Method and system for recycling and liberating material

Abstract

A versatile waste processing system that converts various waste materials into valuable products, such as syngas, oils, char, proteins, and glass fibres. The system includes advanced components for material separation, thermal treatment, and by-product recovery. It features reactors, gas cleaning units, separation systems, and handling lines for solids, along with cracking units for refining heavier hydrocarbons and reforming technologies to enhance hydrogen production. Additionally, it supports processes like protein extraction and glass fibre recovery, offering flexible configurations to handle a wide range of waste types while maximizing energy and material recovery in various industrial applications.

Description

METHOD AND SYSTEM FOR RECYCLING AND LIBERATING MATERIALFIELD OF INVENTION

[0001] Aspects of the present disclosure relate to sorting, processing, or recycling of source material for extracting a liberated product. Specifically, but not exclusively, aspects of the present disclosure are directed to the liberation of particles, products and / or other components from waste or alternative source material of organic origin or inorganic origin. Specially, but not exclusively, aspects of the present disclosure are directed to the extraction of protein from vegetable matter, or the extraction of glass fiber from glass fiber composites such as wind turbine blades, or the extraction of hydrogen or methanol from domestic and industrial waste.BACKGROUND

[0002] Domestic waste is a mixture of materials, comprising a variety of matter ranging from food, such as food of animal and plant origin, to paper and other products made of plant fibers, such as fabric, to building material, such as wood and wood-based products, to plastic and concrete, to natural and synthetic polymer materials, such as plastics of different kinds, to rubber, synthetic rubber, metals, etc. Industry waste is also a mixture of materials, comprising a range of materials from mining waste products to used wind turbine blades.

[0003] Traditionally, domestic waste and industry waste have been filled into landfills. Landfills contribute to environmental degradation by releasing methane and other greenhouse gases, leachate that contaminates groundwater, and causing long-term soil degradation, while also being an inefficient use of space for waste disposal. Additionally, landfill waste often comprises poisonous and / or environmentally unacceptable compounds, such as Volatile Organic Compounds (or VOC), that is released from the waste into the ground or atmosphere. Liquids, either being a part of the waste, or water caused by rain, draining through the landfill, will solubilize solid compounds in the landfill, and will leak from the landfill,to pollute both surface water in streams, lakes, and may penetrate into the ground water.

[0004] To avoid pollution associated with landfills and numerous known problems associated with inadequate waste processing and / or recycling, plants for sorting of domestic and industrial waste have been developed. Recyclable materials are separated from non-recyclable waste. The recyclable material is sent to plants to recover valuable materials, and recycle the materials, such as metals. The non- recyclable materials may be separated into combustible materials and noncombustible materials. The non-combustible materials are sent to landfills or the like, whereas combustible materials are introduced into an incineration plant. In the incineration plant the combustible material is combusted at high temperature to destroy all temperature degradable or combustible material, including poisonous and environmentally unwanted compounds. Additionally, different means are included to avoid emission of hazardous gases from the incineration plant.

[0005] Known combustion methods reduce the volume of solid waste by approximately 50-90% dependent on the composition of the waste, and the combustion technology used. Technology for sorting waste is also known. Typically, the waste is sorted based on physical properties, such as magnetic properties, density, surface to weight, etc. Accordingly, incineration plants for sorting and combustion of waste are known, and a large number of such plants are in operation.

[0006] However, in the absence of advanced features like feedstock control, efficient separation techniques, and environmental management systems, traditional pyrolysis and gasification processes in currently operational plants face several technical challenges. One of the primary issues is the variability in the feedstock properties. Without precise control over factors such as moisture content and carbon concentration, the thermal decomposition process can be inefficient, leading to inconsistent gas production and incomplete conversion of materials. This is especially problematic in systems like US9631153B2 and DE10025916A1 , which handle a wide variety of organic materials. Variations in feedstock composition can result in uneven heating within the reactor, causingsome portions of the material to underperform in terms of conversion, while others may overheat, leading to excessive coking or char formation. This inefficiency not only reduces the quality of the produced gas but also necessitates more frequent maintenance to remove build-ups of unreacted or partially reacted materials.

[0007] Another significant problem is the lack of advanced separation mechanisms, which is particularly evident in EP0850743B1 and EP1160307B1. These systems focus on simple thermal treatment and do not employ sophisticated methods for separating valuable by-products from waste streams. This leads to lower material recovery rates and increased waste generation. For instance, in processes that handle composite materials like wind turbine blades, the inability to effectively separate glass fibres from the resin matrix results in the loss of potentially valuable materials and contributes to the inefficiency of the overall process. Additionally, basic mechanical or thermal separation methods may not handle a diverse range of input materials, further limiting the applicability of these systems to more specialized waste streams.

[0008] Environmental management is another beneficial area where traditional systems fall short. Processes like those in US9631153B2 and DE10025916A1 produce significant amounts of carbon dioxide (CO2) and other by-products that are often released into the atmosphere, contributing to greenhouse gas emissions. Without a CO2 capture or recycling mechanism, the environmental footprint of these systems remains substantial, limiting their sustainability and compliance with modem environmental regulations. Furthermore, these systems typically lack mechanisms to convert CO2 into valuable by-products, missing an opportunity to improve the economic viability of the waste conversion process. In essence, the absence of these advanced features results in inefficiencies in gas production, poor material recovery, increased environmental impact, and limited flexibility in handling diverse waste streams.

[0009] Additionally, no other potential uses are indicated for the plants described in the aforementioned prior art, providing limited functionality as society moves away from using fuel gasses.SUMMARY OF INVENTION

[0010] According to an aspect of the present disclosure, there is provided a method for producing hydrogen gas or other combustible gas, hydrocarbon oil, or biochar not contaminated by volatile organic compounds (VOC) from municipal solid waste (MSW), the method comprising: controlling the humidity of an MSW feed comprising carbonaceous material to be within a predefined humidity range by adding water or steam to increase humidity of the MSW feed, or drying the MSW feed to decrease humidity, thereby generating a humidity controlled MSW feed; producing a raw pyrolysis gas and a carbonaceous rest by introducing the humidity controlled MSW feed into a unit for pyrolysis, wherein the unit for pyrolysis is heated at least in a bottom part; introducing the carbonaceous rest and steam into a cracking unit, thereby producing a further gas and a further carbonaceous rest; introducing the further carbonaceous rest from the cracking unit into the bottom part of the unit for pyrolysis; separating or cleaning output from the unit for pyrolysis, resulting in hydrogen gas or other combustible gas, hydrocarbon oil, or produced char.

[0011] According to an aspect of the present disclosure, there is provided a method wherein the MSW is sorted such that the MSW feed of MSW comprises a desired quantity of carbonaceous material.

[0012] According to an aspect of the present disclosure, there is provided a method wherein introducing the further carbonaceous rest from the cracking unit into the bottom part of the unit for pyrolysis results in remaining carbonaceous rest, and the remaining carbonaceous rest is introduced into a further unit arranged downstream or in parallel to the cracking unit or unit for pyrolysis.

[0013] According to an aspect of the present disclosure, there is provided a method wherein the further unit comprises: a further unit of pyrolysis, and remaining carbonaceous rest is introduced into the bottom part of the further unit of pyrolysis where the temperature is highest; or a further cracking unit, and remaining carbonaceous rest is introduced into the part of the further cracking unit where temperature is highest, or steam is injected.

[0014] According to an aspect of the present disclosure, there is provided a method wherein carbonaceous rest comprises solid or liquid carbonaceous rest.

[0015] According to an aspect of the present disclosure, there is provided a method wherein produced char is cooled using a cooling unit.

[0016] According to an aspect of the present disclosure, there is provided a method further comprising controlling produced char for VOC contamination, wherein produced char without VOC contamination is separated from produced char contaminated with VOC.

[0017] According to an aspect of the present disclosure, there is provided a method wherein produced char contaminated with VOC is separated according to size, such that at least one larger char particle size part is associated with less VOC contamination in comparison to at least one smaller char particle size part.

[0018] According to an aspect of the present disclosure, there is provided a method wherein produced char contaminated with VOC is separated according to weight sequentially or in parallel to separation according to size.

[0019] According to an aspect of the present disclosure, there is provided a method wherein produced char is regenerated by thermal regenerating or solvents for desorbing VOC from produced char contaminated with VOC, resulting in clean biochar.

[0020] According to an aspect of the present disclosure, there is provided a method further comprising: sorting the MSW into at least two groups of MSW, each group of MSW associated with different calorific value with respect to combustion; and combining the MSW from one or more groups of the at least two groups of MSW, such that the MSW feed is associated with a stable calorific value over a time period.

[0021] According to an aspect of the present disclosure, there is provided a method further comprising: sorting the MSW into at least two groups of MSW, each group of MSW associated with different types of source material; and combining the MSW from one or more groups of the at least two groups of MSW, such that the MSW feed is associated with a stable composition over a time period.

