the steam.

BACKGROUND OF THE INVENTION [0002] Waste production is rising enormously in the world with increasing population. The impact of waste on the environment has become a serious problem for the planet.

[0003] There are currently several options for removing organic waste. One of them, controlled landfilling (1), based on the burial of solid waste, and is performed by spreading non-hazardous waste in layers, holes, or trenches dug in the ground, compacting them, and covering them with earth at the end of each working day. Unfortunately, this process results in the emission of toxic gases and might lead to spontaneous ignitions and explosions due to build-up of methane. The main costs associated with controlled landfilling include the land acquisition costs, lining the ground with impervious plastic sheeting to prevent leakage of dangerous substances into the soil and underground water and aquifers, transportation to remote and very large landfill sites, and continuous monitoring/treatment to avoid excessive methane build-up. If leakages or methane build-up are present, the landfill requires fixing prior to dumping (2).

[0004] Aerobic composting is decomposition of organic matter using microorganisms that require oxygen. The microbes responsible for composting are naturally occurring and live in the moisture surrounding organic matter. Oxygen from the air diffuses in to the moisture and is taken up by the microbes. As aerobic digestion takes place, the by-products are heat, water and carbon dioxide (CO₂).

[0004a] While CO₂ can be classified as a greenhouse gas its evolution from the composting process is not counted in emissions. The heat produced in aerobic composting

2018200824 04 Feb 2018 is sufficient to kill harmful bacteria and pathogens as these organisms are not adapted to these environmental conditions. It also helps support the growth of beneficial bacteria species including psychrophilic, mesophilic, and thermophilic bacteria which thrive at the higher temperature levels. The majors disadvantages of aerobic composting can be cited as follow: Generates odors and leachate which must be managed, larger site required, less control over potential nuisances, slow process (12-18 months), Substantial pretreatment required , High consumption of water and heat, Precipitation of the heavier fraction of the waste to the bottom of the reactor can reduce gas yields.

[0004b] When leakages occur, underground water may become contaminated. In addition, the fertilizer produced by composting is of poor quality, containing few carbon and nitrogen because during fermentation the carbon and the nitrogen were transformed into carbon dioxide and ammonia (3).

[0005] Anaerobic composting (AC) results in fermentation of a portion of the waste. With such technologies in general, large spaces are required, which can also be expensive. The process of composting anaerobically produces a biogas (e.g. methane ammoniac and carbon dioxide). Since anaerobic composting occurs in a sealed oxygen free environment or under water, decomposition of the organic materials can lead to very unpleasant odors due to the release of sulfur-containing compounds such as hydrogen sulfide. One of the main disadvantages of anaerobic composting is that if the compost is not allowed adequate time (at least one year) to ferment and to breakdown the biomass feedstock, there is a risk that the compost will contain harmful pathogens. Also, if leakages occur, underground water may become contaminated.

[0005a] In addition, the fertilizer produced by composting is of poor quality, containing few carbon and nitrogen because during fermentation the carbon and the nitrogen were transformed into carbon dioxide and ammonia. As the material is broken down by anaerobic digestion, it creates a sludge-like material that is even more difficult to break down. This material, digestate, typically requires aerobic composting to complete the stabilization process.When carried out at a commercial scale on farms and at wastewater treatment works, it requires a high level of investment in large tanks and other process vessels. If run inefficiently (AC) can cause an odour nuisance.

2018200824 04 Feb 2018 [0006] Methanisation is a waste treatment method where biogas is naturally produced through the fermentation of many different types of animal- and plant-derived organic matter from waste treatment plants and even landfills. Methanisation can provide heating, electricity or fuel. It is nevertheless a complex process leading to the generation of methane and carbon dioxide. The biological transformations that occur during methanisation can lead to large quantities of ammonia or hydrogen sulfide being produced if the waste is rich in nitrogen or sulphur.

[0006a] It may be necessary to manage the waste going into the methaniser carefully and to clean the outgoing biogas to ensure proper operation of the plant. In addition, leackage prevention is required to avoid underground waste pollution (4).

[0006b] Methanisation process is highly capital intensive compared to other existing technologies, since critical and expensive equipment are needed; and it is not suitable for waste containing few biodegradable matter.

[0007] Incineration is a thermal waste treatment that involves the combustion of organic substances contained in waste materials, converting them into ash and flue gas. The ash is mostly formed by the inorganic constituents of the waste, and may take the form of either solid lumps or particles carried by the flue gas.

[0007a] The generated flue gases must be cleaned of possibly toxic pollutants before they are disseminated into the atmosphere. In some cases, the heat generated by incineration can be used to generate electric power through steam. It can reduce the waste volume and weight. Unfortunately it might also result in the emission of toxic gases like dioxin, furan, and NOx gases, which requires monitoring and treating the air. The cost of an incineration plant is high and operating personnel needs to be skilled and trained. In addition, some waste materials require additional fuel to incinerate them. (5) [0008] Waste gasification involves the reaction of carbonaceous feedstock with an oxygencontaining reagent, usually oxygen, air, steam or carbon dioxide, generally at temperatures in excess of 700 °C. It involves the partial oxidation of a substance which implies that oxygen is added but the amounts are not sufficient to allow the fuel to be completely oxidized and full combustion to occur.

