Waste treatment system and method using energy recycling technology

Abstract

A system (28) for treating waste is provided. The waste treatment system of the present invention is a waste treatment reactor (10) configured to treat waste. The waste treatment reactor (10) has a cylindrical body (12) having an inlet (14) for receiving waste, a waste chamber (26) for storing waste (28), and an outlet (16) for discharging treated waste from the waste chamber. A first tube bundle reactor (38) has a waste treatment reactor and performs waste treatment on the waste stored in the waste chamber. An energy recycle assembly (40) is connected to the tube bundle reactor and recycles thermal energy associated with the tube bundle reactor during waste treatment. The energy recycle assembly (40) includes a heating device (42) for heating a first region of the tube bundle reactor and a cooling device (44) for cooling a second region of the tube bundle reactor.

Description

[Technical Field]

[0001] The present invention relates to a waste treatment system, and more particularly to a waste treatment system and a waste treatment method using energy recycling technology. [Background technology]

[0002] In recent years, the amount of waste generated in the world has increased at an alarming rate, and the current waste disposal methods using existing waste disposal systems are extremely complex and energy inefficient. Furthermore, due to industrial evolution and population growth, landfill capacity is significantly reduced, and waste disposal costs are significantly increasing. Therefore, various disposal systems have been developed to enhance waste reduction, carbon capture, and waste reuse during waste disposal.

[0003] For example, in municipal solid waste (MSW) processing, existing waste treatment systems typically use large reactors that require heavy machinery, resulting in skyrocketing power and energy consumption for MSW processing. Because most MSW treatment technologies rely on such high-energy and mechanical systems, existing MSW systems often incur significant costs for operation. Furthermore, there are growing concerns about potential contamination of water resources and air pollution, as well as increased health risks posed by certain types of reactor equipment. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need to develop an enhanced waste treatment system for treating waste that overcomes one or more of the above-mentioned shortcomings of existing waste treatment systems. [Means for solving the problem]

[0005] In one embodiment of the present disclosure, a system for treating one or more waste products is provided, the system including a first waste treatment reactor configured to treat the waste products. The first waste treatment reactor has a cylindrical body including an inlet configured to receive the waste products, a waste chamber configured to store the waste products and an aqueous solution, and an outlet configured to discharge the treated waste products from the waste chamber. The first tube bundle reactor includes a first waste treatment reactor and is configured to perform waste treatment on the waste products stored in the waste chamber of the first waste treatment reactor. A first energy recycle assembly is connected to the first tube bundle reactor and configured to recycle thermal energy associated with the first tube bundle reactor during waste treatment. The first energy recycle assembly includes at least one of a first heating device configured to heat a first region of the tube bundle reactor and a first cooling device configured to cool a second region of the first tube bundle reactor.

[0006] In one example, the first waste treatment reactor includes a recirculation device configured to facilitate circulation of vapor and liquid formed within the cylindrical body of the first waste treatment reactor.

[0007] In another example, the first heating device is configured to heat the aqueous solution in a first region of the first tube bundle reactor, and the first cooling device is configured to cool the waste in a second region of the first tube bundle reactor.

[0008] In yet another example, the system further includes a second tube bundle reactor having a second waste treatment reactor and configured to perform waste treatment on waste stored in a waste chamber of the second waste treatment reactor, and a second energy recirculation assembly connected to the second tube bundle reactor and configured to recirculate thermal energy associated with the second tube bundle reactor during waste treatment. The second energy recirculation assembly includes at least one of a second heating device configured to heat a first region of the second tube bundle reactor and a second cooling device configured to cool a second region of the second tube bundle reactor. In one variation, the first energy recirculation assembly and the second energy recirculation assembly are configured to recirculate thermal energy between the first tube bundle reactor and the second tube bundle reactor using at least one of the first cooling device, the first heating device, the second cooling device, and the second heating device. In another variation, the first cooling device is configured to provide thermal energy associated with the first cooling device to treated waste associated with the second tube bundle reactor. In yet another variation, the first heating device is configured to provide thermal energy associated with the first heating device to waste associated with the second tube bundle reactor. In yet another variation, thermal energy associated with the first tube bundle reactor at a first waste treatment process step is provided to waste associated with the second tube bundle reactor at a second waste treatment process step that is different from the first waste treatment process step. In yet another variation, the first cooling device is configured to provide thermal energy associated with the first cooling device to a second cooling device associated with the second tube bundle reactor. In a further variation, the first heating device is configured to provide thermal energy associated with the first heating device to a second heating device associated with the second tube bundle reactor.

[0009] Another embodiment of the present disclosure provides a reactor for treating one or more waste materials. The reactor is a cylindrical body having a first end and an opposite second end. The first end is configured to receive waste material for treatment, and the second end is configured to discharge the treated waste material from the cylindrical body. The cylindrical body has a predetermined length-to-diameter ratio that operates as a heating tube when the waste material is treated. The predetermined length-to-diameter ratio is defined by the longitudinal length of the cylindrical body and the outer diameter of the cylindrical body, and has a predetermined value defined by a lower limit and an upper limit.

[0010] In one example, the reactor includes a heating element configured to heat a first heating zone of the reactor. In a variation, the waste material is heated using at least one of a volumetric steam flow and a volumetric fluid flow generated by the heating element. In another variation, the reactor includes a retention element configured to retain the waste material within the retention element. In yet another variation, the reactor includes a support element configured to support the retention element of the reactor within the waste chamber during waste treatment. In yet another variation, the support element is configured to space the retention element a predetermined distance from the heating element. In yet another variation, the reactor includes a suspension support element configured to allow the retention element to be suspended within the reactor during waste treatment. In a further variation, the retention element includes a flow path configured to facilitate flow of the aqueous solution within the reactor.

[0011] In another example, the reactor includes a supplemental heating element configured to heat a second heating zone of the reactor. In a variation, the heating element is configured to heat the first heating zone to a first predetermined temperature and the supplemental heating element is configured to heat the second heating zone to a second predetermined temperature.

[0012] In yet another example, the reactor further includes a condensate injection member configured to generate condensate within the reactor and inject the condensate into the waste to heat a predetermined portion of the waste.

[0013] In yet another example, the reactor is configured to heat the waste material using at least one of a volumetric vapor flow and a volumetric liquid flow generated within the cylindrical body.

[0014] The methods, systems, and apparatus disclosed herein can be implemented in any manner to achieve various aspects. Other features will be apparent from the accompanying drawings and the detailed description that follows.

[0015] Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like reference numerals refer to similar equipment and in which: [Brief explanation of the drawings]