[0022] According to an aspect of the present disclosure, there is provided a method wherein sorting or combining the MSW is performed using one or more feeders and based on weight data of the MSW.

[0023] According to an aspect of the present disclosure, there is provided a method wherein the one or more feeders comprise belts or rotating conveyors associated with variable speed controllers, such that controlling speed of the one or more feeders controls the calorific value or the composition of the MSW feed over the time period.

[0024] According to an aspect of the present disclosure, there is provided a method further comprising autoclaving the MSW feed.

[0025] According to an aspect of the present disclosure, there is provided a method further comprising: subjecting the MSW feed to torrefaction; and pelletizing the MSW feed.

[0026] According to an aspect of the present disclosure, there is provided a method wherein the predetermined humidity range is: 10-30% humidity content by weight; 15-25% humidity content by weight; or approximately 20% humidity content by weight.

[0027] According to an aspect of the present disclosure, there is provided a method wherein the unit for pyrolysis or catalyst unit comprises a catalyst, and the method further comprises reforming or replacing the catalyst.

[0028] According to an aspect of the present disclosure, there is provided a method wherein the catalyst is reformed or replaced: periodically with respect to operation time; or based on a measured functionality of the catalyst.

[0029] According to an aspect of the present disclosure, there is provided a method wherein reforming or replacing comprises: taking out the catalyst through an opening for catalyst removal in the unit for pyrolysis or catalyst unit; and introducing a reformed catalyst or new catalyst into the unit for pyrolysis or catalyst unit.

[0030] According to an aspect of the present disclosure, there is provided a method wherein the catalyst is reformed using steam or cleaning liquid.

[0031] According to an aspect of the present disclosure, there is provided a method wherein the unit for pyrolysis or catalyst unit is operated at approximately atmospheric pressure.

[0032] According to an aspect of the present disclosure, there is provided a method wherein hydrogen gas is extracted from the top part or near the top part of the unit for pyrolysis.

[0033] According to an aspect of the present disclosure, there is provided a method wherein hydrogen gas is extracted to maintain an operation pressure of the unit for pyrolysis.

[0034] According to an aspect of the present disclosure, there is provided a method wherein the unit for pyrolysis comprises one or more reactors.

[0035] According to an aspect of the present disclosure, there is provided a unit for pyrolysis or cracking configured for use in the method of any preceding claim, wherein the unit comprises: an inner wall and an outer wall, thereby providing a double wall configuration, such that there is a volume between the inner wall and the outer wall; wherein the inner wall and the outer wall is dimensioned for an operating pressure and temperature of the unit; wherein the volume comprises at least one gas that is not hydrogen or oxygen; and at least one sensor for detecting leakage of the at least one gas communicatively coupled to a control and safety system.

[0036] According to an aspect of the present disclosure, there is provided a unit wherein the at least one gas comprises an inert gas, nitrogen, or carbon dioxide.

[0037] According to an aspect of the present disclosure, there is provided a unit wherein the volume is at overpressure relative to a process pressure inside the inner wall, thereby providing tension to the inner wall.

[0038] Beneficially, introducing the humidity-controlled MSWfeed into the bottom part of the pyrolysis unit ensures that the feedstock is exposed to the highest temperature zone first. This maximizes the thermal efficiency of the pyrolysis process, as the bottom part is typically the hottest. By optimizing the heat transfer, the process can achieve a more complete and rapid breakdown of the feedstock into pyrolysis gas and carbonaceous rest. Furthermore, feeding the MSW into thebottom part of the pyrolysis unit can enhance the pyrolysis reaction by ensuring that the feedstock is immediately subjected to the most intense thermal conditions. This can lead to a more efficient conversion of the organic material into valuable pyrolysis gas, reducing the amount of unreacted material and improving the overall yield of the process.

[0039] Additionally, re-introducing the further carbonaceous rest from the cracking unit back into the bottom part of the pyrolysis unit creates a closed-loop system. This is beneficial because it allows for the continuous recycling of carbonaceous material, ensuring that any unreacted carbon is subjected to further pyrolysis. This maximizes the utilization of the feedstock and minimizes waste, leading to a more sustainable and efficient process. By re-introducing the carbonaceous rest from the cracking unit into the pyrolysis unit, the process ensures that the carbon content is fully utilized. The further carbonaceous rest, which may still contain valuable hydrocarbons, is given another opportunity to be converted into pyrolysis gas. This step enhances the overall carbon conversion efficiency of the system, reducing the amount of residual carbon and increasing the production of valuable gases.

[0040] The combination of these steps creates a synergistic effect where the pyrolysis and cracking units work together to maximize the conversion of MSW into useful products. The re-introduction of the carbonaceous rest ensures that the system operates at peak efficiency, with minimal waste and maximum output. This integrated approach is beneficial because it leverages the strengths of both units to achieve a more effective and sustainable process.

[0041] Further beneficially, controlling the humidity of the MSW feed ensures optimal conditions for pyrolysis, leading to more efficient conversion and higher quality outputs. This reduces the risk of incomplete pyrolysis and contamination by VOCs. Sorting MSW to ensure a desired quantity of carbonaceous material improves the consistency and efficiency of the pyrolysis process, leading to better quality and yield of the desired products. Introducing remaining carbonaceous rest into further units ensures maximum utilization of the feedstock, reducing waste and improving overall efficiency. Using additional pyrolysis or cracking units for remaining carbonaceous rest ensures complete conversion andmaximizes the yield of required end-products. Carbonaceous rest can be solid or liquid, allows for flexibility in handling and processing different types of residues, improving the adaptability of the system.

[0042] Further beneficially, cooling the produced char prevents re-ignition and makes handling safer, while also preserving the quality of the char for further use. Ensuring that produced char is free from VOC contamination enhances its quality and usability, particularly for applications where purity is critical. Separating char by size to manage VOC contamination ensures that larger, less contaminated particles can be used directly, improving efficiency and reducing the need for further processing. Weight-based separation provides an additional method to ensure the purity of the char, enhancing the overall quality control process. Regenerating char contaminated with VOCs ensures that valuable biochar can be reused, reducing waste and improving the sustainability of the process.

[0043] Further beneficially, sorting MSW by calorific value ensures a stable and predictable feedstock, leading to more consistent and efficient pyrolysis operations. Sorting by source material ensures a stable composition of the feedstock, which is crucial for maintaining consistent process conditions and product quality. Using feeders to sort or combine MSW based on weight data allows for precise control over the feedstock composition, improving process efficiency and product consistency. Variable speed controllers on feeders allow for real-time adjustments to the feed rate, ensuring optimal process conditions and consistent product quality. Autoclaving the MSW feed sterilizes it, reducing the risk of contamination and improving the safety and quality of the pyrolysis process. Torrefaction and pelletizing improve the energy density and handling characteristics of the MSWfeed, making the pyrolysis process more efficient and manageable. Maintaining the MSWfeed within a specific humidity range ensures optimal pyrolysis conditions, leading to higher efficiency and better quality products.

[0044] Further beneficially, using a catalyst enhances the pyrolysis reactions, improving the yield and quality of the desired products. Regularly reforming or replacing the catalyst ensures its effectiveness, maintaining high process efficiency and product quality. A defined process for catalyst reforming orreplacement ensures minimal downtime and consistent process performance. Using steam or cleaning liquid for catalyst reforming is an efficient and effective method to restore catalyst functionality, ensuring continuous high performance. Operating at approximately atmospheric pressure simplifies the system design and reduces the need for complex pressure management, improving safety and reliability. Extracting hydrogen gas from the top part of the unit ensures efficient collection of the gas, improving the overall yield and purity. Using hydrogen gas extraction to maintain operation pressure ensures stable process conditions, enhancing efficiency and product quality. Using multiple reactors allows for scalability and flexibility in the pyrolysis process, improving overall system efficiency and capacity.

[0045] Further beneficially, a double wall configuration with a volume between the walls enhances safety by containing leaks and providing structural integrity under operating conditions. Using an inert gas in the volume between walls prevents oxidation and other unwanted reactions, improving safety and process stability. Maintaining overpressure in the volume between walls provides additional structural support, enhancing the durability and safety of the unit.