2018200824 04 Feb 2018 [0008a]The process is largely exothermic but some heat may be required to initiate and sustain the gasification process. The main product is a syngas, which contains carbon monoxide, hydrogen and methane. The other main product produced by gasification is a solid residue of non-combustible materials (ash) which contains a relatively low level of carbon. During gasification, tars, heavy metals, halogens and alkaline compounds are released within the product gas and can cause environmental and operational problems. Tars are high molecular weight organic gases that ruin reforming catalysts, sulphur removal systems, ceramic filters and increase the occurrence of slagging in boilers and on other metal and refractory surfaces.

[0008b] Alkalis can increase agglomeration in fluidized beds that are used in some gasification systems and also can ruin gas turbines during combustion. Heavy metals are toxic and accumulate if released into the environment. Halogens are corrosive and are a cause of acid rain if emitted to the environment. (6) [0009] Plasma Arc gasification is considered the newest type of technology in the Thermal Waste to Energy field, even though applications of plasma arc have been commonly used for decades in industrial and commercial use. Plasma Arc gasification uses very high temperatures to convert all types of waste; municipal, hazardous, commercial, organic etc into gas.

[0010] Plasma arc technology is based on electricity fed to a torch creating an electric arc between two electrodes. Inert gas is then blown through the electric arc heating it up to extremely high temperature. Due to these extremely high temperatures the waste is gasified. At these temperatures all inorganic materials such as metal, silica, concrete, gravel, glass, etc. or organic materials are vitrified and after cooling fall to the bottom of the oven. The resulting material should be stored to cool before being discharged.

[0010a] This technology is usually employed in the treatment of hazardous waste. It is a very complicated and very expensive technology. It requires the replacement of the plasma torch continuously, and it produces very high and unacceptable noise pollution.

2018200824 04 Feb 2018 [0011] Pyrolysis is a type of thermolysis, i.e. a thermochemical decomposition, which occurs in organic materials exposed to high temperatures and in the absence of oxygen, humidity, and any halogen.

[0011a] Pyrolysis requires the organic material to be dry (usually less than 10% moisture) before it enters the reaction chamber. It involves the irreversible and simultaneous change of chemical composition and physical state. It works under pressures ranging from 1 to 4.5 Bar and at temperatures in the range of 400 to 600 °C, sometimes up to 1200 °C, and the residence time is several hours.

[0011b] In general, pyrolysis of organic substances produces gas and liquid (water and bio-oil) products and leaves a solid residue rich in carbon content and char. Pyrolysis is used heavily in the chemical industry. It is also one of the processes involved in charring wood, and also occurs in fires where solid fuels are burning or when vegetation comes into contact with lava in volcanic eruptions.

[0011c] Extreme pyrolysis, which leaves mostly carbon as the residue, is called carbonization. As disadvantages, waste must be shredded or separated before entering the pyrolysis unit to prevent blockage of the feed and transport systems. It results in the production of high concentration of CO gases, which need to be treated. Furthermore, pyrolytic oils and tars contain toxic and carcinogenic compounds. The pyrolysis process is complex and requires high operational and investment costs. Moreover, an air purification installation is necessary in order to further treat flue gases from the pyrolysis. Produced ashes contain an high heavy metal content, depending on the concentrations in the to-beprocessed flow. These ashes are regarded as dangerous waste and must also be disposed of.

[0012] There is indeed an unresolved need for a process of waste treatment that is at least, compared to the state of the art technologies, less costly, in need of less space, environmental friendly with no emission of pollutants, is fast, or that can reduce the waste volume to a minimum [0013] WO 2016062881 A1 (7) discloses a method for transforming waste into carbon in a reactor, said method comprising: a) drying the waste by submitting said waste to a

2018200824 04 Feb 2018 pressure of at least 3 bar, and a temperature of at least 250 °C; b) releasing the water vapor out of the reactor, and; c) carbonizing at least partially the waste by maintaining said waste during a period of time of at least 5 minutes to a pressure of at least 3 bar, and a temperature of at least 250 °C, thereby obtaining carbon; and d) optionally separating nonorganic material from the obtained carbon.

[0013a] There are some problems in this system presenting obstacles during the operational processes and it reflects non environmental friendly impact. We particularly mention the ejection of steam loaded with hydrocarbons. A second problem is the highpressure operation which requires a very rapid ejection of hydrocarbons. Third technical problem which exists in the catalysts mentioned in this work which does not possess a high heat transfer coefficient due to the low value of helium thermal conductivity and this can cancel its role as a heat conductor. This system is designed in batches and cannot operate continuously because of the stop planned each operation to cool the reactor to remove the by-product of the operation.

[0014] WO 2017083544 A1 (8) and WO 2009127727 A1 (9) disclose a hydrothermal carbonization, i.e. a solid-liquid heating system, where the pressure is adjusted to at least 7 Bar and varies between 10 to 34 Bar, the temperature varies between 100 and 300 °C. The time of treatment is at least 2 hours and can be between 12 and 60 hours. The starting materials must be cut in millimeters. The process needs pretreatment by incubation of the materials in an acid during 2 to 6 hours. The catalyst must be added before and after the treatment. This catalyst is a (di-, tri-)carboxylic acid or sulfuric acid. Metals are also used as catalyst, these metals are heavy metals and might be toxic. The process employs a liquid jet mixing pump during the treatment. After treatment the end product is a kind of sludge and the water needs to be removed and the material dried. The water is treated by nano-filtration or reverse osmosis. The process is based on the Maillard reaction (chemical reaction between amino acid and reducing sugar), which involves three stages of treatment. The end products are peat, lignite, black coal humus (a kind of fertilizer). The final products represent 65% of the original starting mass. In the said process, reducing hydrogen, O₂, and N₂ are employed.