[0016] [Figure 1A] 1 is a schematic diagram illustrating an exemplary configuration of a waste treatment reactor configured to treat one or more waste materials in accordance with an embodiment of the present disclosure. [Figure 1B] 1 is a schematic diagram illustrating an exemplary configuration of a waste treatment reactor configured to treat one or more waste materials in accordance with an embodiment of the present disclosure. [Figure 1C] 1 is a schematic diagram illustrating an exemplary configuration of a waste treatment reactor configured to treat one or more waste materials in accordance with an embodiment of the present disclosure. [Figure 2] 2 is a schematic diagram of the waste treatment reactor of FIG. 1 when waste and an aqueous solution are introduced into the waste treatment reactor for waste treatment. [Figure 3] 3 is an exemplary graph showing the relationship between the temperature of an aqueous solution and time of waste in the waste treatment reactor of FIG. 2 during waste treatment. [Figure 4] FIG. 1 is a schematic diagram of a tube bundle reactor configured for treating one or more waste products in accordance with an embodiment of the present disclosure. [Figure 5] FIG. 5 is a schematic diagram of the tube bundle reactor of FIG. 4 connected to a heating assembly in accordance with an embodiment of the present disclosure. [Figure 6] FIG. 6 is a schematic diagram of the tube bundle reactor of FIG. 5 connected to a gate valve in accordance with an embodiment of the present disclosure. [Figure 7]FIG. 7 is a schematic diagram of the tube bundle reactor of FIG. 6 operating together with another tube bundle reactor as a continuous waste treatment system in accordance with an embodiment of the present disclosure. [Figure 8] FIG. 5 is a schematic diagram illustrating an example of a waste treatment system using the twin tube bundle reactor of FIG. 4 in accordance with an embodiment of the present disclosure. [Figure 9] FIG. 7 is a schematic diagram illustrating another example of a waste treatment system using multiple tube bundle reactors of FIG. 6 in accordance with an embodiment of the present disclosure. [Figure 10] 10 is a schematic diagram illustrating an embodiment of a dewatering and drying vessel configured for use in the waste treatment system of FIG. 9. [Figure 11] 10 illustrates the relationship between each of the tube bundle reactors of the waste treatment system of FIG. 9 and an example of the waste treatment process steps associated with each of the tube bundle reactors during waste treatment. [Figure 12] FIG. 7 is a schematic diagram illustrating yet another example waste treatment system using three of the tube bundle reactors of FIG. 6 and a dewatering system according to an embodiment of the present disclosure. [Figure 13] 13 illustrates the relationship between each of the tube bundle reactors of the waste treatment system of FIG. 12 and an example of the waste treatment process steps associated with each of the tube bundle reactors during waste treatment. [Figure 14] 1 illustrates a detailed cross-sectional side view of a waste treatment reactor having a heating element configured to heat a first heating zone of the waste treatment reactor according to an embodiment of the present disclosure. [Figure 15] 15 shows a side cross-sectional detail of another embodiment of the waste treatment reactor of FIG. 14, featuring different configurations of heating elements configured to heat different regions of the waste treatment reactor. [Figure 16] 15 shows a side cross-sectional detail of yet another embodiment of the waste treatment reactor of FIG. 14, featuring a support member configured to support a retaining member containing waste within the waste treatment reactor. [Figure 17]15 is a side cross-sectional detail of yet another embodiment of the waste treatment reactor of FIG. 14, featuring a retaining member having a longitudinally extending channel; [Figure 18] 18 shows a perspective view of a retaining member having a channel shown in FIG. 17. [Figure 19] 15 is a detailed side cross-sectional view of the waste treatment reactor of FIG. 14 treating waste within a retention element using a steam flow generated by a heating element. [Figure 20] 15 is a side cross-sectional detail showing another configuration of the waste treatment reactor of FIG. 14, characterized in that the heating element has an additional heating element configured to heat a second heating zone of the waste treatment reactor in accordance with an embodiment of the present disclosure. [Figure 21] 15 shows a schematic diagram of yet another configuration of the waste treatment reactor of FIG. 14 with inlet and outlet valves according to an embodiment of the present disclosure. [Figure 22] 20 shows a schematic diagram of yet another configuration of the waste treatment reactor of FIG. 19 with a condensate injection member according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0017] Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.

[0018] Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.

[0019] FIG. 1 (i.e., FIGS. 1A, 1B, and 1C) illustrates an example of a waste treatment reactor 10 configured to treat waste, such as household sludge or solid waste. For example, the waste is MSW. In one embodiment, the waste treatment reactor 10 has a cylindrical or tubular body 12 having a first end 14 and an opposite second end 16. In one embodiment, the waste treatment reactor 10 is an elongated stainless steel tube configured for use as a kiln or reaction vessel.

[0020] In an embodiment, the first end 14 includes an inlet configured to receive waste into the cylindrical body 12 for treatment, and the second end 16 includes an outlet configured to discharge treated waste out of the cylindrical body 12. The cylindrical body 12 of the waste treatment reactor 10 illustratively has a longitudinal length L of approximately 2 meters and an outer diameter D of approximately 0.2 meters. The volume or capacity of the cylindrical body 12 illustratively is approximately 50 liters.

[0021] In one embodiment, to operate properly as a reaction vessel (e.g., a heated tube), the waste treatment reactor 10 is specifically configured such that the length and diameter of the cylindrical body 12 have a predetermined ratio R. An example of the length to diameter ratio R of the cylindrical body 12 is related to the surface area ratio and can be expressed by the following equations (1) and (2):

[0022]

number

[0023]

number

[0024] For example, the lower limit λ1 can be 10 and the upper limit λ2 can be 30. However, other suitable values ​​for the lower and upper limits, i.e., λ1 and λ2, can be considered to suit different applications. In this way, to appropriately increase the size of the cylindrical body 12 of the waste treatment reactor 10, the length-to-diameter ratio R is not changed, and the length-to-outer diameter ratio R is maintained between the lower limit λ1 and the upper limit λ2.

[0025] In one embodiment, the waste treatment reactor 10 is configured to operate as a heating tube configured to efficiently transfer heat between the first end 14 and the second end 16 during waste treatment. In one embodiment, the inner surface 18 of the cylindrical body 12 includes a closed-loop recirculation system 20 configured to facilitate circulation of vapor and liquid generated within the cylindrical body 12 during waste treatment. In one embodiment, the inner surface 18 of the cylindrical body 12 is welded by overlay welding.

[0026] For example, the recirculation device 20 includes a plurality of protrusions 22 made of a nickel-based powder overcoat or powder additive material extending longitudinally from the inner surface 18 of the cylindrical body 12 between the first end 14 and the second end 16. In this configuration, after steam condenses on the inner surface 18 of the cylindrical body 12, the condensed water can move or flow along the plurality of internal grooves 24 formed by the protrusions 22 between the first end 14 and the second end 16 due to gravity or capillary force.

[0027] 2, the waste treatment reactor 10 includes a waste chamber 26 configured to hold or store one or more waste materials 28, such as MSW, mixed with an aqueous solution 30, such as water, to form a waste sludge or slurry. In an embodiment, the mixture of waste materials 28 and aqueous solution 30 is introduced into the waste chamber 26 of the waste treatment reactor 10.

[0028] In one embodiment, the weight ratio of water to MSW is, for example, approximately 1:1 (e.g., approximately 12.5 kilograms (kg) of MSW to approximately 12.5 liters (L) of water, where the MSW is metal-free organic waste and the water is at approximately 70-80°C. The bulk density of MSW is, for example, approximately 4.09 liters per kilogram (L / kg).

[0029] Figure 3 shows a specific example of the relationship between the temperature [Temp] of the aqueous solution 30 during waste treatment and the time [Time] of the waste 28 in the waste treatment reactor 10. In Figure 3, the X-axis represents the time [Time] of the waste 28 in the waste treatment reactor 10, and the Y-axis represents the temperature [Temp] of the aqueous solution 30 during waste treatment.

[0030] In one embodiment, the waste 28 in the waste treatment reactor 10 is first heated for a first predetermined time [Time1] to reach a first predetermined temperature [Temp1], as shown in the first line 32. This is referred to as the heating step of the waste treatment. Specific examples of the first predetermined temperature [Temp1] are in the range of approximately 100 to 350°C.

[0031] For example, the first predetermined time [Time1] is approximately 10 minutes, and the first predetermined temperature [Temp1] is approximately 280° C. In one embodiment, subcritical water is used to treat the waste. The heating method can be any conventional heating technique, such as induction heating or electrical heating.

[0032] After the heating step is completed, the current temperature of the waste 28 in the waste treatment reactor 10 is maintained at the first predetermined temperature [Temp1] for a second predetermined time [Time2], as shown by the second line 34. This is called the waste treatment holding step. For example, the residence time defined by the second predetermined time [Time2] is approximately 10 minutes.

[0033] After the holding step is completed, the waste 28 in the waste treatment reactor 10 is cooled for a third predetermined time [Time3] to reach a second predetermined temperature [Temp2], as shown by the third line segment 36. This is called the cooling step of the waste treatment. For example, the third predetermined time [Time3] is approximately 10 minutes, and the second predetermined temperature [Temp2] is in the range of approximately 70-100°C.

[0034] In the illustrated embodiment, all of the heating, holding, and cooling process steps of the waste treatment require approximately 30 minutes to complete the necessary chemical reactions on the waste 28 within the waste treatment reactor 10 and convert the waste 28 into value-added recycled materials. For example, the waste treatment reactor 10 can be used to perform hydrothermal carbonization (HTC) to convert MSW into sterile charcoal-like products such as hydrochar or biochar, which are characterized by high carbon content and high calorific value.

[0035] 4 illustrates a tube bundle reactor 38 configured to treat one or more waste materials 28 in accordance with an embodiment of the present disclosure. In one embodiment, the tube bundle reactor 38 includes one or more waste treatment reactors 10, each of which simultaneously treats a waste material 28. A distributed reactor, such as the tube bundle reactor 38, can enhance the thermal response of the waste material 28 during waste treatment.