[0046] The skilled person will understand that any above-described aspects are not limited to the treatment of MSW and may be applied to alternative contexts and usage scenarios. For example, the same principles can be applied to the pyrolysis and cracking of other organic waste materials such as agricultural residues, industrial waste, and biomass. This flexibility allows for the adaptation of the process to various feedstocks, enhancing its applicability and utility across different industries and waste management practices.BRIEF DESCRIPTION OF DRAWINGS

[0047] Embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

[0048] Figure 1 illustrates a system architecture diagram for a material transformation, extraction or recycling plant according to an aspect of the present disclosure;

[0049] Figure 2 illustrates a system architecture diagram for a material transformation, extraction or recycling plant according to a further aspect of the present disclosure;

[0050] Figure 3A and 3B illustrate system architecture diagrams for a reactor;

[0051] Figure 4 illustrates a system architecture diagram for a waste sorting system;

[0052] Figures 5A and 5B illustrate system architecture diagrams for part of a plant according to an aspect of the present disclosure;

[0053] Figure 6 illustrates a system architecture diagram of a methanol isolation or production system;

[0054] Figure 7 schematically illustrate a cyclonic particle separator;

[0055] Figure 8 schematically illustrate a rotor design according to an aspect of the present disclosure;

[0056] Figures 9A-9D schematically illustrate a comminutor;

[0057] Figures 10A and 10B shows a flowchart illustrating a method for liberation and separation of particles;

[0058] Figure 11 illustrates a system architecture diagram of a plurality of cyclonic particle separators;

[0059] Figure 12 illustrates a system architecture diagram of a plurality of comminutors;

[0060] Figure 13 illustrates a system architecture of a system for liberating particles;

[0061] Figure 14 shows an example computing environment for performing any of the methods described herein;

[0062] Figure 15 illustrates a system architecture diagram of a municipal solid waste processing system;

[0063] Figure 16A illustrates a schematic of a method for producing a plant-based texturized product; and

[0064] Figure 16B illustrates a schematic diagram of an extrusion process.

[0065] Reference list:1 waste line 47 air line2 waste pre-treatment section 48 flue gas line3 autoclave system 49 motor4 wastewater line 50 screw conveyor5 wastewater treatment unit 40 51 high temperature chamber6 treated water line 52 pyrolysis gas line7 autoclaved waste line(s) 53 mixing arms8 sorting system 54 heating jacket9 non-recyclables line 55 high temperature chamber10 waste line 45 outlet11 humidity adjustment unit 12 59 heating jacket excess water line 60 secondary reactors13 pre-treated waste line 61 raw gas withdrawal line20 gas production and 62 first gas cleaning unit treatment section 50 63 wastewater line21 pyrolysis and thermolysis 64 scrubbed raw gas line unit 65 gas separation unit22 fuel gas line 66 hydrogen rich gas line23 solid rest line 67 gas line24 separation unit 55 68 first light oil line25 carbon dioxide export line 69 solid line(s)26 low carbon dioxide fuel gas 70 conversion unit line 71 steam line27 loop line 72 gas line30 gas turbine power plant 60 74 cracked gas line31 electric power line 75 second gas cleaning unit32 steam line 76 used water line33 steam line(s) 77 second light oil line39 startup gas line 78 heating collar40 reactor 65 79 heating jacket41 gas line 80 cracking unit45 mixing chamber 81 light oil recycle line46 heating jacket 82 exhaust line83 exhaust gas return line 122 high calorific end product90 char handling unit fraction91 char line 123 non-ferrous fraction92 ash line 40 200 cyclonic particle separator93 uncontaminated char line 210 main chamber94 contaminated char line 211 inlet95 supply line(s) 212 third outlet96 supply line(s) 213 first outlet97 supply line(s)45214 second outlet100 magnetic separator 215 impeller101 first iron fraction 216 ultrasound generator102 first screen 217 electromagnetic coil103 calorific value fraction 220 rotor104 second screen 50 221a, b holes105 separator 222 interior cavity106 magnetic drum over belt 223 chamber separator 225 end cap107 flock / fibre fraction 310 comminutor108 first wind sifting separator 55 371 entrance opening109 light materials fraction 381 spinnable shaft110 screening unit 382 processing chamber(s)111 magnetic drum over belt 383 segmented plate separator 384 rotor disc112 separator60385 vortex generator113 second wind sifting 386 side wall separator 387 rotor vane(s)114 magnetic drum over belt 400 comminution separator 401 size fractionating115 non-ferrous separator 65 402 fluid116 near infrared detection 403 first cyclonic particle separator section separator117 ferrous fraction 404 second cyclonic particle118 PVC fraction separator119 Nylon fraction 70 410 size fraction120 PET fraction 411 size fraction121 mixed plastic fraction 412 size fraction420 solid particles of a density421 solid particles of a density 614 methanol / water separator422 solid particles of a density 615 valve500 bearing 30 616 heat recovery system501 entry flow 617 unreacted gas line502 exit opening 618 purge line503 exit flow 619 flotation unit504 high pressure 620 heavy particles505 low pressure 35 621 light particles506 first flow generator 622 middle particles506A first flow generator portion 623 source material506B first flow generator portion 624 solid particles507 second flow generator 625 liberated product508 spin direction 40 1600 method601 input unit 1601 ORM602 cleaning unit 1602 pre-grind603 dehulling unit 1603 source material604 fractionating unit 1604 extraction605 packing unit 45 1604a fiber606 agglomerating / pelletizing 1604b low protein unit 1604c protein concentrate607 particle size adjusting unit 1605 combine608 output unit 1606 extrude609 methanol 50 1610 dehulling610 cooling unit 1611 fiber separation611 flash separator 1612 micronisation612 compressor 1613 air classificatoin613 mixer

[0066] All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

[0067] As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure.

[0068] Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure. Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure, and are made merely for the purposes of providing a full and enabling disclosure.

[0069] The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself. Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein — as understood by the ordinary artisan based on the contextual use of such term — differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail. Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextualuse dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.”

[0070] The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims.

[0071] The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header. Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

[0072] Unless otherwise indicated, the drawings are intended to be read together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up”, “down” and the like, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, “radially”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing Figure faces the reader. Similarly, the terms “inwardly,” “outwardly” and “radially” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

[0073] The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in the context of an authorship authentication system, embodiments of the present disclosure are not limited to use only in this context. In the context of the present invention any systems, methods or processes disclosed herein comprise an at least one processing unit whereby said at least one processing unit performs the process of the present invention.

[0074] Furthermore, where specific numerical values are provided in this description, they are intended as non-limiting examples to illustrate the principles and functionality of the described processes and systems. A skilled person in the field(s) will recognize that the invention is not restricted to these particular values, and other suitable values, ranges, or parameters may be applied based on the specific circumstances, materials, or operating conditions. These alternative values may achieve the same or similar results without departing from the scope and spirit of the invention. Therefore, any references to precise figures are illustrative and should not be construed as limitations on the possible embodiments or variations of the system.DETAILED DESCRIPTION

[0075] Embodiments of the present disclosure will now be described with reference to the attached figures. It is to be noted that the following description is merely used for enabling the skilled person to understand the present disclosure, without any intention to limit the applicability of the present disclosure to other embodiments which could be readily understood and / or envisaged by the reader. In particular, whilst the present disclosure is primarily directed to the processing of organic waste materials, the skilled person will appreciate that the apparatus, processes, methods and systems described herein are applicable to a wide range of waste materials, including but not limited to synthetic materials, composites, and industrial waste streams. For example, the described methods could be used to process composite materials like wind turbine blades or to handle plastic waste from various industries.

[0076] Without advanced features like feedstock control, efficient separation, and environmental management, traditional pyrolysis and gasification systems suffer from inconsistent material conversion, poor gas quality, and low recovery of valuable by-products. Additionally, these systems have a significant environmental impact due to uncontrolled emissions and lack the ability to handle diverse waste streams efficiently.

[0077] The present disclosure solves these issues through an advanced feedstock control system that adjusts moisture content and composition, optimizing the material’s calorific value before pyrolysis. This resolves problems seen in prior art, where inconsistent feedstock properties lead to unstable gas production. By ensuring a stable, optimized input, the enclosed systems produce more consistent and efficient gas output, making it suitable for high-efficiency applications like gas turbines. The ability to manage different types of waste, including complex composite materials such as wind turbine blades, extends applicability beyond the narrow scope of prior biofuel systems, making it more versatile for modern waste processing needs.

[0078] The integration of a conversion unit for steam reforming in the present disclosure also addresses the limitations of prior systems by enhancing the production of high-value gases, particularly hydrogen. Unlike prior art, which focus primarily on basic pyrolysis, the steam reforming feature described herein increases gas yield and improves the quality of the syngas. This additional step ensures that the resulting gases are of higher quality and more suited for energy applications, solving the issue of low-value gas output seen in earlier technologies. Furthermore, the enclosed light oil recycling system prevents the buildup of unwanted hydrocarbons in the final gas, which is a problem in simpler systems that lack this feedback mechanism.