[0015] Lebanese patent LB 9444 (Dr. Jamil Rima) claims a wet carbonization process to transform solid organic waste into coal. The following conditions are applied to the reactor:

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1) fixing air pressure at 10 Bar; 2) fixing temperature at 450 °C; 3) introducing the catalyst which is made out of graphite and helium gases. According to this disclosure, after introducing the garbage into the reactor and after appropriate conditioning, organic material is transformed into carbon in fifteen minutes and with no toxic emissions. Unfortunately, this method does not work as water remains in the reactor thereby interfering with the carbonization reaction. Char is obtained instead of coal. Noteworthy, organic waste has a 70-80% of water content.

[0016] Rima et al. (Journal of Applied Sciences Research, 9(3): 1666-1674, 2013) (10) disclose a carbonization process using high pressure and temperature to treat medical and municipality wastes for coal production. Chars are obtained according to this process. No details are provided regarding the catalyst, mechanism and the conditions used for carbonization of the organic solid waste.

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SUMMARY OF THE INVENTION

TECHNICAL PROBLEMS [0017] Some problems exist in the High Temperature classified treatment methods presenting obstacles during the operational processes and reflecting a non- environmental friendly impact.

[0017a] The first problem is the ejection of steam which is highly loaded with hydrocarbons formed during the transformation process.

[0017b] A second problem is the high-pressure operation which requires a very rapid ejection of hydrocarbons. This requires the treatment of the steam before ejection in the environment.

[0017c] The third technical problem which exists in the catalysts, mentioned in the above works, which does not possess a high heat transfer coefficient due to the low value of helium thermal conductivity and this can cancel its role as a heat conductor.

TECHNICAL SOLUTIONS [0018] It is an objective of the present invention to provide a process and apparatus that can generate valuable materials during the treatment of organic solid waste including but not limited to, municipalities solid waste, most hospital waste, expired drugs, slaughterhouse waste, sludge collected from sewage, and industrial organic waste, without any toxic emissions.

[0018a] It is an objective of the present invention to provide a process and apparatus working continuously [0018b] It is an objective of the present invention to provide an organic waste treatment process, apparatus and materials which can give rise to clean water, sodium carbonate and carbon as source of fuel for the apparatus [0018c] It is an objective of the present invention to provide a system able to treat organic waste, within short time (10-30 minutes) without any emission in the atmosphere [0018d] It is an objective of the present invention to provide a waste treatment process that has a low operating cost as it requires minimal labor and energy resources.

2018200824 04 Feb 2018 [0018e] It is an objective of the present invention to provide an apparatus for waste treatment with continuous system 24/24 generating water, sodium carbonate and carbon [0018f] It is an objective of the present invention to provide a waste treatment process that is versatile. To improve the technology a drying system such as micro-wave has been used to dry the waste before transferring it into the carbonization reactor. Our apparatus can work also in the presence of halogen, or that requires minimal sorting of the waste prior to applying the treatment process.

[0018g] It is an objective of the present invention to provide waste treatment equipment that needs a small area to operate and is durable.

[0018h] It is an objective of the present invention to provide an apparatus for organic waste treatment process that produces high quality carbon, which can be used or sold as a source of energy, water which can be used as a new source of water, and sodium carbonate for industrial applications [0018i] It is an objective of the present invention to provide a waste treatment process that allows the treatment of most medical waste without the need for traditional sterilization and without toxic emissions.

[0018j] It is an objective of the present invention to provide a waste treatment process that allows for the treatment of soil polluted by chemicals such as organochloric or organophosphoric compounds.

[0018k] It is an objective of the present invention to provide a fossil coal treatment process that allows improving the quality of fossil coal by converting it into carbon.

[0019] The present invention attempts to meet at least one of the above mentioned objectives.

[0019a] Surprisingly, the inventor has found that, by drying the organic materials using a microwave or dryer machine before transferring the materials into the reactor, it results a carbonization during about 10 minutes.

2018200824 04 Feb 2018 [0019b] Surprisingly, the inventor has found that by speeding the rate of heating the carbonization will take place within 5 to 10 minutes.

[0019c] Surprisingly, the inventor has also found that by working under nitrogen gas the process can be improved.

[0019d] Surprisingly, the inventor has also discovered that by using an agitator equipped with blades close to the walls of the reactor, the heat will be transferred to the materials homogeneously and fast.

ADVANTAGEOUS EFFECTS OF THE INVENTION [0020] A process and an apparatus called VMW (valuable materials from solid organic wastes) is a technology that can produce from solid organic waste three valuable materials which are clean water, carbon and sodium carbonate, without producing any environmentally toxic emissions.

[0020a] VMW technology is capable of transforming waste and organic material into three valuable materials within 5 to 10 minutes in case of drying the organic waste before launching the process. It is environmentally friendly, and an economical method. The obtained carbon can be reused for heating, in cement manufacturing or other metallurgic industries. This technology is also a new source of clean and hot water.

[0021] The basis of this invention relies on the drying of the organic materials outside reactor using an industrial microwave for 20 minutes or other dryer machine. The steam water is directed inside a heat exchanger to be cooled and to produce clean water. The dry material is then transferred automatically to carbon inside the reactor which is ready at 500 °C. The process starts under nitrogen or carbon dioxide gas pressure above 1 Bar to avoid any possibility of combustion. In a short period of time, thereby carbonizing organic material and converting it into carbon within 5 to 10 minutes. The carbon dioxide obtained during the combustion of fuel with a burner is directed inside a sodium hydroxide tank which is converted into sodium carbonate. This is possible by an effective and fast transfer of heat, which in one embodiment is achieved by means of stainless steel agitator system that diffuses the heat into the material to be carbonized, in a highly effective manner. This

2018200824 04 Feb 2018 invention has the additional advantage that is its ability to work with the presence of both oxygen and humidity.