[0036] 4, four waste treatment reactors 10 are used, and thus the volume or capacity of the tube bundle reactor 38 is illustratively approximately 200 liters. Although four waste treatment reactors 10 are shown for illustrative purposes, any number of waste treatment reactors 10 may be provided in the tube bundle reactor 38 to suit different applications. For example, the tube bundle reactor 38 may have a single waste treatment reactor 10 or two or more waste treatment reactors 10, depending on the desired configuration.

[0037] 5, in one embodiment, the tube bundle reactor 38 is a single waste treatment reactor 10 and is connected to an energy recycle assembly 40 configured to recycle thermal energy associated with the tube bundle reactor 38. In one embodiment, the energy recycle assembly 40 includes a heating device 42 configured to heat a first region of the tube bundle reactor 38 and a cooling device 44 configured to cool a second region of the tube bundle reactor 38.

[0038] For example, the heating device 42 is configured to inductively heat the aqueous solution 30 in the lower portion of the tube bundle reactor 38 to a first predetermined temperature [Temp1] during a heating process step of the waste treatment to induce a chemical reaction in the waste 28. In one embodiment, the heating device 42 comprises a continuous pipe configured to surround the outer surface of the lower portion of the tube bundle reactor 38.

[0039] Conversely, the cooling device 44 is configured to cool the waste 28 in the upper portion of the tube bundle reactor 38 to a second predetermined temperature [Temp2] during the cooling process step of the waste treatment. In one embodiment, the cooling device 44 comprises a continuous pipe configured to surround the exterior surface of the upper portion of the tube bundle reactor 38.

[0040] 2 and 4-5, in one embodiment, tube bundle reactor 38 is fluidly connected at one end to a first connector 46 configured to transfer waste 28 out of waste chamber 26 (FIG. 2) and at an opposite end to a second connector 48 configured to receive waste 28 into waste chamber 26. For example, first connector 46 and / or second connector 48 can be used to connect additional piping or other suitable components for transferring waste 28 into and out of waste chamber 26.

[0041] In one embodiment, a relief valve 49 is connected to the tube bundle reactor 38 and configured to release internal pressure built up in the waste chamber 26 of each waste treatment reactor 10 in the tube bundle reactor 38. For example, oxygen gas accumulated in the waste chamber 26 of each waste treatment reactor 10 can be released through the relief valve 49 during the heating step of the waste treatment process. As steam generated in the waste chamber 26 evaporates through the relief valve 49, the oxygen gas is pushed out of the waste chamber 26 by the steam. As a result, primarily carbonized waste and water remain in the waste treatment reactor 10.

[0042] 6, in one embodiment, the first connector 46 is fluidly connected to a first reducer 50 configured to permit the flow of waste 28, which in turn is fluidly connected to a first gate valve 52 configured to stop or start the flow of waste 28. The first gate valve 52 functions as a shut-off valve in the pipeline, although other suitable valves, such as a control valve or regulator valve, are contemplated depending on the application.

[0043] Similarly, the second connector 48 is fluidly connected to a second reducer 54 configured to permit the flow of waste 28, which in turn is fluidly connected to a second gate valve 56 configured to stop or start the flow of waste 28. Other suitable connectors, such as additional conduits, manifolds, piping, etc., may also be connected to suit different applications. For example, a four-way manifold may fluidly connect the four waste treatment reactors 10 of the tube bundle reactor 38 to the first reducer 50.

[0044] 7, the tube bundle reactor 38 operates side-by-side with another tube bundle reactor 38' as a continuous waste treatment system according to embodiments of the present disclosure. In one embodiment, a second gate valve 56 is fluidly connected to a hopper 58 configured to receive the waste 28.

[0045] At the opposite end, a first gate valve 52 is fluidly connected to a holding tank 60 configured to hold the treated waste 28', such as biochar, biogas, or biofuel, upon completion of at least one of the heating, holding, and cooling process steps of the waste treatment. Additional process steps of the waste treatment, such as dehydration and drying of the treated waste 28', can be performed for further processing. A detailed description of the additional process steps is provided below in the paragraphs associated with Figures 9-13.

[0046] 8 illustrates an example waste treatment system 100 using a pair of tube bundle reactors 38 and 38'. In the illustrated embodiment, a pair of tube bundle reactors 38 and 38' are used to recycle the thermal energy associated with each of the tube bundle reactors 38, 38' during waste treatment. In one embodiment, a transport system 62, such as a conveyor system, is used to feed the waste 28 into the hopper 58 and is configured to continuously advance the waste 28 in the flow direction indicated by arrow A.

[0047] 8, the first tube bundle reactor 38 is connected to a first energy recycle assembly 40 configured to recycle thermal energy associated with the first tube bundle reactor 38. Similarly, the second tube bundle reactor 38' is connected to a second energy recycle assembly 40' configured to recycle thermal energy associated with the second tube bundle reactor 38'. In this configuration, the first energy recycle assembly 40 includes a cooler 44 for the first tube bundle reactor 38, and the second energy recycle assembly 40' includes a cooler 44' for the second tube bundle reactor 38'.

[0048] In one embodiment, the heating device 42 has one or more heating induction coils 64 configured to surround at least a portion (e.g., a lower region) of the first tube bundle reactor 38 and is connected to a high-frequency power supply 66 to operate the heating induction coils 64 by electromagnetic induction. The heating device 42′ also has one or more heating induction coils 64 configured to surround at least a portion (e.g., a lower region) of the second tube bundle reactor 38′ and is connected to the high-frequency power supply 66.

[0049] In one embodiment, the RF power supply 66 generates and applies a RF current sufficient to raise the temperature of the first and second tube bundle reactors 38, 38' to a first predetermined temperature [Temp1]. During waste treatment, the mixture of waste 28 and aqueous solution 30 is treated using the heating induction coil 64, and the treated waste 28' is delivered to the holding tank 60.

[0050] An example of the RF power supply 66 has an energization frequency of approximately 20 kilohertz (KHz) and a maximum power output of approximately 270 kilowatts (KW). In one embodiment, the energization frequency of the RF power supply 66 ranges between 100 KW and 120 KW. However, the frequency and maximum power output of the RF power supply 66 can be varied to suit different applications.

[0051] In the illustrated embodiment, a control system 68 is communicatively coupled to the radio frequency power supply 66 via a communication link 70. In some embodiments, the communication link 70 may include a wired and / or wireless data transmission interface. In one embodiment, the control system 68 is communicatively coupled to various portions of the waste treatment system 100, such as the transfer system 62 and the energy recycle assembly 40, via the communication link 70 and is configured to control the operation of the waste treatment system 100 during waste treatment.

[0052] In one embodiment, the control system 68 executes computer-readable program instructions that are stored in one of the memories of the electronic controllers within the control system 68 and executed by the processors of the respective electronic controllers or other computer-usable media. In another embodiment, the control system 68 includes modules or controllers that may or may not be separate from one of the electronic controllers of the waste treatment system 100.

[0053] In one embodiment, the control system 68 can command or direct the associated valves (e.g., the first gate valve 52 and the second gate valve 56) to appropriately operate the corresponding valves to maintain appropriate internal pressures in the first and second tube bundle reactors 38, 38' when operating. Other suitable automated operation of the waste treatment system 1100 can be accomplished by the control system 68.

[0054] In one embodiment, the control system 68 is communicatively coupled to the RF power supply 66 via a communication link 70. In one embodiment, the control system 68 executes computer-readable program instructions that are stored in one of the memories of an electronic controller within the control system 68 and executed by a processor of the electronic controller or other computer-usable medium.

[0055] In another embodiment, the control system 68 includes a module or controller that may or may not be separate from one of the electronic controllers of the waste treatment system 100. For example, the control system 68 may be a programmable logic controller (PLC) or a programmable controller.

[0056] In one embodiment, the control system 68 automatically controls the opening and closing of the first gate valve 52 and / or the second gate valve 56 by instructing each of the gate valves 52, 56 using computer readable program instructions. In another embodiment, the control system 68 automatically controls the starting and stopping of the transfer system 62 by instructing the transfer system 62 using computer readable program instructions. Other suitable operations, such as measuring the current temperature of the waste treatment reactor 10 within the corresponding tube bundle reactor 38, 38', are contemplated as appropriate for the application.