[0079] Additionally, the incorporation of CO2 capture and the ability to utilize it for methanol production sets improves the enclosed systems and methods regarding optimised positive environmental impacts. While prior art focus on gas production, it do not address the environmental impact of CO2 emissions. The disclosed systems not only captures CO2 to reduce greenhouse gas emissions but also transforms it into a valuable by-product, further improving the economic and environmental efficiency of the process. Additionally, the cyclonic particle separator and comminutor systems disclosed herein enable efficient separation and recovery of valuable materials like glass fibres, overcoming the material recovery limitations of older systems that rely on less precise separation methods. This comprehensive approach solves the challenges of inefficient waste processing, poor material recovery, and inadequate environmental control present in earlier technologies.

[0080] The present invention is partially directed to improvements to technology associated with pyrolysis and thermolysis of organic compounds, resulting in a product gas having a predetermined composition, e.g. mainly comprising hydrogen, carbon monoxide, carbon dioxide and lower hydrocarbons, adjusted to fit the intended use and having a WOBBE-index (WOBBE-index = calorific value I (gas specific gravity)-1 / 2), that is substantially constant over time.

[0081] When the intended use for the produced gas is as fuel for a gas turbine, it is important to ascertain a constant WOBBE-index fulfilling the requirements of a modem efficient gas turbine, i.e. , that the fluctuations in the WOBBE-index is less than 2% over a period of 10 minutes. The composition of the produced gas having high hydrogen content, high purity hydrogen content respectively, resulting in a high temperature flame, makes it especially important to keep the WOBBE-index substantially constant. Similarly, when the intended use for a liberated product is a protein concentrate for a texturized protein product, it is important the ascertain a constant calorific value of source material into the protein extraction systems and processes.

[0082] In areas as diverse as mining, recycling, or food production it is commonly necessary to process materials consisting of multiple intermingled components by mechanically liberate, micronize, and separate such components from each other. In the case of food processing, it can be necessary to separate fibers from protein and in recycling it can be advantageous to sort recyclable materials that need to be handled separately, e.g., glass fragments (so called fine cullet) of different colors as well as liberate and sort metals from other minerals in bottom ash. In the case of mining, it may be the case that post-process waste materials, such as slag or tailings, still contain a sizeable fraction of potentially useful minerals that could represent a valuable resource if they can be reliably sorted. However, separating these minerals from the greater mass of e.g., silica oxides is difficult as it first requires liberating the component metals and minerals from each other and subsequently sorting the resulting particles according to mineral content as expressed in their differences in relative weight.

[0083] Combustion residues, like char and ash, are valuable materials, containing, as mentioned above, multiple intermingled components. The residues need further processing.

[0084] Thus, there is a need for better material separation methods, particularly methods for separating and sorting very small particles by use of mechanic methods as compared to chemical extractions.

[0085] Aspects of the present disclosure will now be described more fully with reference to the accompanying drawings. The different devices and methods disclosed herein can, however, be realized in many different forms and should not be construed as being limited to the aspects set forth herein. Like numbers in the drawings refer to like elements throughout.

[0086] The terminology used herein is for describing aspects of the disclosure only and is not intended to limit the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0087] One application of the methods and devices disclosed here is associated with the treatment of char products from processes, although many other applications are also possible. Such waste products can take the form of e.g., char, slag, dross, or tailings and may still contain a sizeable fraction of useful and valuable minerals that were not extracted in previous processes. Methods for extracting these useful minerals may involve comminuting the waste material into smaller solid particles and mixing them with liquid to form a slurry, and then processing said particles with the purpose of separating them and sorting them by mineral content based in their specific density.

[0088] Herein, a particle or solid particle is taken to be a small piece of solid material. Small, in this case, is somewhat dependent on the specific context and application, but may be understood as the piece of material being less than a centimeter across, and preferably less than a millimeter across and even smaller than just a micron in size.

[0089] Separating and sorting a mix of solid particles of different elements can be done either dry or wet. The challenge is commonly increased as the particles become smaller in size. Micronized particles below 100 microns in size can be specially demanding due to their liking to become electrically charged for instance in a dry sorting resulting in conglomerated larger structures of smaller particles often of different kind. These conglomerates would obviously not have a unique element-based density. Of these and other reasons a slurry tend to keep individual particles suspended in the liquid fluid. A typical wet mix could consist of a slurry containing solidparticles comprising different groups of minerals and other materials suspended in water. Such slurries consist commonly of a significant volume of liquid allowing the slurry to be pumped. One way of sorting said solid particles is by density. In particular, if the particles are of similar size, the difference in density or specific weight between, for example, a particle of sand and a particle of an iron compound will result in the two particles having different weights for the same size, with the iron compound particle being heavier than the silica particle in this example. Successful sorting the particles by weight will then make it possible to separate the iron oxide from the sand.

[0090] In cyclonic separation the particles are commonly suspended in a fluid, which can be either a liquid or a gas, in a chamber that is typically round conical or cylindrical. The fluid containing the particles flows through the chamber in a spiral pattern, causing heavier particles to be pushed towards a wall of the chamber. Depending on the type of cyclonic separator, the particles may strike the chamber wall and then fall to the bottom of the chamber due to gravity or be caught in a secondary fluid stream and carried to one end of the chamber, where they can be extracted. In some cyclonic separators, the fluid is induced to flow in one direction (e.g., in the direction of gravitational power) in a spiral pattern, then turn at an end of the cyclone and flow in the opposite direction closer to the center of the chamber. In this case, heavier particles will tend to fall out of the main flow of the fluid at the turning point and accumulate near the turning point. As lighter particles are pushed out towards the chamber walls to a lower degree and thereby may follow the fluid up through the chamber center, a cyclonic particle separator can be used to separate particles by weight, as well as to simply remove particles of all kinds from the fluid.

[0091] Throughout the description and claims, the pressure is about ambient pressure, i.e. approximately atmospheric pressure of 101.3 kPa, 1010 mbar, 1 atm, or 14.7 psi, e.g. within 25% of these values, if nothing else is specifically stated. Any boiling point and / or boiling ranges indicated are boiling points or boiling ranges at atmospheric pressure, if not specifically defined differently.

[0092] Figure 1 is an overview illustration of an embodiment of the present invention according to the first part, where incoming is introduced via a waste line 1 , into a waste pre-treatment section 2.

[0093] The pre-treatment section of the illustrated embodiment comprises an autoclave system 3, into which the MSW in line 1 is first introduced. Autoclaves suitable for the purpose are delivered i.a. by AeroThermal Group, UK. The autoclave system preferably comprises a series of parallel arranged rotating autoclaves wherein the MSW is treated batchwise. During normal operation the autoclaves will be in different parts of an autoclave cycle, giving a semi-continuous operation. The autoclave cycle comprises the following steps: Filling MSW into the autoclave, and thereafter closing the autoclave. Closing and then evacuating the autoclave to remove most of the air from the inside of the autoclave. Introduction of steam into the autoclave to heat the autoclave and its content to about 160 °C typical at about 5,2 barg (bar gauge). Keeping the temperature and pressure for a predetermined period, such as e.g., 30- 40 minutes. The autoclaves are rotated during this process.

[0094] During the autoclaving process, the MSW in the autoclave is sanitized, and the volume is typically reduced by about 60%. The heat treatment kills all the bacteria and other degrading life in the MSW, and thus removes the odor of the waste. Plastics, such as PE and PET, reach their glass-rubber transition stage and are reduced through deformation. Plastic films are mostly unaffected by the autoclaving but are cleaned during the process cycle. Grass cuttings and small yard waste are reduced to cellulose fibres. Additionally, lignin and other macromolecules are broken down, and / or coagulated. The autoclaving process thus reduces bonds between parts of the MSW and makes the further processing easier.

[0095] After finalization of the heat treatment, the autoclave is vented and the steam therein is introduced to a condenser, where the steam is condensed to give water. The water is withdrawn through a wastewater line 4 and is introduced into a wastewater treatment unit 5 treated before being released or re-used, to avoid pollution to the surroundings or to avoid accumulation of pollutants in water circulating in the plant. Treated wastewater is withdrawn through a treated water line 6 to be released, further treated or re-used.

[0096] The autoclave is then again filled to restart the autoclave cycle. To obtain a semi-continuous process, the cycles of the autoclaves in parallel, are controlled so that they are out of phase which each other. The autoclaved MSW is thereafter taken out of the autoclaves 3 through autoclaved waste lines 7 and introduced into a sortingsystem 8 comprising a set of conveyors and sorting devices, separating the autoclaved MSW into different fractions. The sorting system is preferably a state-of-the-art sorting system for separating the incoming MSW in a plurality of fractions, such as plants marketed and delivered by Stadler Anlagenbau GmbH, Germany.

[0097] In such a sorting plant the MSW is sorted into fractions such as:• PET (polyethylene terephthalate),• HDPE (high-density polyethylene),• Mixed plastics, that may be sorted in individual fractions,• Films,• Tetra Packs,• Mixed paper,• SRF (solid recovered fuel),• Non-ferrous metals,• Ferrous metals, and / or• Residues (non-combustible solid residue).