[0022] This invention has the additional advantage of working continuously

DETAILED DESCRIPTION OF THE INVENTION [0023] The present invention is an apparatus and mode of operation producing three products having values from solid organic wastes. The Combination of heat, nitrogen pressure for avoiding combustion and rapid heat transfer by using of stainless steel agitator equipped with blades close to the wall of the reactor, lead to (i) clean water after cooling via heat exchanger, (ii) to carbon by cracking the organic compounds and (iii) to sodium carbonate by capturing the carbon dioxide inside a caustic soda tank as shown in FIG 1. Starting organic materials after processing become high-purity carbon, preferably in a 92% to 97% content.

[0024] The present invention is capable of treating organic waste (for example municipality waste, hospital waste, expired drugs, slaughter house waste, skins and meat, sewage sludge, industrial organic waste, soil polluted by toxic organic chemicals, improvement of the quality of fossil coal etc.) (FIG 6) and can work both in the presence or absence of oxygen and in the presence or lack of moisture.

[0025] The beneficial results of this invention include production of carbon as an energy source; production of steam/ distilled water which can be further used; and the production of sodium carbonate by trapping the CO₂ inside a sodium hydroxide tank. Space required of use is small; processing time is fast; cost is low; and the process is environment friendly without causing any toxic emissions.

[0026] In particular, the present invention is capable of dealing with most hospital waste by transforming it to carbon without the need for sterilization.

[0027] The invention is also capable of processing expired drugs by transforming them to carbon without any toxic emissions.

[0028] The invention is also capable to transform sewage sludge to carbon without any toxic emissions.

2018200824 04 Feb 2018 [0029] The invention is also capable of transforming slaughter house waste to carbon without any toxic emissions.

[0030] This invention is capable to remediate soil polluted by toxic chemicals like Organochloric or Organophosphoric or petroleum derivatives.

[0031] This invention is capable to improve the quality of fossil coal by cracking the organic compounds which are present in this fossil compounds.

[0032] The process according to the present invention works as follows. The chemical molecules which form the starting waste include a large number of molecules like those shown in Figure 3. After water evaporates, the bonds holding the carbon molecules start to break as it is shown in Figure 4b. At the end of the required cycle, all the water is extracted from the organic material as water vapor which is directed inside heat exchanger for cooling of the steam and all the remaining material transforms into coal (carbon) as it is shown in Figure 4f.

[0033] The carbon dioxide produced during the combustion of fuel is trapped by sodium hydroxide tank to produce sodium carbonate.

[0034] According to the following reaction: 2NaOH + CO2 Na2CO₃ + H₂O [0035] Testing has shown that after cooling the water, vapor transforms into distilled water and that the carbon produced from the above-mentioned carbonization process represents a high purity carbon (like 95% to 98%) of the dry material after water evaporation as set out in Table 1 below.

Table 1

No.	Sample	Trial	%N	%c	%H	%s
1	Solid	1	0	97.8558	0	0
2	Solid	2	0	98.1207	0	0

2018200824 04 Feb 2018 [0036] After evaporating the majority of water from the processed waste by using a microwave, or dryer machine only the dry material remains which, under the influence of heat, nitrogen air pressure, and the fast transfer of heat into the waste, in one embodiment by using special agitator, it transforms into carbon through the internal breaking of C-C bonds of the organic molecules. Breaking of C-C bonds is achieved in a fast, economic, clean, and efficient way according to the present invention.

[0037] The invention relies on the speed by which the heat reaches the required temperature level and the diffusing capability to transfer the heat to all the components of the organic material inside the reactor. The invention provides an agitation system using a stainless steel agitator equipped with blades all along the axis of the agitator in order to achieve the required temperature fast and to insure the heat transfer. The blades are rather long and close to the walls of the reactors. This architecture is designed to facilitate the heat diffusion through the treated materials.

[0038] Another important aspect is the mixture of nitrogen and air at a ratio 20/80 to avoid the combustion of the material inside the reactor, with the consequent undesirable formation of carbon without ash.

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BRIEF DESCRIPTION OF DRAWINGS

FIGURE 1 - Schematic representation of VMW system showing the input of waste and the output of the water, carbon and sodium carbonate (A), detailed structure of VMW plant (B)

FIGURE 2 - Photo for the external side of the reactor

FIGURE 3 - Schematic presentation for the molecular structure of the MSW waste

FIGURE 4 - Schematic presentation showing the internal breaking of the C-C, C-H, and ΟΧ bonds in a molecule and its transformation from organic into Carbon and Water under the invention conditions

FIGURE 5 - Carbon obtained from 100 Kg of MSW under the condition of the present invention

FIGURE 6 - Show the same material, MSW, cabbage, synthetic leather, pharmaceutical products and textile, before and after VMW carbonization

FIGURE 7 - Effect of the temperature on carbon production by using VMW carbonisation process

FIGURE 8 - Effect of the pressure on carbon production by using VMW carbonisation process

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DESPRIPTION OF EMBODIMENTS [0039] The present invention relates to a method for transforming waste into carbon, distilled water and sodium carbonate in an apparatus constituted by three main components, (a) heat exchanger to cool the steam water, (b) reactor equipped with special agitator, having blades as large as they are very close to the walls of the reactor, and (c) cooling system for the exhaust equipped with sodium hydroxide tank for trapping of the carbon dioxide.