[0057] In one embodiment, the cooling device 44 includes one or more cooling pipes 72 configured to surround at least a portion (e.g., an upper region) of the first tube bundle reactor 38 and to deliver a coolant 74 into the hopper 58. The cooling device 44′ also includes one or more cooling pipes 72 configured to surround at least a portion (e.g., an upper region) of the second tube bundle reactor 38′ and to deliver a coolant 74 into the hopper 58.

[0058] A coolant 74, such as water, is placed in one end of the cooling tubes 72 of the cooling device 44 in the first tube bundle reactor 38 to cool the upper region of the first tube bundle reactor 38. As the upper region of the first tube bundle reactor 38 is cooled, the coolant 74 is heated within the cooling tubes 72. The heated coolant 74 is sent from the other end of the cooling tubes 72 of the cooling device 44 to the hopper 58 associated with the second tube bundle reactor 38', where it is mixed with the waste 28 and enters the waste treatment reactor 10 of the second tube bundle reactor 38'.

[0059] Conversely, the coolant 74 is admitted to one end of the cooling tubes 72 of the cooling device 44' associated with the second tube bundle reactor 38' and cools the upper region of the second tube bundle reactor 38'. As the upper region of the second tube bundle reactor 38' is cooled, the coolant 74 is heated within the cooling tubes 72. The heated coolant 74 is sent from the opposite end of the cooling tubes 72 of the cooling device 44' to the hopper 58 associated with the first tube bundle reactor 38, where it is mixed with the waste 28 and enters the waste treatment reactor 10 of the first tube bundle reactor 38.

[0060] Thus, the first energy recycle assembly 40 and the second energy recycle assembly 40' can recycle thermal energy between the first tube bundle reactor 38 and the second tube bundle reactor 38' using the respective cooling devices 44, 44'. Similarly, thermal energy recycle can also be performed with the thermal energy associated with the respective heating devices 42 and 42'. Further description of thermal energy recycle techniques is provided below in the paragraphs associated with Figures 9-13.

[0061] 9 illustrates another example waste treatment system 200 using multiple tube bundle reactors 38A-38F in accordance with an embodiment of the present disclosure. While six tube bundle reactors 38A-38F are shown for illustrative purposes, any number of tube bundle reactors may be used depending on the application. In the illustrated embodiment, the multiple tube bundle reactors 38A-38F are configured to share and recycle thermal energy between the tube bundle reactors, advantageously improving energy efficiency during waste treatment.

[0062] In this configuration, the first tube bundle reactor 38A is connected to a first energy recycle assembly 40A having a first heating device 42A and a first cooling device 44A, and is configured to recycle thermal energy associated with the first tube bundle reactor 38A. Unlike FIG. 8, the first energy recycle assembly 40A includes both the first cooling device 44A and the first heating device 42A for the first tube bundle reactor 38A. This configuration is similar for the other tube bundle reactors 38B-38F. A first hopper 58A is fluidly connected to the first tube bundle reactor 38A at one end, and a first holding tank 60A is fluidly connected to the first tube bundle reactor 38A at the opposite end.

[0063] Similarly, the second tube bundle reactor 38B is connected to a second energy recycle assembly 40B having a second heating device 42B and a second cooling device 44B configured to recycle thermal energy associated with the second tube bundle reactor 38B. A second hopper 58B is fluidly connected to the second tube bundle reactor 38B at one end, and a second holding tank 60B is fluidly connected to the second tube bundle reactor 38B at an opposite end.

[0064] The third tube bundle reactor 38C is connected to a third energy recycle assembly 40C having a third heating device 42C and a third cooling device 44C configured to recycle thermal energy associated with the third tube bundle reactor 38C. A third hopper 58C is fluidly connected to the third tube bundle reactor 38C at one end and a third holding tank 60C is fluidly connected to the third tube bundle reactor 38C at an opposite end.

[0065] The fourth tube bundle reactor 38D is connected to a fourth energy recycle assembly 40D having a fourth heating device 42D and a fourth cooling device 44D configured to recycle thermal energy associated with the fourth tube bundle reactor 38D. A fourth hopper 58D is fluidly connected to the fourth tube bundle reactor 38D at one end and a fourth holding tank 60D is fluidly connected to the fourth tube bundle reactor 38D at an opposite end.

[0066] The fifth tube bundle reactor 38E is connected to a fifth energy recycle assembly 40E having a fifth heating device 42E and a fifth cooling device 44E configured to recycle thermal energy associated with the fifth tube bundle reactor 38C. A fifth hopper 58E is fluidly connected to the fifth tube bundle reactor 38E at one end, and a fifth holding tank 60E is fluidly connected to the fifth tube bundle reactor 38E at an opposite end.

[0067] The sixth tube bundle reactor 38F is connected to a sixth energy recycle assembly 40F having a sixth heating device 42F and a sixth cooling device 44F configured to recycle thermal energy associated with the sixth tube bundle reactor 38F. A sixth hopper 58F is fluidly connected to the sixth tube bundle reactor 38F at one end, and a sixth holding tank 60F is fluidly connected to the sixth tube bundle reactor 38F at an opposite end.

[0068] Specifically, the first energy recycle assembly 40A recycles thermal energy between the first tube bundle reactor 38A and the second tube bundle reactor 38B using a first heating device 42A. More specifically, the thermal energy associated with the first heating device 42A is applied to the waste material 28 in the second hopper 58B to preheat it before it enters the second tube bundle reactor 38B. The preheat temperature is illustratively approximately 70-80°C.

[0069] The first energy transfer medium 76A is used to recirculate thermal energy and is configured to transfer thermal energy associated with the first heating device 42A to the waste material 28 in the second hopper 58B. The energy transfer medium used in the first heating device 42A is illustratively a fluid, such as water, that can be transported by a conduit (not shown).

[0070] As another example, the second energy recycle assembly 40B recycles thermal energy between the second tube bundle reactor 38B and the third tube bundle reactor 38C using a second heating device 42B. More specifically, the thermal energy associated with the second heating device 42B is applied to the waste material 28 in the third hopper 58C to preheat it before it enters the third tube bundle reactor 38C. The second energy transfer medium 76B is used to recycle the thermal energy and is configured to transfer the thermal energy associated with the second heating device 42B to the waste material 28 in the third hopper 58C.

[0071] As yet another example, the third energy recycle assembly 40C recycles thermal energy between the third tube bundle reactor 38C and the fourth tube bundle reactor 38D using a third heating device 42C. More specifically, the thermal energy associated with the third heating device 42C is applied to the waste material 28 in the fourth hopper 58D to preheat it before it enters the fourth tube bundle reactor 38D. The third energy transfer medium 76C is used to recycle the thermal energy and is configured to transfer the thermal energy associated with the third heating device 42C to the waste material 28 in the fourth hopper 58D.

[0072] Additionally, the first energy recycle assembly 40A recycles thermal energy between the first tube bundle reactor 38A and the fourth tube bundle reactor 38D using a first cooling device 44A. More specifically, the thermal energy associated with the first cooling device 44A is applied to the treated waste 28' in the fourth holding tank 60D to dehydrate or dry the treated waste 28'. The dehydration or drying temperature is illustratively approximately 100-200°C.

[0073] The fourth energy transfer medium 76D is used to recirculate thermal energy and is configured to transfer thermal energy associated with the first cooling device 44A to the treated waste 28' in the fourth holding tank 60D. The energy transfer medium is illustratively another fluid, such as ambient air, that can be transported by conduits (not shown).

[0074] As another example, the second energy recycle assembly 40B recycles thermal energy between the second tube bundle reactor 38B and the fifth tube bundle reactor 38E using a second cooling device 44B. More specifically, the thermal energy associated with the second cooling device 44B is provided to the treated waste 28' in the fifth holding tank 60E to dehydrate or dry the treated waste 28'. The fifth energy transfer medium 76E is used to recycle thermal energy and is configured to transfer the thermal energy associated with the second cooling device 44B to the treated waste 28' in the fifth holding tank 60E.