[0098] Plastics rich in nitrogen or chlorine are unwanted in most of the potential uses for the fuel produced according to the invention. Nylon, which primarily is contained in carpets, contains nitrogen, and result in formation of NOx in a plant for combustion, whereas PVC produces HCI, which is strongly acidic in combination with water. Additionally, both nylon and PVC may be sold as valuable products for recirculation. Separation of nylon and PVC from the remaining plastics may be performed by means of computer operated wind sifting in combination with near infrared detection, as further described below. A minor amount of Nylon and / or PVC are, however, acceptable as a contamination to the different fractions. PVC may by be used, provided that the weight of PVC amounts to less than 1 % by weight of the total MSW.

[0099] The waste enters the plant, as above described, through the waste line 1 and is introduced into the autoclave 3, as detailed in relation to Figure 4 below. The autoclaved waste is withdrawn from the autoclave 3 and introduced via line 7 into a first magnetic separator 100 which catches big ferrous pieces, that are present in the autoclaved waste material, and removes it from the remaining waste, into a first iron fraction 101. Non-recyclable and combustible waste fractions are withdrawn from the sorting plant, even though the export lines are not illustrated in Figure 4.

[0100] The skilled person understands that the size limits given for the fractions above are examples, and that the size limits may differ substantially depending on the supplier of the plant and the concrete plans for a new plant. The number of fractions and the sequence of the different sorting processes may also differ. Additionally, fractions that are not sufficiently homogenous after sorting, may be recycled to an earlier sorting step.

[0101] A normal MSW has normally a humidity of about 20 to 30 % by weight. After autoclaving the humidity has normally increased to about 50 % by weight. The humidity required for further treatment in normally from about 10 to 25 % by weight, such as from 15 to 20 % by weight, e.g., about 18 % by weight. Accordingly, the humidity of the waste normally has to be dried. If the waste is too dry, water and / or steam are added to humidify the waste. Any excess water is removed from the humidity controlling unit 11 through excess water line 12 and introduced into the wastewater treatment unit 5, as described above. Alternatively, water and / or steam may be added through not shown line(s).

[0102] Drying of the MSW may be obtained by blowing air through the MSW, or by heating the MSW, or a combination thereof. Heat for drying of the non-recyclables in the humidity adjustment unit 11 , may come from hot water / steam generated in a later described gas turbine power plant 30, and / or by firing of combustible gas produced later gas producing units, in a combustion chamber arranged for heating of the material to be dried.

[0103] The skilled person will understand that the described pre-treatment section 2 is a presently preferred pre-treatment section and that any pre-treatment unit that can produce a sorted and fractionated waste may replace the described unit without leaving the scope of the invention. Alternative pre-treatment sections may be shredder type waste treatment plants, etc.

[0104] From the humidity adjustment unit 11 , the sorted and humidity adjusted waste is withdrawn through a pre-treated waste line 13 to be introduced into a gas production and treatment section 20. The pre-treated waste is via the pre-treated waste line 13 introduced into a pyrolysis and thermolysis unit 21 , for production of a synthesis gas, mainly comprising hydrogen, carbon monoxide, and carbon dioxide, that is withdrawn through a fuel gas line 22 for the intended use, and a solid rest, mostly comprisingcarbon, that is withdrawn in line 23, that is exported from the plant for further use or deposition. The pyrolysis and thermolysis unit 21 will be further described below.

[0105] The skilled person will understand that if the waste is too dry, water and / or steam may be introduced into waste when the waste is feed into the reactor 21 in addition to or in lieu of adding water and / or steam in a separate humidity adjustment unit.

[0106] The synthesis gas withdrawn from in line 22 may be used as it is, or be introduced into an optional separation unit 24, for separation, or capturing of carbon dioxide from the synthesis gas. In the second separation unit, the incoming synthesis gas is separated, to produce a carbon dioxide stream that is withdrawn through a carbon dioxide export line 25, and a low carbon dioxide synthesis gas, that is withdrawn through a low carbon dioxide fuel gas line 26. The second separation unit 21 may be of any well-known type, such as an absorption / desorption unit, pressure swing unit, or a membrane-based unit. The presently preferred carbon dioxide capture unit is a membrane-based unit, due to its low running costs. Such solutions are commercially available.

[0107] Carbon dioxide from the carbon dioxide capture unit and exported through a carbon dioxide export line 25 may be sent to a methanol production unit or a carbon storage facility to store the carbon dioxide in a depleted oil or gas well, or in an aquifer in a well-known way, or be sold for use for pressure support in enhance oil recovery. Alternatively, the captured carbon dioxide or parts thereof, may be used for agricultural or aquaculture purposes, and be introduced into greenhouses or plants for algae production as a source of carbon.

[0108] The gas produced in the thermolysis and pyrolysis unit 21 have many potential uses. In the illustrated embodiment, the gas is introduced into a gas turbine after being passed through the carbon dioxide capture unit 24. The gas may, optionally, be sent for its final use, such as e.g., a gas turbine, without carbon dioxide capture, depending on the intended use. For most purposes, the carbon dioxide present in the gas in line 22 is an inert gas that reduces the calorific value of the gas and increases the volume of the gas. Both from such a technical viewpoint, and from an environmental viewpoint, it is therefore an advantage to capture carbon dioxide, before using or selling theproduced gas. By capturing carbon dioxide, the carbon dioxide footprint of the plant is substantially reduced.

[0109] In the illustrated embodiment, the produced gas leaving the gas production and treatment unit 20 in line 26, is introduced into a gas turbine plant 30, to produce electrical power that may be used for internal processes requiring electrical power, and where the surplus electric energy may be sold to the electric grid through an electric power line 31 .

[0110] Steam produced in the gas turbine plant 30, is withdrawn through a steam line 32, to deliver hot water and / or steam to heat requiring processes in the plant, such as the autoclaves, 3, and drying in the humidity adjusting unit 11 via internal steam lines 33a, 33b. The skilled person will also be able to identify other possible internal consumers of the heat energy in the hot water or steam. Excess heat in form of steam and / or hot water may be exported from the plant for e.g., district heating through steam export line 33.

[0111] According to an alternative embodiment, the gas turbine 30 is substituted with a Fischer-Tropsch (FT) plant, for conversion of the synthesis gas to synthetic hydrocarbons in a well-known way.

[0112] The skilled person will understand that the present gas production and treatment unit 20 may be used for other hydrocarbon rich materials than MSW, such as e.g., more homogenous waste materials as waste plastic materials such as agricultural plastic waste, or tires. Such materials have humidity that is too low for efficient thermolysis and pyrolysis in unit 21. Water may be added to such types of waste in the humidity adjustment unit 11 and / or be added into the thermolysis and pyrolysis unit 21 through a not shown water introduction line, to give water content in unit 21 of about 20 % by weight of the introduced waste.

[0113] The solids withdrawn from the thermolysis and pyrolysis unit 21 through line 22, may differ in composition and potential use based on the incoming waste. One potential use for the solid rest, withdrawn through line 22, is for soil improvement, by spreading the material on farmland.

[0114] The skilled person would understand that not all aspects of Figure 1 are required, and each component may be used individually or together with any othercomponent of the Figures described herein for methods, systems, or processes related to transforming source material, e.g. MSW or plant matter, into a desired product, e.g. protein, fuel, hydrocarbons, or other sorted, separated, or liberated product.

[0115] For example, for configuring a thermolysis plant, the material is introduced into the input unit 601 where it undergoes initial processing before entering the thermolysis and pyrolysis unit 21. The main processing line consists of a reactor system with a primary reactor 40, equipped with a heating jacket 46 to facilitate the thermal breakdown of organic materials. The heated waste is transferred via a screw conveyor 50 into a high temperature chamber 51 , where it is further broken down. Gases generated are extracted through the pyrolysis gas line 52 for subsequent treatment in the gas cleaning unit 62. To ensure operational stability and safety, the plant includes redundant lines such as additional gas separation units 65, with secondary units like light oil recycle lines 81 to manage fluctuations in input material and maintain consistent output. In parallel, solid residues are directed into the char handling unit 90, allowing for a comprehensive, dual-line operation that increases plant resilience and throughput.

[0116] Beneficially, such a thermolysis plant can stabilize the calorific value of the produced synthesis gas, ensuring that the WOBBE-index remains within an acceptable range, e.g. beneficial for gas turbine operation. This is achieved through advanced material separation and recycling systems, such as the CO2 capture unit 24, which improves the fuel quality by removing excess carbon dioxide, and the use of light oil cracking 80 to reduce unwanted components. The integration of one or more redundant lines, such as those for hydrogen-rich gas production 66, allows for continuous operation even under varying feedstock conditions, making this plant highly efficient and adaptable to different waste compositions, enhancing its sustainability and economic viability.