[0040] Said apparatus and method comprising:

[0040a] Dry the waste by using a microwave or oil dryer machine [0040b] Transfer the dry material automatically inside the reactor at high temperature preferred 500 °C in a mixture of nitrogen and air 20/80 [0040c] Releasing the steam remaining in the waste out of the reactor, and optionally cooling said released water vapor thereby obtaining distilled water;

[0040d] Carbonizing at least partially the waste by maintaining said waste during a period of time of at least 5 minutes, thereby obtaining carbon; and [0040e] The carbon dioxide produced during the heating of the reactor is directed via cooling system for the gas toward the sodium hydroxide tank to produce sodium carbonate [0040f] Optionally separating non-organic material from the obtained carbon [0041] In one embodiment, in the method according to the invention operate continuously after ejection of remaining water [0041c], the dry material is carbonized [0041 d]. The method comprises production of sodium carbonate inside the component of sodium hydroxide [0041 e]. Collection of the carbon obtained has been done via a valve installed at the end of the system.

[0042] In one embodiment, in the method according to the invention, the temperature of at least 250 °C is supplied by a fuel oil burner and diffused to the materials by using agitator

2018200824 04 Feb 2018 equipped with blades all along the axis of the agitator such that the blades are quite large and close to the walls of the reactor.

[0043] In one embodiment, the catalytic system comprises a heat trapping composed of graphite coating at least partially the inside walls of the reactor, and at least one metallic agitator equipped with blades as large to close to the walls of reactor.

[0044] In one embodiment, the waste is selected from municipality solid waste, hospital waste, drugs, slaughterhouse waste, sludge collected from sewage, and industrial organic waste.

[0045] In one embodiment, the waste comprises non-organic material such as metal or glass.

[0046] In one embodiment, at least a portion of the obtained carbon is recycled to heat the reactor [0047] In one embodiment, said continuously working reactor further comprises a heating system, a heat exchanger as cooling system of steam water, security valves, a microwave or oil dryer machine to dry the waste.

[0048] In one embodiment, the obtained carbon of the present invention has a purity of at least 80%, preferably at least 90% (w/w), more preferably at least 92%, even more preferably at least 95%, yet even more preferably at least 98%.

[0049] In one embodiment, the obtained water of the present invention is distilled water.

[0050] In one embodiment, the carbon dioxide obtained during the combustion of the fuel is directed via cooling exhaust system to sodium hydroxide tank to produce sodium carbonate [0051] In one embodiment the present invention can be classified in the negative carbon category according to the following definition of carbon negative “A negative carbon dioxide emission or negative emission or a process that is carbon negative gives a permanent removal of the greenhouse gas carbon dioxide from Earth's atmosphere. It is considered the direct opposite of carbon dioxide emission, hence its name”

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INDUSTRIAL APPLICABILITY AND EQUIPMENTS [0052] The device can be made out of anti-rust metal, like stainless steel, or an ironcontaining material suitable for heat induction, or any other metal capable of sustaining temperatures up to 500 °C.

[0053] Implementing this invention is done by manufacturing special machines based on the above mentioned specifications to process waste and transforming it into carbon while moisture transforms into distilled water and the carbon dioxide generated during the heating of the reactor into sodium carbonate.

[0054] This invention is done by manufacturing an automatic and continuous system.

[0055] Figure 1 presents a schematic design for the VWM.

[0056] The main components of these machines are:

[0056a] A pre-treatment system consisting of a microwave or an oil drying machine to dry the organic waste.

[0056b] anti-rust metal vessel or reactor, preferably of cylindrical shape, which is a container that can withstand the heating and pressure conditions of the invention;

[0056c] A vertical agitator installed inside the reactor which can accelerate the heat transfer [0056d] Cooling system for the steam water [0056e] Cooling carbon chamber to collect the carbon after treatment [0056f] A system designed to trap the carbon dioxide generated from the burner and bubbled into sodium hydroxide solutions to transform it into sodium carbonate [0056g] A heating system or mechanism which can be powered from different energy sources, such as but not being limited to, electricity, gas, fuel oil, the carbon generated by the machine itself or other ways, and providing sufficient heat to achieve the required

2018200824 04 Feb 2018 temperatures of the process of the invention, the sufficient heat may be in the order of

1000 to 5000 W, preferably around 2000 W.

[0056h] Mixture of nitrogen and air (20/80) pressure system, for example a nitrogen bottle and compressor, which can ensure a working pressure of at least 1.5 Bar, with the proper safety release valves, and a pressure controller may be implemented for the regulation and monitoring of the pressure; the agitator is used to accelerate the heat transfer into the material as shown in Figure 1.

[0057] The reactor is constituted of the five main parts [0057a] Three cylinders made of stainless steel 316L and each cylinder welded with dished-end top and bottom specially manufactured to support heat and pressure.

[0057a-1] The first cylinder represents the core of the reactor having a thickness of 15 mm. A metallic helicoidally serpentine with thickness of 5 mm is welded on the outer body of the reactor from bottom to top. The role of this serpentine is to conduct and diffuse heating to the inside of the reactor. Figure 2 represents an external photo for reactor [0057a-2] The second cylinder having a thickness of 8 mm is clamped to the serpentine, made from stainless steel 316L. The heating is ensured with a burner installed in nuzzle at the bottom to drive the flame bottom to top via the installed helicoidal serpentine. This nuzzle crosses the third cylinder to meet the burner which is installed outside the reactor. At the top of the second cylinder an outlet is designed and also continues to cross the third cylinder to drive the flame into a reservoir of caustic soda through a cooling system. A ceramic insulating layer covers the second cylinder from the outside with a thickness of 5 cm.