[0075] As yet another example, the third energy recirculation assembly 40C recirculates thermal energy between the third tube bundle reactor 38C and the sixth tube bundle reactor 38F using a third cooling device 44C. More specifically, the thermal energy associated with the third cooling device 44C is provided to the treated waste 28' in the sixth holding tank 60F to dehydrate or dry the treated waste 28'. The sixth energy transfer medium 76F is used to recirculate thermal energy and is configured to transfer the thermal energy associated with the third cooling device 44C to the treated waste 28' in the sixth holding tank 60F.

[0076] 10 illustrates an example of a configuration for a dewatering and drying vessel 78 configured to perform the dewatering and / or drying steps of waste treatment. For example, the dewatering and drying vessel 78 is the fourth holding tank 60D. In one embodiment, the dewatering step is a process for dewatering the treated waste 28' to reduce the total liquid content to less than a predetermined percentage (i.e., weight %) of the total weight of the treated waste 28'.

[0077] In the dewatering step, the predetermined percentage of total liquid content in the treated waste 28' is illustratively approximately 5-30%, although other suitable percentages are contemplated for different applications. For example, a mesh filter 80 configured to filter a liquid 82, such as water, by gravity is used to dewater the treated waste 28' until the total liquid content is less than 30% by weight.

[0078] In one embodiment, the drying step dries the treated waste 28' to less than a predetermined percentage (i.e., weight %) of the total weight of the treated waste 28'. The predetermined percentage of total liquid content in the drying step is, for example, approximately 0-5%, although other suitable percentages are contemplated for different applications.

[0079] For example, energy transfer elements 84, such as piping, tubes, channels, jackets, etc., configured to discharge thermal energy transferred from tube bundle reactor 38, are used to dewater treated waste 28' to a total liquid content of less than 5% by weight. Referring to Figure 10, by way of example, a fourth energy transfer medium 76D can be used to transfer thermal energy associated with first cooling device 44A (Figure 9) to energy transfer elements 84 to dry treated waste 28' in dewatering and drying vessel 60D.

[0080] 11 shows an example of the relationship between each of the tube bundle reactors 38A-38F of the waste treatment system 200 and each of the waste treatment process steps associated with the tube bundle reactors during waste treatment. The duration of each waste treatment process step is, for example, approximately 10 minutes.

[0081] In this arrangement, first, the first tube bundle reactor 38A performs a heating process step, the second tube bundle reactor 38B performs a drying process step, the third tube bundle reactor 38C performs a dehydration process step, the fourth tube bundle reactor 38D also performs a dehydration process step, the fifth tube bundle reactor 38E performs a cooling process step, and the sixth tube bundle reactor 38F performs a holding process step for waste treatment. Other suitable initial process steps are also contemplated, depending on the application.

[0082] As shown by arrow B1, thermal energy associated with the first tube bundle reactor 38A in the heating process step is imparted to the waste 28 in the second hopper 58B of the second tube bundle reactor 38B to preheat it before it enters the second tube bundle reactor 38B. As shown by arrow B2, thermal energy associated with the second tube bundle reactor 38B in the heating process step is imparted to the waste 28 in the third hopper 58C of the third tube bundle reactor 38C to preheat it before it enters the third tube bundle reactor 38C. In a similar manner, arrows B3, B4, and B5 represent thermal energy recirculation techniques performed between associated tube bundle reactors.

[0083] As shown by arrow C1, thermal energy associated with the first tube bundle reactor 38A undergoing a cooling process is applied to the treated waste 28' in the fourth holding tank 60D of the fourth tube bundle reactor 38D to dry the treated waste 28'. As shown by arrow C2, thermal energy associated with the second tube bundle reactor 38B undergoing a cooling process is applied to the treated waste 28' in the fifth holding tank 60E of the fifth tube bundle reactor 38E to dry the treated waste 28'. In a similar manner, arrows C3 and C4 represent thermal energy recirculation techniques performed between the associated tube bundle reactors.

[0084] 12 illustrates yet another waste treatment system 300 using multiple tube bundle reactors 38A-38C in accordance with an embodiment of the present disclosure. Although three tube bundle reactors 38A-38C are shown for illustrative purposes, any number of tube bundle reactors may be used to suit the application.

[0085] In the illustrated embodiment, as shown in Fig. 8, a transfer system 62 is used to transfer the waste 28 to each of hoppers 58A, 58B, and 58C, and the waste 28 is advanced sequentially in the flow direction indicated by arrow A. Also, as shown in Fig. 9, multiple tube bundle reactors 38A to 38C are used, and thermal energy is shared and recycled between the tube bundle reactors, improving energy efficiency during waste treatment.

[0086] In this configuration, the first tube bundle reactor 38A is connected to a first energy recycle assembly 40A having a first heating device 42A and a first cooling device 44A. Similarly, the second tube bundle reactor 38B is connected to a second energy recycle assembly 40B having a second heating device 42B and a second cooling device 44B. The third tube bundle reactor 38C is connected to a third energy recycle assembly 40C having a third heating device 42C and a third cooling device 44C.

[0087] An important aspect of waste treatment system 300 is the use of dewatering and drying system 310, which is configured to perform the dewatering and drying steps of treated waste 28' as separate and independent systems, rather than using respective holding tanks 60A-60C. In the illustrated embodiment, dewatering and drying system 310 performs the dewatering step using a continuous transfer system 312, such as a conveyor apparatus. Upon completion of the dewatering and drying steps, transfer system 312 delivers treated waste 28' to a collection tank 314 configured to receive treated waste 28'.

[0088] A transfer belt 316 having a mesh filter 80 is included in the transfer system 312 and is configured to receive and deliver the treated waste 28' from each of the first, second, and third tube bundle reactors 38A, 38B, and 38C. In one embodiment, the treated waste 28' received from the tube bundle reactors 38A, 38B, and 38C is dewatered on the transfer belt 316 while moving in the flow direction indicated by arrow X. During the dewatering step, liquid 82 filtered from the treated waste 28' is collected by gravity in a liquid container 318.

[0089] In one embodiment, the dewatering and drying system 310 performs a drying step using a first drying device 320 and a second drying device 322. As a first step in the drying step, the first drying device 320, such as a pair of heated rollers, is configured to press the treated waste material 28' and is used to further extract liquid 82.

[0090] During the drying process, the first drying device 320 is heated by thermal energy associated with at least one of the first, second, and third tube bundle reactors 38A, 38B, and 38C. In the illustrated embodiment, the first energy transfer medium 324A is used to recirculate thermal energy and is configured to transfer thermal energy associated with the first heating device 42A to the second heating device 42B.

[0091] The heat energy associated with the second heating device 42B is then transferred to the third heating device 42C via the second energy transfer medium 324B. Similarly, the heat energy associated with the third heating device 42C is transferred to the first dryer 320 via the third energy transfer medium 324C. In this manner, when the treated waste material 28' is pressed or squeezed by the first dryer 320, the transferred heat energy further reduces the total amount of liquid in the treated waste material 28'.

[0092] As a second stage of the drying process step, additional liquid 82 is drawn off or dried from the treated waste 28' using a second drying device 322, such as a hot air outlet configured to heat the treated waste 28'. During the drying process step, the second drying device 322 is heated by thermal energy associated with at least one of the first, second, and third tube bundle reactors 38A, 38B, 38C.

[0093] In the illustrated embodiment, thermal energy recycling is achieved using a fourth energy transfer medium 324D, configured to transfer thermal energy associated with the first cooling device 44A to the second cooling device 44B, which is then transferred to the third cooling device 44C via a fifth energy transfer medium 324E.

[0094] Similarly, thermal energy associated with the third cooling device 44C is transferred to the second dryer 322 via the sixth energy transfer medium 324F. In this manner, when the treated waste material 28' is heated by the second dryer 322, the transferred thermal energy further reduces the total amount of liquid in the treated waste material 28'. As a result, the treated waste material 28' can be dried in an energy-efficient manner to produce a sterilized charcoal analog, such as hydrochar or biochar.

[0095] 13 illustrates an exemplary relationship between each of the tube bundle reactors 38A, 38B, and 38C of the waste treatment system 300 and the waste process steps associated with each of the tube bundle reactors during waste treatment. The duration of each waste treatment process step is illustratively approximately 10 minutes.