[0117] In another example, e.g. configuration of a low-pressure thermolysis plant, material is first fed into the input unit 601 and undergoes pre-treatment, ensuring the optimal condition for thermal breakdown. From there, it moves into a low-pressure pyrolysis unit 21 , where the reactor operates at reduced pressures compared to standard systems, enhancing safety by minimizing the risk of high-pressure gas leaks or explosions. The material is processed in a series of primary reactors 40, which areequipped with heating jackets 46 to regulate the temperature. The reduced pressure allows for lower temperature operation, preventing uncontrolled reactions and reducing stress on equipment. Gases produced during this process are withdrawn via the pyrolysis gas line 52 and passed through the first gas cleaning unit 62 for further purification. To maintain consistent operation and safety, the system includes multiple redundant reactors 60 operating in parallel, ensuring that a malfunction in one line does not compromise the entire process. Solid residues, such as char, are transported via the char line 91 to the char handling unit 90 for safe disposal or further processing. Additionally, the low-pressure design is supported by the CO2 capture unit 24 to prevent excess gas buildup and reduce the potential for accidents.

[0118] The benefits of this low-pressure plant are significant, particularly in terms of enhanced safety and process stability. Operating at reduced pressures lowers the risk of equipment failure and catastrophic leaks, a common concern in conventional pyrolysis systems. The plant’s innovative design allows for precise control of temperature and pressure, reducing the chance of uncontrolled reactions, and ensuring smooth, continuous operation. The use of multiple, redundant reactor lines and pressure relief systems significantly increases operational safety by providing alternative pathways for gas flow if one system encounters issues. Moreover, the integration of advanced gas separation units 65 and CO2 capture technology ensures the production of clean, high-quality synthesis gas with minimal fluctuations in its calorific value. This makes the plant not only safer but also more efficient and reliable compared to current pyrolysis systems, offering a safer approach to large-scale waste conversion.

[0119] Alternatively, or additionally to this thermolysis plant design or an alternative plant design, material is introduced via the input unit 601 and then fed directly into the bottom of the primary reactor 40, e.g. where temperatures are highest. The feed enters through a screw conveyor 50 or a similar mechanism designed to withstand high temperatures, ensuring the material is delivered into the high temperature chamber 51 , which preferably operates at around 1000°C. By feeding the material into the hottest part of the reactor, the thermolysis reactions are initiated rapidly, maximizing the efficiency of thermal breakdown and ensuring more complete conversion of organic materials into valuable gases and solid residues. Gases generated in this process are extracted via the pyrolysis gas line 52 and passed through the gas cleaning unit 62,where they are purified. Any remaining solids, such as char, are moved through the char line 91 to the char handling unit 90 for further processing. To support continuous operation and safety, the plant is equipped with redundant reactors 60, ensuring that the system can handle fluctuations in feedstock without downtime.

[0120] This feed system offers significant advantages, particularly in terms of thermal efficiency and reaction speed. By introducing the feedstock directly into the hottest region of the reactor, the plant accelerates the thermolysis process, ensuring rapid conversion of material and minimizing energy losses. The intense heat at the bottom of the reactor promotes the breakdown of even the most resistant organic compounds, resulting in a higher yield of synthesis gas and a more complete conversion of the feedstock into useful by-products. This configuration also reduces the need for additional heating stages, improving the overall energy efficiency of the plant. Additionally, the design improves operational safety by minimizing the risk of cold spots or incomplete reactions that can lead to gas buildup or process instability. By concentrating the hottest temperatures at the bottom, the plant enhances both the speed and completeness of the thermolysis reactions while maintaining high safety standards.

[0121] In another example, the plant is configured or otherwise modified to recycle vegetable mass such as legumes for protein extraction, which can then be combined with components associated with brewer's spent wheat to generate a protein-rich product. The material(s) are optionally processed using units traditionally associated with hydrocarbons, which are repurposed for organic recycling. First, the vegetable matter is introduced into the plant’s pre-treatment section 2, e.g. via input unit 601 , similar to the systems used in hydrocarbon waste processing. Here, the vegetable matter (legumes) and, optionally, spent wheat undergo an initial cleaning process, analogous to the sorting of hydrocarbon-rich materials, but adapted to separate organic impurities and prepare the materials for downstream processing. The autoclave system 3, which is typically used for thermal treatment of hydrocarbon waste, can be repurposed to sterilize and sanitize the plant material, reducing its volume and making it easier to handle. This stage also softens the legumes and wheat, breaking down macromolecules such as lignin in a way that facilitates the separation of protein and fiber later in the process.

[0122] Once pre-treated, the plant material is directed into the humidity adjustment unit 11 , which, while originally designed for controlling moisture in hydrocarbon feedstocks, is beneficial here for optimizing the water content of the legumes and wheat. Controlled moisture levels are useful for effective protein extraction and fiber / starch / protein separation. The spent wheat, which may have varying levels of moisture from the brewing process, is adjusted to match the requirements for blending with the legumes. Any excess water is removed via the excess water line 12, which is typically used to manage moisture in hydrocarbon waste but serves here to ensure the optimal conditions for organic material processing.

[0123] Following humidity adjustment, the material optionally enters the pyrolysis and thermolysis unit 21 , which has been reconfigured for low-temperature operation in this context. Instead of breaking down hydrocarbons, this unit facilitates the thermal treatment of organic compounds in the legumes and wheat. Here, proteins are denatured and made more accessible for extraction, while fibers in the wheat are softened and prepared for blending. The plant operates at temperatures tailored for food-safe processing, ensuring that the valuable proteins and fibers are preserved rather than decomposed. The gases produced, which in a hydrocarbon context would be combusted or processed further, are minimal in this case and can be safely vented or collected for minimal energy recovery.

[0124] Next, the material is optionally passed through a separation unit 24, originally designed to separate gas and solid residues in hydrocarbon systems. In this adapted version, the unit isolates the protein-rich fractions from the fibrous components of the legumes and spent wheat. The protein is drawn off for further purification, while the remaining fibers are routed for blending. This process leverages the separation efficiencies developed for hydrocarbon gas cleaning but applies them to separating organic materials for future consumption.

[0125] The final step involves the agglomerating and pelletizing unit 606, which, while not explicitly part of the hydrocarbon setup, can be integrated into the process to form the protein and fiber mixture into a uniform product. By leveraging technologies designed for complex material separation, this plant efficiently converts organic waste into valuable food-grade products, with the potential for applications in both human and animal consumption.

[0126] The benefits of adapting hydrocarbon-processing units to this recycling method are manifold. The repurposing of systems like the pre-treatment section 2, humidity adjustment unit 11 , and pyrolysis and thermolysis unit 21 introduces a level of efficiency and precision not previously known in organic recycling. These units, designed to handle complex hydrocarbon mixtures, are highly adaptable to vegetable mass processing, providing enhanced control over moisture, temperature, and separation. This ensures the maximum recovery of valuable proteins and fibers, reduces waste, and allows for the upcycling of agricultural by-products that would otherwise be discarded. By combining the strengths of hydrocarbon processing technology with the needs of organic recycling, this plant offers a unique, scalable solution for turning vegetable waste into high-value food resources

[0127] In any of the hydrocarbon processing or plant matter recycling plants described herein, one or more comminutors 310 or cyclonic particle separators 200 are optionally integrated to enhance the efficiency of material breakdown and separation. The comminutors 310, optionally used for reducing the size of hydrocarbon-rich waste, can be employed in the early stages of both plants to break down the raw input material into smaller, more manageable particles. For a hydrocarbon plant, the comminutor would shred plastic or rubber into finer particles, allowing for more uniform thermal treatment in the pyrolysis and thermolysis units 21 . Similarly, in a plant matter recycling facility, the comminutor would break down legumes and brewer’s spent wheat into finer fragments, ensuring that the proteins and fibers are more readily accessible for separation and further processing. By reducing the particle size, the comminutor facilitates more efficient downstream processes and ensures consistent material flow throughout the plant.

[0128] Following comminution, the cyclonic particle separators 200 preferably play a role in the precise sorting of materials based on density and size. In a hydrocarbon plant, the cyclonic separator can be used to separate heavier char and ash residues from lighter gas fractions, ensuring that only clean gases are passed on to the gas cleaning unit 62, while the solid by-products are efficiently handled or disposed of. In the plant matter recycling plant, the cyclonic particle separator can be adapted to separate protein-rich particles from fibrous or heavier components of the plant material. The separator’s ability to process fluids with solid particles suspended, using centrifugal forces, makes it ideal for this application, as it can ensure high-qualityprotein extraction and fiber / starch separation in a single step. By integrating these units, both types of plants can significantly improve the efficiency of their separation processes, leading to higher-quality end products and minimizing waste.