[0057a-3] The third cylinder is a cover for the insulating layer and it is also equipped with two dished-ends at the top and the bottom.

[0057b] The upper dished-end contains openings for the followings:

[0057b-1] Inlet for waste [0057b-2] Exit for water vapour

2018200824 04 Feb 2018 [0057b-3] Sensors for temperature and pressure [0057b-4] Automatic and manual safety valves [0057c] The bottom dished-end contains an automatic valve as an outlet for the carbon ejected into the cooling carbon chamber which is equipped with a cooling system. When the carbon is below than 50 °C another automatic valve is open to eject the carbon in a stock tank.

[0057d] A heat exchanger is installed on the exit of the steam in order to cool the steam down and to get clean water [0057e] A Sodium hydroxide tank is connected to the exhaust of the burner in order to trap the carbon dioxide and convert it into sodium carbonate [0058] The present invention depends on heat which needs to reach at least 250 °C, preferably between 350 and 450 °C through several possible sources of energy such as electricity, gas, coal or any other appropriate source with the need to accelerate the increase of temperature through the agitation system in the invention. Heat can be generated and transferred to the reactor from any energy source including but not limited to electricity, gas, fuel oil, coal or any alternatively appropriate source. Heat can also be generated using the Carbon produced by the machine itself. Heat inside the reactor preferably reaches 350°C to 500°C.

[0059] Nitrogen/Air Pressure should be at least 1.5 Bar, preferably to at least 8, 9, or 10 Bar. Pressure is used to ensure the waste is transformed to carbon instead of ash by preventing incineration. Although carbon starts forming at pressure of 1 Bar, the preferred implementation of the process of the invention is at a pressure of at least 8 Bar, preferably 10 Bar, at which carbon formation is full.

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DEFINITIONS [0060] The term “carbonization” or “carbonizing” refers to the conversion of organic molecules into carbon or a carbon-containing residue, by breaking carbon-carbon bonds [0061] STEAM WATER is water in the gas phase, which is formed when water boils. Steam is invisible; however, steam often refers to wet steam, the visible mist or aerosol of water droplets formed as this water vapor condenses. At lower pressures, such as in the upper atmosphere or at the top of high mountains, water boils at a lower temperature than the nominal 100°C (212°F) at standard pressure. If heated further it becomes superheated steam.

[0062] A HEAT EXCHANGER is a device used to transfer heat between a solid object and a fluid, or between two or more fluids. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact. They are widely used in space heating, refrigeration, air conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries, natural-gas processing, and sewage treatment. The classic example of a heat exchanger is found in an internal combustion engine in which a circulating fluid known as engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air. Another example is the heat sink, which is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid coolant.

[0063] SODIUM CARBONATE (IUPAC name: sodium hydrogen carbonate) is a chemical compound with the formula NaHCO₃. It is a salt composed of sodium ions and carbonate ions. Sodium bicarbonate is a white solid that is crystalline but often appears as a fine powder. It has a slightly salty, alkaline taste resembling that of washing soda (sodium bicarbonate). The natural mineral form is nahcolite. It is a component of the mineral natron and is found dissolved in many mineral springs. It is among the food additives encoded by the European Union, identified as E 500 [0063a] NaHCO₃ may be obtained by the reaction of carbon dioxide with an aqueous solution of sodium hydroxide. The initial reaction produces sodium carbonate:

CO₂ + 2 NaOH -+ Na₂CO₃ + H₂O

2018200824 04 Feb 2018 [0064] AGITATORS are machines used in industries that process products in the chemical, food, pharmaceutical and cosmetic industries, in a view of:

[0064a] mixing liquids together [0064b] promote the reactions of chemical substances [0064c] keeping homogeneous liquid bulk during storage [0064d] increase heat transfer (heating or cooling) [0065] APPARATUS WORKING CONTINUOUSLY, comprising a charging belt adapted to transfer the waste from the microwave to the reactor after drying the materials. When the treatment is completed, the final product is ejected outside the apparatus and a second batch replaces ejected batch [0066] EXTINGUISHING FIRES While N₂ would be excellent at extinguishing fires, it would also tend to extinguish human lives that would be saved if something like CO₂ were used instead.

[0067] CALORIFIC POWER is the total energy released as heat when a substance undergoes complete combustion with oxygen under standard conditions. The chemical reaction is typically a hydrocarbon or other organic molecule reacting with oxygen to form carbon dioxide and war and release heat. It may be expressed with the quantities: energy/mole of fuel (kj/mol), energy/mass of fuel, energy/volume of the fuel. As Examples Diesel fuel :44800 Kj/kg;

Lignite 16300 Kj/kg; wood 14400 Kj/kg; charcoal 29600 ; carbon 3408 Kj/kg.

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EXAMPLES

EXAMPLE 1: TREATMENT OF MUNICIPAL SOLID WASTE [0068] 100kg of municipal waste was collected and dried with microwave system and automatically was transferred into the reactor which was then pressurized to one bar by adding nitrogen/air in a proportion of 20/80 and sealed appropriately to avoid any leakage during the carbonization. A burner was used to heat the reactor and an air compressor and bottle of nitrogen to maintain the pressure more than one bar.