[0096] In this configuration, the first tube bundle reactor 38A initially performs a heating process step, the second tube bundle reactor 38B initially performs a cooling process step, and the third tube bundle reactor 38C initially performs a holding process step. Other suitable initial process steps are also contemplated, depending on the application.

[0097] As indicated by arrow Y1, thermal energy associated with the first heating device 42A of the first tube bundle reactor 38A in the heating step is provided to the treated waste 28' in the first stage of the drying step using the first dryer 320. As indicated by arrow Y2, thermal energy associated with the second heating device 42B of the second tube bundle reactor 38B in the heating step is provided to the treated waste 28' in the first stage of the drying step using the first dryer 320. In a similar manner, arrow Y3 represents a thermal energy recirculation technique that can be performed between the third tube bundle reactor 38C and the first dryer 320.

[0098] As indicated by arrow Z1, heat energy associated with the first tube bundle reactor 38A in the cooling step is provided to the treated waste 28' in the second stage of the drying step using the second dryer 322. As indicated by arrow Z2, heat energy associated with the second tube bundle reactor 38B in the cooling step is provided to the treated waste 28' in the second stage of the drying step using the second dryer 322. In a similar manner, arrow Z3 represents a heat energy recirculation technique that can be performed between the third tube bundle reactor 38C and the second dryer 322.

[0099] As such, the multiple tube bundle reactors 38A-38C are advantageously configured to share and recycle heat energy between associated tube bundle reactors and dryers 320, 322 of the waste treatment system 300. In the illustrated embodiment, improved energy efficiency is achieved during the dewatering and drying steps of waste treatment.

[0100] It should be understood that the waste treatment steps described herein may be implemented by a process controller or other similar device in the control system 68. Specifically, the process controller is configured to execute computer-readable instructions for performing one or more steps of the waste treatment. In one embodiment, the process controller may also be configured to transition from an operational state, in which more operations are performed, to a sleep state, in which a limited number of operations are performed.

[0101] 14, in this embodiment, the waste treatment reactor 10 includes a heating element 400 configured to heat a first heating zone 402 of the waste treatment reactor 10. In one embodiment, the first heating zone 402 is inductively heated by the heating element 400 configured to surround an outer surface of the first heating zone 402 of the waste treatment reactor 10. In one embodiment, the heating element 400 includes one or more heating induction coils 64 configured to surround at least a portion (e.g., a lower region) of the waste treatment reactor 10 and connected to a radio frequency power supply 66 (FIG. 8) configured to inductively power the heating induction coils 64.

[0102] In one embodiment, the waste treatment reactor 10 includes a retaining member 404 having a plurality of openings 406 configured to retain or store waste material 28 within the retaining member 404. During waste treatment, the retaining member 404, which retains the waste material 28, is inserted into the waste chamber 26 of the waste treatment reactor 10. When inserted, the outer surface of the retaining member 404 and the inner surface of the waste chamber 26 are longitudinally spaced apart from each other. In this manner, a gap 408 is formed between the outer surface of the retaining member 404 and the inner surface of the waste chamber 26 of the waste treatment reactor 10, allowing the aqueous solution 30 to flow freely within the waste treatment reactor 10.

[0103] In one embodiment, the retaining member 404 is fabricated from a metal mesh, grid, or screen that, when fully submerged in the aqueous solution 30, allows the aqueous solution 30 to move freely within the retaining member 404 through the plurality of openings 406 and through the gaps 408. For example, during waste treatment, the heating member 400 inductively heats the aqueous solution 30 in the first heating zone 402, and the heated aqueous solution 30 flows upward through the gaps 408 and / or openings 406 toward and through the retaining member 404, heating the waste 28. In this manner, heat from the aqueous solution 30 is efficiently circulated within the waste chamber 26 and transferred between the first end 14 and the second end 16 of the waste treatment reactor 10 during waste treatment.

[0104] The support member 410 is in the waste treatment reactor 10 and is configured to support the retention member 404 within the waste chamber 26 of the waste treatment reactor 10 during waste treatment. In one embodiment, the support member 410 is a protrusion that extends inward from the inner surface of the waste chamber 26 of the waste treatment reactor 10 toward the central axis 412 of the waste chamber 26. Other suitable configurations for the support member 410, such as fins or ridges, are also contemplated depending on the application.

[0105] An important aspect of the support member 410 is that it is configured to separate or space the retaining member 404 from the heating member 400 by a predetermined distance D2. In one embodiment, the predetermined distance D2 is the longitudinal distance between the retaining member 404 and the heating member 400 as viewed along the central axis 412 of the waste chamber 26 of the waste treatment reactor 10. In one embodiment, the predetermined distance D2 is, for example, greater than zero millimeters. In another embodiment, the predetermined distance D2 is, for example, zero, such that the retaining member 404 and the heating member 400 longitudinally abut one another, forming a continuous and seamless interface.

[0106] 14, the retaining member 404 is located longitudinally spaced apart from the first heating region 402 of the waste treatment reactor 10. In one embodiment, the heating member 400 is located in a first or lower region 414 of the waste treatment reactor 10, and the retaining member 404 is located in a second or upper region 416 of the waste treatment reactor 10. In this manner, the first region 414 and the second region 416 are spaced apart at different locations of the waste treatment reactor 10.

[0107] 14, when the retaining member 404 separates (i.e., does not overlap) the first and second regions 414 and 416 of the waste treatment reactor 10 and is positioned longitudinally away from the heating member 400, heat transfer by thermal convection is enhanced. Conventional reactors typically do not separate (i.e., overlap) the first and second regions 414 and 416 of the waste treatment reactor 10, and the heating device is configured to directly heat the waste within the reactor. In this case, the waste is located directly below the heating device, which creates an undesirable insulating effect during waste treatment and results in insufficient heat transfer by thermal convection from the aqueous solution 30 to the waste 28.

[0108] 14, the first region 414 is located in a lower region of the waste treatment reactor 10, and the second region 416 is located in an upper region of the waste treatment reactor 10, creating no overlap between the first region 414 and the second region 416. In this configuration, the separation of the first region 414 and the second region 416 advantageously allows the aqueous solution 30 to receive the heat generated by the heating element 400, eliminating any undesirable insulating effect.

[0109] Thus, the temperature measured in the first region 414 of the waste chamber 26 of the waste treatment reactor 10 is approximately equal to the temperature measured at the outer surface of the first heating region 402 surrounded by the heating element 400. In this manner, the heating element 400 advantageously improves uniform and efficient heating, and further improves temperature control of the waste 28 within the waste chamber 26 of the waste treatment reactor 10.

[0110] 15, in this embodiment, instead of the induction heating coil 64 shown in FIG. 14, a pancake coil 418 is provided within the heating element 400 to heat the first region 414 of the waste treatment reactor 10. Other suitable types of heating coils may be used for different applications, such as a water-cooled copper conductor coil made of copper tubing.

[0111] In one embodiment, the pancake coil 418 is positioned outside the waste chamber 26 of the waste treatment reactor 10 near the outer surface of the second end 16. In another embodiment, the pancake coil 418 is positioned inside the waste chamber 26 of the waste treatment reactor 10 near the inner surface of the second end 16. In yet another embodiment, the pancake coil 418 is positioned both inside and outside the waste chamber 26 of the waste treatment reactor 10 near the second end 16.

[0112] 16, in this embodiment, instead of the support member 410 shown in FIG. 14, a hanging support member 420 is configured to suspend the holding member 404 within the waste chamber 26 of the waste treatment reactor 10 during waste treatment. In one embodiment, the hanging support member 420 has a plurality of arms 422 configured to releasably engage at least a portion of the holding member 404. For example, the arms 422 have a plurality of hooks configured to engage with the upper portion of the holding member 404.

[0113] In this configuration, the holding member 404 is movably held within the waste chamber 26 from the first end 14 of the waste treatment reactor 10 by the hanging support member 420. This allows the aqueous solution 30 to freely circulate within the waste chamber 26 through the gap 408, and the holding member 404 can move with the free flow of the aqueous solution 30 within the waste chamber 26 of the waste treatment reactor 10. As a result, the hanging support member 420 further facilitates the free flow of the aqueous solution 30 through the plurality of openings 406, efficiently heating the waste 28 within the holding member 404.