[0129] In another example, a plant is configured for recycling wind turbine blades and similar composite materials, such as boat hulls and other fiberglass-reinforced products, using units traditionally associated with hydrocarbon processing. While use of a comminutor 310 for post-reactor processing is described in detail below, the comminutor 310 can also be used for pre-reactor processing. The process begins by introducing the composite waste into the plant’s pre-treatment section 2, or input unit 601 , where materials such as wind turbine blades, boat hulls, and automotive parts are broken down into manageable sizes. These materials often consist of fiberglass embedded in resin, alongside other materials like plastics, carbon fibers, and metals. The autoclave system 3, typically used for thermally treating municipal waste, can be adapted here to heat the composite materials to soften the resins, making it easier to separate the glass fibers from the matrix. During this thermal pre-treatment, the resins begin to break down without damaging the structural integrity of the glass fibers.

[0130] Following pre-treatment, the material is processed in the comminutor 310, which reduces the composite material into finer fragments. The comminutor ensures that large pieces of fiberglass, resin, and metal are uniformly reduced in size, making the downstream separation more efficient. The reduced material then optionally moves into the pyrolysis and thermolysis unit 21 , which operates at a temperature and pressure profile that breaks down the resin matrix further while preserving the integrity of the glass fibers. During this thermal decomposition, volatile organic compounds are driven off, leaving behind a mixture of solid materials including glass fibers, carbon residues, and other components. Additionally, or alternatively, the comminutor 310 is used after any thermal decomposition process to separate glass fibers from other solid materials, where the comminutor 310 is tailored to extract glass fibers with minimal damage to the fibers. For example, chaotic vortex flow within a tailored comminutor 310 is configured to extract a desired product from a source material without overly damaging the desired produce.

[0131] The step of separating the valuable glass fibers from other materials is optionally carried out in the cyclonic particle separator 200. This unit uses centrifugalforces to sort materials based on their size, weight, or density. The glass fibers, being lighter than the remaining carbonaceous solids and metal fragments, are separated and collected in a distinct output stream. The cyclonic particle separator ensures that the glass fibers remain intact and free of significant contamination, while heavier particles such as metal components and carbon residues are extracted via other outlets for further processing or disposal. For example, metals like steel or aluminium that may have been part of the boat materials or turbine structures can be recovered and recycled separately.

[0132] This plant configuration is particularly versatile, capable of processing a wide range of composite materials beyond wind turbine blades. In addition to boat hulls, which are typically made of fiberglass and polyester or epoxy resins, the plant can handle automotive body panels, sports equipment (like surfboards or ski components), and even aerospace materials. The ability to extract clean, reusable glass fibers from these composites is one of the key innovations, allowing for the recycling of materials that would otherwise be destined for landfills. Furthermore, the pyrolysis process helps recover other valuable by-products, such as oils and gases, that can be reused within the plant or sold as secondary resources, making the entire recycling process both sustainable and efficient / viable.

[0133] A plant configured to operate with the minimum number of components is optionally tailored for the essential functions required for safe and effective thermolysis or pyrolysis, prioritizing simplicity and ease of operation. In this streamlined version, the core of the plant would include a basic pyrolysis and thermolysis unit 21 to handle the thermal breakdown of materials. The reactor would be designed to maintain the necessary temperatures for the decomposition of organic or composite materials without requiring the complex feed and separation systems seen in larger plants. Material would be introduced directly into the reactor, either manually or through a simple conveyor system 50, minimizing the need for additional preprocessing stages like humidity control or extensive sorting. Therefore, only a reactor and / or basic pyrolysis and thermolysis unit 21 should be considered essential to pyrolysis and thermolysis concepts described herein.

[0134] To ensure safety, the plant preferably integrates basic monitoring systems for temperature and pressure control, but optionally avoids more advanced units like gasseparation or secondary reactors. The gas cleaning unit 62 is optionally included to remove particulates and contaminants from the gas stream, ensuring that emissions meet environmental regulations. However, more intricate systems like light oil cracking or CO2 capture would be omitted to keep the plant simple and / or streamlined. Solid residues, such as char, is preferably handled by a char line 91 , where they could be collected for disposal or reuse without requiring a char handling unit 90 for further separation. This minimal configuration ensures that the plant can operate safely and efficiently with the least complexity, reducing both cost and maintenance requirements while still producing useful by-products like syngas and solid residues.

[0135] In contrast, a plant that includes additional components described in the documentation would be designed for maximum efficiency, throughput, and environmental compliance. The process would begin in the pre-treatment section 2, where waste materials are fed into the plant via a waste line 1 . If the feedstock includes organic material, like municipal solid waste or industrial composites, it would first be sanitized and volume-reduced in the autoclave system 3, which heats the material to remove odours and bacteria, making it easier to handle in subsequent steps. The autoclaving process is beneficial for sterilizing the input material and reducing its mass before thermolysis or pyrolysis.

[0136] After pre-treatment, the material is passed through the humidity adjustment unit 11 , where its moisture content is optimized for the pyrolysis process. Proper humidity levels are essential to ensure that the material breaks down efficiently and doesn’t hinder the thermal decomposition. Any excess water is removed through the excess water line 12, and treated in the wastewater treatment unit 5 to prevent pollution.

[0137] Next, the material is introduced into the pyrolysis and thermolysis unit 21 , which serves as the heart of the plant. Here, the waste is subjected to high temperatures in the absence of oxygen, breaking it down into syngas, oils, and solid residues. To maximize efficiency, the plant employs multiple secondary reactors 60 in parallel or series, ensuring complete breakdown of the feedstock. The reactor’s temperature is carefully controlled, with the heating jackets 46, 54 providing precise thermal input to maintain optimal reaction conditions. The use of screw conveyors 50 ensures that the material moves steadily through the reactor system, preventing blockages or uneven heating.

[0138] The gases generated during the thermolysis process are extracted through the pyrolysis gas line 52 and sent to the first gas cleaning unit 62, where they are scrubbed to remove tars, oils, and particulate matter. This cleaning step is beneficial for ensuring that the gas can be further processed or used as a clean energy source. The cleaned gas is then passed into a gas separation unit 65, which separates it into different fractions. One stream may be enriched in hydrogen, while another contains hydrocarbons like methane or carbon monoxide. These gases are then either recycled back into the system or used as fuel for a gas turbine power plant 30.

[0139] In the more complex plant, the gas also passes through a CO2 capture unit 24, which removes carbon dioxide to improve the calorific value of the remaining gas. This captured CO2 can be stored, used in methanol production, or applied in other industries like enhanced oil recovery. The integration of a methanol production unit allows the plant to produce methanol from hydrogen and carbon dioxide, further increasing its versatility and economic value.

[0140] Meanwhile, the solid residues from the reactor, primarily consisting of char, are conveyed to the char handling unit 90, where they are separated into usable products like biochar or ash. This char can be used for agricultural or industrial applications, adding further efficiency to the plant’s processes. The inclusion of cyclonic particle separators 200 further enhances the separation process by using centrifugal forces to segregate lighter materials like glass fibers from denser ones, a beneficial feature when recycling composite materials like wind turbine blades or boat hulls.

[0141] The plant also incorporates an oil cracking unit 80, which processes light oils collected from the gas cleaning units. These oils are thermally or catalytically cracked to break down heavier hydrocarbons into useful fuel gases, which are then returned to the main system. This closed-loop system maximizes the recovery of energy from the input material, ensuring that minimal waste is generated.

[0142] The integration of the comminutor 310 and cyclonic particle separator 200 into the further equipped plant adds another layer of precision and efficiency. The comminutor 310 ensures that materials are (a) properly pre-treated before pyrolysis, reducing the risk of inefficiency or incomplete breakdown during the thermal process, and / or (b) broken down or otherwise comminated / liberated before separation. The cyclonic separator 200, meanwhile, allows for meticulous sorting of by-products,enhancing the plant’s ability to recover and recycle valuable materials. Together, these components help optimize the plant’s operation, whether it’s processing organic waste, industrial plastics, or complex composites like wind turbine blades

[0143] Optionally, the plant’s electric power line 31 connects to a gas turbine 30, allowing it to generate electricity from the syngas produced in the pyrolysis unit. This power can be used to run the plant’s operations, with any excess stored or transferred, making the plant energy self-sufficient. The system also recycles heat through steam lines 32, 33, supplying energy for the autoclaves, humidity control, and other heatdemanding processes, further improving energy efficiency. Alternatively, or additionally, syngas such as hydrogen or hydrogen-enriched fractions is extracted, e.g. extracted from pyrolysis gas line 52, and optionally stored.

[0144] Overall, this embodiment of a plant is designed to extract maximum value from the input material, producing not only clean syngas and reusable solids but also methanol, electricity, and potentially even glass fibers from composite materials. Each component plays a role in optimizing the efficiency, safety, and environmental sustainability of the plant, making it an ideal solution for large-scale waste processing and resource recovery.