[0068a] When internal temperature reached 150-160 °C the pressure increased to 7 Bar, and the water presented in the reactor started coming out of the reactor as water vapour. An agitator connected with large blades, mixed the materials inside the reactor and diffused the heat through them. When temperature started reaching 250-300 °C and pressure was about 9 Bar, substantially all water in the reactor had already been released out as vapour.

[0068b] After these 20 minutes, the bottom valve of the reactor is open and the carbon is ejected inside a cooling carbon chamber which is cooled by an air blower specially made for this objective. When the temperature of the carbon is less than 50 °C the exit valve is open to deliver the carbon in a stock tank.

[0068c] The resulting product was made almost entirely of carbon with a total weight of only around 70 kg from the corresponding starting material of 100 kg of dried waste and it proved that the internal breaking of the C-C bonds of the organic compounds took place and thus a conversion of organics into carbon was achieved. Figure 5 shows the carbon obtained from the starting 100kg of municipalities solid waste, the resulting product is a black material and had no odours.

EXAMPLE 2: TREATMENT OF HOUSEHOLD WASTE [0069] Samples of approximately 1 kg of household waste were introduced into the reactor. Within 15 minutes from placing the household waste inside the reactor and operating it, the resulting material was extracted from the inside of the reactor. All the material had been transformed into coal. Laboratory tests showed that the weight of the

2018200824 04 Feb 2018 coal was 20% to 25% of the original weight of the waste, knowing that the remaining 75% to 80% represented the amount of water inside the waste and the carbon represented 92% to 95% of the remaining dry material after evaporating the water.

[0070] Tests were performed on other kinds of industrial waste like municipal solid waste, expired drugs, leather, vegetables, banana fruit, grains, synthetic materials (Figure 6), and, just like before, it was shown that after 15 minutes everything was transformed into carbon residue.

[0070a] The resulting product obtained after the carbonization of the different waste samples was analyzed with an Organic Elementary Analysis machine (Flash EA 1112, Thermo Scientific).

[0070b] The elemental analyzer is equipped with two combustion columns, one for the analysis of the carbon, nitrogen, hydrogen and sulfur under high oxygen conditions, while the other column is set up for the oxygen analysis in an oxygen free environment. All of the samples were weighed into either tin or aluminium cups for CHNS analysis or into silver cups for oxygen analysis.

[0070c] The results of the elemental analysis are shown in the Table 2 below [0071] The present invention works in a convertor and by combining heat, air/nitrogen pressure, thereby transforming wet organic material into charcoal in 10 minutes to 20 minutes. Starting organic materials after processing become carbon by cracking process, sodium carbonate by trapping the carbon dioxide into sodium hydroxide aqueous solution, purified water by cooling the steam ejected.

EXAMPLE 3: EFFECT OF TEMPERATURE ON CARBON FORMATION [0072] To test the effect of temperature on the carbon formation, the pressure inside the reactor was fixed at 10 Bar and the temperature was changed from 150 °C to 450 °C. For each value of temperature a sample was withdrawn and analyzed by the Organic Elementary Analyzer (Flash EA 1112, Thermo Scientific).

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Table 2

Sample number	%N	%c	%H	%s
1	0	98	0	0.2
2	0	98.5	0	0.1
3	0	94	0	0
4	0	97	0	0
5	0	93	0	0.07
6	0	97.5	0	0.5
7	0	99	0	0
8	0	98.8	0	0

[0073] We made several tests on the same amount of organic waste which was carbonized for 15 minutes under different temperatures. For each test, analyses in the Flash EA 1112 machine were conducted to identify the percentage of carbon.

[0074] All the obtained results were combined in a graph (Figure 7) by plotting the mass of carbon obtained in each sample in function of the temperature. Figure 7 shows that the percentage of carbon formation increases with the increase of the temperature to reach the appropriate level at around 380 °C, becoming stable at around 400 °C.

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EXAMPLE 4: EFFECT OF PRESSURE ON CARBON FORMATION [0075] To test the effect of pressure on the carbon formation, after fixing the temperature at 450 °C, we made several tests on the same amount of organic waste which was carbonized for 15 minutes while changing the air pressure by one unit bar, starting from 1 to 10 Bar. For each test, organic elemental analysis was conducted to identify the percentage of carbon and ash after an equal processing time of 15 minutes.

[0076] All the obtained results depicted in the graph of Figure 8, show that carbon starts forming when pressure is more than 3 Bar, after 4 Bar the carbonization starts to become significant, while the high level of carbonization is reached once the pressure reaches 8 Bar, preferably 10 Bar. At the atmospheric pressure the material was completely burned and it converted into ash. After 4 Bar, the ash formation was minimal and some of the organic material was converted into carbon instead. Figure 8 shows the evolution of the carbonization in function of pressure change.

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REFERENCES (1) .Sorg, T.J., H. Lanier Hickman, Sanitary Landfill Facts, SW-4ts U.S. Department of Health, Education and Welfare, Public Health Service, National Center for Urban and Industrial Health, Solid Waste Program, Cincinnati, Ohio, USA, 1968.

(2) Karen M. Slimak Landfill Disposal Systems. Environmental Health Perspectives Vol. 27, pp. 309-316, 1978 (3) G. Tchobanoglous, H. Theisen, S.A. Vigil, Integrated Solid Waste ManagementEngineering Principles and Management Issues, McGraw-Hili, New York, 1993. pp671 716.