[0114] As shown in Figures 17 and 18, in this embodiment, the retaining member 404 has a channel 424 extending the length of the retaining member 404 and is configured to facilitate the free flow of the aqueous solution 30 through the channel 424. While one channel 424 is shown, the retaining member 404 may have multiple channels 424 to suit different applications. Other suitable types of channels, such as diagonal or irregularly shaped tunnels, are also contemplated. In this configuration, the aqueous solution 30 circulates freely within the waste chamber 26 through the channel 424 between the first end 14 and the second end 16 of the waste treatment reactor 10. This efficiently transfers heat throughout the waste 28 within the retaining member 404.

[0115] 14 and 19, waste 28 can be heated by the free flow of aqueous solution 30 within waste chamber 26 of waste treatment reactor 10. In embodiments, the free flow of aqueous solution 30 is at least one of a volumetric liquid flow and a volumetric vapor flow of aqueous solution 30, both of which are generated by heating element 400.

[0116] In one embodiment, as shown in Figure 14, the waste material 28 is heated by a volumetric liquid flow of aqueous solution 30 produced by a heating element 400. In another embodiment, as shown in Figure 19, the waste material 28 is heated by a volumetric vapor flow of aqueous solution 30 produced by a heating element 400.

[0117] 19, the waste material 28 within the retention member 404 is not completely submerged in the aqueous solution 30. In this configuration, the retention member 404 is separated or spaced a predetermined distance D3 from the aqueous solution 30 by the support member 410, and a volumetric steam flow, indicated by arrows 426, is used to heat the waste material 28 within the retention member 404.

[0118] In one embodiment, the temperature of the vapor stream 426 is, for example, approximately 280° C., and the temperature of the aqueous solution 30 is, for example, also approximately 280° C. In this configuration, the waste treatment reactor 10 operates as a reaction vessel (e.g., a heated tube) configured to efficiently transfer heat between the first end 14 and the second end 16 of the waste treatment reactor 10 during waste treatment.

[0119] 20, in this embodiment, the waste treatment reactor 10 is configured to use a supplemental heating element 428 configured to heat a second heating zone 430 of the waste treatment reactor 10. In one embodiment, the second heating zone 430 is inductively heated by the supplemental heating element 428 configured to surround an outer surface of the second heating zone 430 of the waste treatment reactor 10. In one embodiment, the supplemental heating element 428 has one or more heating induction coils 64 configured to surround at least a portion (e.g., an upper region) of the waste treatment reactor 10 and is connected to a radio frequency power supply 66 (FIG. 8) configured to power the heating induction coils 64 via electromagnetic induction.

[0120] 20, the waste material 28 within the retention member 404 is not completely submerged in the aqueous solution 30. In this configuration, the second heating zone 430 is separated or separated from the first heating zone 402 by the support member 410, and a steam flow, indicated by arrows 426, 426', is used to heat the waste material 28 within the retention member 404. However, in this embodiment, the steam flow 426' within the second heating zone 430 is further heated by the supplemental heating element 428. In some embodiments, superheated steam provides the steam flow 426' within the second heating zone 430.

[0121] In one embodiment, the heating element 400 is configured to heat the first heating zone 402 of the waste treatment reactor 10 to a first predetermined temperature T1, and the auxiliary heating element 428 is configured to heat the second heating zone 430 of the waste treatment reactor 10 to a second predetermined temperature T2. In one embodiment, the second predetermined temperature T2 is greater than the first predetermined temperature T1.

[0122] In one embodiment, the second predetermined temperature T2 of the vapor stream 426' in the second heating zone 430 is, for example, between approximately 400° C. and 500° C., and the first predetermined temperature T1 of the vapor stream 426 and aqueous solution 30 in the first heating zone 402 is, for example, approximately 280° C. In this configuration, the waste treatment reactor 10 operates as a reaction vessel (e.g., a heated tube) and is configured to efficiently transfer heat between the first end 14 and the second end 16 of the waste treatment reactor 10 during waste treatment.

[0123] As shown in Figures 19 and 20, the waste treatment reactor 10 is configured to heat the waste 28 using at least one of a volumetric vapor flow and a volumetric liquid flow within the waste treatment reactor 10. More specifically, in Figure 20, the waste treatment reactor 10 is configured to heat the waste 28 within the retention member 404 using one or more vapor flows 426, 426' when treating the waste 28.

[0124] 19, however, the waste treatment reactor 10 is configured to heat the waste 28 using the aqueous solution 30' by at least partially or completely submerging the waste 28 in the aqueous solution 30'. In this configuration, the aqueous solution 30' enters through a plurality of openings 406 and heats the waste 28 within the retention member 404. In this manner, the waste treatment reactor 10 is configured to heat the waste 28 using at least one of a volumetric vapor flow of the aqueous solution 30 and a volumetric liquid flow of the aqueous solution 30'.

[0125] 21 shows an exemplary system configuration for treating waste 28 using a waste treatment reactor 10. In this embodiment, the waste treatment reactor 10 includes a lid 432 removably attached to a first end 14 of the waste treatment reactor 10. For example, the lid 432 may be a clutch door, latch, or flange mechanism. In one embodiment, the lid 432 is configured to appropriately maintain the internal pressure of the waste chamber 26 of the waste treatment reactor 10 during operation. The saturated vapor pressure within the waste chamber 26 when the aqueous solution 30 is at approximately 280° C. is illustratively approximately 6.5 megapascals (MPa).

[0126] 21, a heating element 400 having a heating induction coil 64 inductively heats a first heating zone 402 of a waste treatment reactor 10. In one embodiment, the temperature of the aqueous solution 30 in the first heating zone 402 of the waste treatment reactor 10 is approximately 280°C, and the temperature near the outer surface of the first heating zone 402 of the waste treatment reactor 10 is approximately 350°C.

[0127] When the waste 28 in the holding member 404 is heated in this state for a predetermined time (for example, as shown in FIG. 3), certain types of waste, such as paper dust, are carbonized into a mud-like charcoal. During waste treatment, the charcoal dissolves or disperses in the aqueous solution 30. Once the dissolution of the charcoal material is complete, non-reactive materials in the waste 28, such as glass and metal, remain in the holding member 404. When the lid 432 is opened, the non-reactive materials in the holding member 404 can be removed by lifting the holding member 404 upward from the waste treatment reactor 10.

[0128] In one embodiment, the waste treatment reactor 10 is fluidly connected to a steam inlet valve 434 configured to receive steam, indicated by arrow V, from, for example, another adjacent waste treatment reactor. In another embodiment, the waste treatment reactor 10 is fluidly connected to a steam outlet valve 436 configured to discharge steam, indicated by arrow V, into the waste chamber 26 of the waste treatment reactor 10. In one embodiment, the steam inlet valve 434 and the steam outlet valve 436 are located near the first end 14 of the waste treatment reactor 10. Other suitable locations for the steam inlet valve 434 and the steam outlet valve 436 are contemplated depending on the application.

[0129] In yet another embodiment, the waste treatment reactor 10 is fluidly connected to an aqueous solution inlet valve 438 configured to receive an aqueous solution, indicated by arrow WIN. In one embodiment, the aqueous solution inlet valve 438 is located near the heating element 400 in the first region 414 of the waste treatment reactor 10. In one embodiment, the steam inlet valve 434, steam outlet valve 436, and aqueous solution inlet valve 438 are located in the second region 416 of the waste treatment reactor 10. Other suitable locations for the aqueous solution inlet valve 438 are also contemplated depending on the application.

[0130] In yet another embodiment, the waste treatment reactor 10 is fluidly connected to an outlet valve 440 configured to drain or pump the char-bearing aqueous solution 30, indicated by arrow C, out of the waste treatment reactor 10. In one embodiment, the outlet valve 440 is located near the second end 16 of the waste treatment reactor 10. Other suitable locations for the outlet valve 440, such as on the side or peripheral edge, are also contemplated to suit the application. In some embodiments, pressure gauges, safety check valves, and the like can be connected to the waste treatment reactor 10 to suit different applications.

[0131] In one embodiment, control system 68 (FIG. 8) commands or directs associated components of waste treatment reactor 10 (e.g., lid 432 and other valves 434, 436, 438, and 440) to operate appropriately to maintain an appropriate internal pressure and / or volume of aqueous solution during operation. Other suitable automated operations associated with waste treatment reactor 10 are also accomplished by control system 68.

[0132] 22 illustrates, by way of example, another system configuration for treating waste 28 using a waste treatment reactor 10. In this embodiment, the waste treatment reactor 10 includes a lid 432 removably attached to the first end 14 of the waste treatment reactor 10 to ensure that the waste chamber 26 maintains an appropriate internal pressure during operation. The saturated vapor pressure within the waste chamber 26 when the aqueous solution 30 is at approximately 270° C. is, by way of example, approximately 6 megapascals (MPa).

[0133] The lid 432 has a sealing ring 442 configured to tightly seal against the first end 14 of the waste treatment reactor 10 to ensure saturated vapor pressure is maintained within the waste chamber 26 when the lid 432 is closed. Other suitable seals, such as O-rings or circumferential or radial protrusions extending from the lid 432, are also contemplated to suit different applications.

[0134] In one embodiment, the waste treatment reactor 10 has a condensate injection member 444 configured to generate condensate in the waste chamber 26 near the first end 14 and add the condensate to the waste 28 in the holding member 404 to heat a predetermined portion of the waste 28. In one embodiment, the condensate injection member 444 is a generally funnel-shaped member that extends downwardly from the first end 14 of the waste treatment reactor 10 to the second end 16 of the waste treatment reactor 10 to create a conduit.

[0135] In one embodiment, the condensate injection member 444 has a first or upper end 446 with a first opening and a second or lower end 448 with a second opening, the first opening being larger than the second opening. In another embodiment, the first opening at the first end 446 becomes smaller relative to the central axis 412 of the waste chamber 26 of the waste treatment reactor 10 toward the second opening at the second end 448. For example, the condensate injection member 444 extends inward and downward from the first end 14 of the waste treatment reactor 10 toward the second end 16 from the interior surface of the waste chamber 26 of the waste treatment reactor 10 toward the central axis 412.

[0136] The waste treatment reactor 10 also includes a cooling member 450 configured to cool at least a portion of the waste treatment reactor 10 associated with the first end 14. In one embodiment, the cooling member 450 comprises a continuous tube configured to engage or directly contact the upper exterior surface of the waste treatment reactor 10. Any suitable cooling arrangement, such as a water-cooled or air-cooled system, is contemplated for different applications.

[0137] In one embodiment, the cooling member 450 is configured to cool at least one of the lid 432, the sealing ring 442, and the condensate injection member 444. In one example, the condensate injection member 444 is cooled by the cooling member 450. The steam flow 426 is then cooled by the condensate injection member 444, and condensate is produced from the cooled steam. Using a funnel-shaped configuration, the condensate injection member 444 directs the condensate from a first end 446 to a second end 448. The directed condensate is then added to the waste 28 within the retention member 404.

[0138] In the illustrated embodiment, the condensate flow, indicated by arrows 444A, is used to heat the waste material 28 within the retention member 404. As noted above, condensate is produced when the steam flow 426 contacts the condensate injection member 444, which is cooled by the cooling member 450.

[0139] The condensed water is then directed from first end 446 to second end 448, aiming for a predetermined portion, such as the center of waste 28, within retention member 404. Due to gravity, the condensed water either settles freely to the center of waste 28 or is forced to be added, causing differential heating of the center of waste 28.

[0140] More specifically, the condensed water is condensed water vapor associated with the steam flow 426 within the waste chamber 26 of the waste treatment reactor 10. In one embodiment, the steam flow 426 can heat an outer portion of the waste 28, and the condensed water generated by the condensed water injection element 444 can heat an inner portion of the waste 28.

[0141] With this configuration, the outer and inner portions of the waste material 28 are heated simultaneously and substantially evenly. Also, because both the outer and inner portions of the waste material 28 are heated simultaneously, the time required to heat the waste material 28 is significantly reduced. Additionally, this cooling effect near the first end 14 of the waste treatment reactor 10 increases the useful life of the sealing ring 442 and makes the functional handling of the lid 432 more manageable for the operator.

[0142] The present disclosure will be more readily understood by reference to the specific embodiments, examples, and figures representative of the present disclosure listed above. However, it should be understood that the same are provided for illustrative purposes, and that the present disclosure may be practiced otherwise than as specifically illustrated without departing from its spirit and scope. In practice, the present disclosure is susceptible to various other embodiments, and its several components and associated details are susceptible to various changes, all without departing from the basic concept of the present disclosure. Accordingly, the description is to be considered illustrative in nature and not limiting in any way. Modifications and variations of the systems, methods, and apparatus described herein will be apparent to those skilled in the art. Such modifications and variations are intended to fall within the scope of the appended claims. [Explanation of symbols]

[0143] 10 Reactor, first waste treatment reactor, second waste treatment reactor 12 Cylindrical body 14 Inlet, first end 16 Outlet, second end 20 Recirculation device 26 Waste Chamber 28 Waste 28' Treated waste 30 Aqueous solution 38 First tube bundle reactor 38A 1st tube bundle reactor 38B 2nd tube bundle reactor 38D 2nd tube bundle reactor 38' 2nd tube bundle reactor 40 First Energy Recirculation Assembly 40' Second Energy Recirculation Assembly 42 1st heating device 42' 2nd heating device 44 1st cooling device 44A 1st cooling device 44' 2nd cooling system 400 Heating element 402 1st heating area 404 Retaining member 410 Support member 420 Support member 428 Auxiliary heating element 430 2nd heating area 444 Condensate injection material

Claims

1. A system for treating one or more waste products (28), comprising: a first waste treatment reactor (10) configured to treat waste, the first waste treatment reactor (10) having a cylindrical body (12) having an inlet (14) configured to receive the waste (28), a waste chamber (26) configured to store the waste (28) and an aqueous solution (30), and an outlet (16) configured to discharge the treated waste (28') from the waste chamber (26); a first tube bundle reactor (38) having a first waste treatment reactor (10) and configured to perform waste treatment on waste (28) stored in a waste chamber (26) of the first waste treatment reactor (10); and a first energy recycle assembly (40) connected to the first tube bundle reactor (38) and configured to recycle thermal energy associated with the first tube bundle reactor (38) during waste treatment, the first energy recycle assembly including a first heating device (42) configured to heat a first region of the first tube bundle reactor (38) and a first cooling device (44) configured to cool a second region of the first tube bundle reactor (38); The first waste treatment reactor (10) comprises a recirculation device (20) configured to circulate vapor and liquid formed in the cylindrical body (12) of the first waste treatment reactor; moreover, a second tube bundle reactor (38') having a second waste treatment reactor (10') and configured to perform waste treatment on waste (28') stored in a waste chamber (26) of the second waste treatment reactor (10'); a second energy recycle assembly (40') connected to the second tube bundle reactor (38') and configured to recycle thermal energy associated with the second tube bundle reactor (38') during waste treatment, the second energy recycle assembly having at least one of a second heating device (42') configured to heat a first region of the second tube bundle reactor (38') and a second cooling device (44') configured to cool a second region of the second tube bundle reactor; A system comprising:

2. 2. The system of claim 1, wherein the first heating device (42) is configured to heat the aqueous solution (30) in a first region of the first tube bundle reactor (38), and the first cooling device (44) is configured to cool the waste (28) in a second region of the first tube bundle reactor (38).

3. 2. The system of claim 1, wherein the first energy recycle assembly (40) and the second energy recycle assembly (40') are configured to recycle thermal energy between the first tube bundle reactor (38) and the second tube bundle reactor (38') using at least one of a first cooling device (44), a first heating device (42), a second cooling device (44'), and a second heating device (42').

4. 4. The system of claim 3, wherein the first cooling device (44A) is configured to provide thermal energy associated with the first cooling device (44A) to treated waste (28') associated with the second tube bundle reactor (38D).

5. 4. The system of claim 3, wherein the first heating device (42A) is configured to provide thermal energy associated with the first heating device (42A) to waste material (28) associated with the second tube bundle reactor (38B).

6. 2. The system of claim 1, wherein thermal energy associated with a first tube bundle reactor (38A) in a first waste process step is provided to waste (28) associated with a second tube bundle reactor (38B) in a second waste process step different from the first waste process step.

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