(4) Daniell, J., Kopke, M., Simpson, S. Commercial Biomass Syngas Fermentation. Energies, 5(12), 5372-5417 2012 (5) Crown Andersen. . Air Pollution Control and Incineration Systems photos. htto://www.crownandersen.com/Rotary.html 1998 (6) Di Blasi, C., Dynamic behaviour of stratified downdraft gasifier. Chemical Engineering Science 55, 2931-2944 2000 (7) Method and apparatus for rapid dry carbonization of organic waste, apparatus and catalytic system associated to the method WO 2016062881 A1 (8) System for hydrothermal treatment of wet biomass WO 2017083544 A1 (9) Process for converting biomass to coal-like material using hydrothermal carbonisation WO 2009127727 A1 (10) Jamil Rima, Karine Assaker, Thibault Roques-Carmes, Abdul Halim

Mouneimne and Fatima El Ali Developing a new carbonization process using high pressure and temperature to treat medical and municipality wastes for coal production Journal of Applied Sciences Research, 9(3):1666-1674, 2013

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Claims

1- Dried Organic Household Waste 11- Dosing Pump (CATALYST) 21-Vent 2- Agitator Motor 12- Flame Arrestor 22- Flue Gas Cooling Chamber 3- Pressure Relief and Temperature Control 13-DIESEL Burner 23-Flue Gas at < 100°C 4- Carbonization Chamber 14- DIESEL Tank 24-Sodium Hydroxide Holding Tank 5- Steam at 500°C 15-AIR DRIVER 25- Inspection Sight Glass 6- Carbon Cooling Chamber 16- COMPRESSOR 26- Sodium Carbonate Collection 7- Carbon 17- Schiller Tank 8- STEAM 18- Control Panel 27-Tank DRAIN 9- Heat Exchanger 19- Flue Gas at 500°C 10- Water 20- Air Blower Cooling

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DRAWINGS

Figure 1

1. The Apparatus VMW (Valuable materials from solid organic waste) is designing to be operating. VMW system requires 316 L stainless steel, high temperature and high pressure vessel capable of 150 psi (10 Bar) and 500°C heat. Heat is provided by a single diesel burner which will heat the vessel up to the required temperature for the carbonization process to take place. The agitator used in the process is designed with blades as large as close the walls of the reactor and then it plays the role of catalyst to convert all organic waste to carbon within 25 minutes.

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2. The walls of the reactor are painted in graphite to conserve the heat

3 20

U

150 200 250 300 350 400 450

Temperature (°C)

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Figure 3

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Figure 4

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Example of Starting Molecule

3. Other systems that will be associated with the Prototype will be, pneumatic valves, compressor,sensors , heat exchanger to convert steam to water

4. A CO₂ trapping system consisting of an exhaust having serpentine shape installed in a cold air chamber .The carbon dioxide is ejected into sodium hydroxide solution at adequate concentration in order to produce sodium carbonate. All systems will be monitored via control panel .The VMW process is ZERO WASTE and ZERO EMISSIONS.

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Figure 5

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5. The Prototype will be built so that entire unit can be transported to any location for demonstration purposes. The VMW will pass all WHO requirements and will be subject to EPA approval.

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Figure 6

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Material

Before VMW

AfterVMW

Municipal Solid Waste

Cabbage

Banana

Leather

Synthetic belt

Expired Drugs

Textile

6. The Prototype for transforming waste into carbon in a reactor, said apparatus is comprising:

i) Drying the waste by submitting said waste to a pressure of at least 3 bar, and a temperature of at least 250 °C;

ii) Releasing the water vapor out of the reactor, and cooling said released water vapor thereby obtaining distilled water;

2018200824 04 Feb 2018 iii) carbonizing at least partially the waste by maintaining said waste during a period of time of at least 5 minutes to a pressure of at least 3 bar, and a temperature of at least 250 °C, thereby obtaining carbon; and iv) Optionally separating non-organic material from the obtained carbon.

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Figure 7

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100 o

OJJ 'S

7. The apparatus according to claim 4, wherein in step a) and in step c), said pressure is, each independently, at least 4 Bar, at least 5 Bar, at least 6 Bar, at least 7 Bar, at least 8 Bar, at least 9 Bar, or at least 10 Bar.

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Figure 8

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Ash percentage (%)

8 60 ω

Oh

I 40 cs

N •

8. The apparatus according to claim 4 or 5, wherein in step a) and in step c), said temperature is, each independently, at least 275 °C, at least 300 °C, at least 325 °C, or at least 350 °C.

9. The apparatus according to any one of claims 1 to 6, wherein in step c), said period of time is at least 7 minutes, at least 10 minutes, at least 15 minutes, or at least 20 minutes.

10. The apparatus according to any one of claims 1 to 7, wherein said method, after the carbonizing step 4- c), the door in the bottom of the reactor is open automatically.

11. The apparatus according to any one of claims 1 to 8, wherein the temperature of at least 250 °C is supplied by a heating means and agitator system to diffuse the temperature inside the waste .

12. The apparatus according to claim 9, wherein the agitator equipped with blades close the walls of the reactor. The shaft is connected to the motor through an insulating partition to prevent the transfer of heat to the motor. This stirring system can work at high pressure (10 bar) and high temperature (500 °C).

13. The method according to any one of claims 1 to 10, wherein the waste is selected from municipality solid waste, hospital waste, drugs, slaughterhouse waste, and sludge collected from sewage, and industrial organic waste.

14. The method according to any one of claims 1 to 11, wherein at least a portion of the obtained carbon is recycled to heat the reactor.

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15. The reactor according to claim 1,12, wherein said reactor further comprises a heating system, a cooling system, an air-pressure system, a security valves.

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Figure 9

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