[0145] For example, after the hydrogen-enriched gas is extracted from the pyrolysis gas line 52 and optionally processed in the gas separation unit 65, it can be directed into a dedicated hydrogen storage tank. For example, any plant described herein optionally comprises storage tanks with pressure regulation systems similar to those used in hydrogen fuel systems. These tanks are preferably located downstream of the second gas cleaning unit 75, which ensures that the hydrogen is clean and suitable for storage. To manage variations in demand and production, the hydrogen storage could integrate with the plant’s CO2 capture unit 24, which regulates the composition of gases. Stored hydrogen could later be redirected for use in methanol production or supplied to fuel cells for generating electricity, as described in relation to the plant’s optional gas turbine systems.

[0146] In the case of glass fiber extracted from composites like wind turbine blades, after it has been separated by the cyclonic particle separator 200, it is collected and stored in dedicated fiber storage silos or containers. Since glass fiber is lightweight but bulky, storage requires spacious containment systems. The processed glass fibers isoptionally stored in bins for later shipment or transferred to packing units 605, where they are bundled and prepared for e.g. industrial use. The glass fiber storage solution ensures that the fibers remain uncontaminated and free of moisture, as this could degrade their quality for future applications in construction or manufacturing.

[0147] For the solid char produced during the thermolysis process, after it has been separated from other residues in the char handling unit 90, it is optionally stored in char silos or bins. These storage units are designed to safely contain the char, which is preferably used as a biochar for agricultural purposes or as a solid fuel. The char line 91 would direct the processed char into these storage silos, which could also include secondary containment systems to manage any potential dust or particulates generated during the handling of the char. From there, the char could be prepared for packaging and distribution or stored for on-site use as a supplementary fuel in the plant’s processes. Optionally, VOC levels are monitored before, during, or after storage. For example, char is stored based on a level of detected VOC.

[0148] By strategically integrating one or more storage solutions with the components and units described herein, e.g. the gas separation unit 65, cyclonic particle separator 200, or char handling unit 90, the plant can efficiently manage both gaseous and solid by-products, ensuring that all valuable materials are safely stored and available for future use.

[0149] Another embodiment is directed towards a plant configured to recycle domestic and industrial waste while ensuring that no volatile organic compounds (VOCs) are released. Beneficially, such a plant simultaneously helps eliminate other landfill-related issues. Waste is first introduced through the waste line 1 and pre-treated in the pretreatment section 2, which may include the autoclave system 3 for sterilization and volume reduction. From there, waste materials are sorted in the sorting system 8 to remove recyclables such as metals and plastics via the magnetic separator 100 and non-ferrous separator 115. Non-recyclable organic and carbon-rich materials are sent through the pre-treated waste line 13 into the pyrolysis and thermolysis unit 21 , housed within the reactor 40 equipped with heating jackets 46 to achieve complete thermal decomposition without combustion. Gases produced from this process are routed through the pyrolysis gas line 52 and treated in the first gas cleaning unit 62 to remove impurities. The cleaned gases are then further refined through the gas separation unit65, capturing VOCs and other contaminants to ensure they are either recycled or converted into less harmful by-products. Meanwhile, solid residues such as char are handled via the char handling unit 90 for reuse as biochar or carbon-based materials, and any remaining ash is safely stored or repurposed.

[0150] Beneficially, by fully processing waste through pyrolysis and thermolysis rather than allowing it to decompose in landfills, the plant prevents the release of VOCs, methane, and other harmful gases typically associated with landfill emissions. The integration of advanced gas cleaning and separation technologies ensures that even trace contaminants are captured, allowing the plant to comply with strict environmental regulations and eliminate air pollution. Additionally, the char handling unit 90 enables the recovery of valuable carbon-rich materials, further reducing the volume of waste sent to landfills and promoting circular waste management. The plant also addresses the issue of leachate, which typically contaminates groundwater in landfills, by processing all liquids through the wastewater treatment unit 5. By recovering recyclables and converting the remaining waste into useful products like syngas and biochar, this plant effectively solves all major problems associated with landfills, from VOC emissions to space inefficiency and environmental degradation, while contributing to a more sustainable waste management system.

[0151] Another embodiment is a plant configured for hydrogen production and extraction. Source material, such as waste, is initially introduced through the input unit 601 and undergoes pre-treatment in the pre-treatment section 2 to prepare it for thermal decomposition. The material is then processed in the pyrolysis and thermolysis unit 21 , where it is subjected to high temperatures within the reactor 40, equipped with heating jackets 46 and high temperature chambers 51 to ensure optimal conditions for breaking down the feedstock. As the waste material decomposes, the produced gas flows through the pyrolysis gas line 52 and into the first gas cleaning unit 62, where impurities such as tars and particulates are removed. The cleaned gas is then directed into the gas separation unit 65, which efficiently separates the hydrogen-rich fractions. The extracted hydrogen is stored or redirected for immediate use through the hydrogen-rich gas line 66. For enhanced efficiency, the plant optionally integrates a conversion unit 70 for partial steam reforming, increasing the hydrogen yield, and a CO2 capture unit 24 to remove carbon dioxide, further purifying the hydrogen. Thesystem can also recycle light oil through the light oil recycle line 81 , optimizing hydrocarbon breakdown and improving gas quality.

[0152] Each of the units of Figures 1 , 2, and 3A are now described in more detail. Any of the units, as shown in the examples above, can be used individually or in combinations not otherwise disclosed in the Figures, and hence the skilled person would understand that each unit is optional, both in relation to Figure 1 and the Figures below.

[0153] Waste line 1 is the primary conveyor or channel through which waste is transported into the processing plant for initial sorting and treatment. The waste line serves as the entry point for all types of materials, including domestic, industrial, agricultural, or composite waste, depending on the plant’s capacity. This line can include mechanical conveyors, pneumatic systems, or pipelines that guide the waste to the pre-treatment section 2, where the sorting and separation processes begin. The waste line 1 is beneficial for ensuring a continuous and controlled flow of waste into the processing system, preventing bottlenecks and ensuring that materials are distributed evenly to the various sorting and treatment units. By efficiently feeding waste into the plant, the waste line improves the overall throughput and ensures that materials are directed to the appropriate stages for recycling, energy recovery, or disposal. Depending on the facility's design, the waste line may include additional features such as material shredders, compactors, or sensors that detect hazardous materials or oversized objects, ensuring the smooth operation of the plant.

[0154] Pre-treatment section 2 is a beneficial initial stage in the waste processing system where incoming waste is prepared for further sorting and processing. The pretreatment section typically includes several processes, such as shredding, sterilization, and volume reduction, to condition the waste for efficient handling in subsequent units. In facilities processing municipal, industrial, or agricultural waste, the pre-treatment section may also include systems like autoclaves 3 or compactors to sanitize, reduce pathogens, and reduce the volume of organic and composite materials. The waste is then better suited for the mechanical or chemical sorting processes that follow. The pre-treatment section 2 is preferable because it ensures that waste entering the facility is uniformly sized, decontaminated, and free from obstructions that might interfere with the subsequent sorting systems. Pre-treating the waste allows for more preciseseparation in units like magnetic separators, wind sifters, or optical sorters. Additionally, the pre-treatment step helps reduce overall waste volume, thus improving plant efficiency and throughput. It can also help in segregating hazardous or non- recyclable materials early in the process, preventing them from contaminating valuable recyclable fractions. Optional enhancements to this section could include advanced shredders for tough materials, or chemical treatments for hazardous waste, depending on the specific type of waste being processed.

[0155] Autoclave system 3 is a high-pressure steam treatment unit used in the waste pre-treatment process. This system subjects waste to high temperatures and pressure, typically using steam, to sterilize and reduce the volume of the waste. The autoclave effectively kills pathogens, neutralizes harmful substances, and softens materials, making them easier to handle and process in subsequent sorting and recycling stages. It is particularly useful for processing organic waste, medical waste, and other materials that require sanitization before further treatment. The autoclave system 3 is highly beneficial because it ensures that potentially harmful waste is rendered safe before it enters the broader waste management system. This process helps reduce the environmental and health risks associated with handling raw waste. Additionally, by reducing the volume of the waste through steam compaction, the autoclave system increases the efficiency of downstream sorting and processing units, allowing the facility to handle larger quantities of waste in a more manageable form. The autoclave also improves the efficiency of other units, such as shredders and separators, by making the waste more uniform and easier to process. Alternative implementations might include various autoclave sizes or additional chemical treatments depending on the specific requirements of the waste stream being handled.

[0156] Wastewater line 4 is responsible for transporting the liquid waste generated during various stages of the waste treatment process. This line collects and channels wastewater that is produced, for example, during the autoclaving process or from moisture released during other pre-treatment and sorting stages. The liquid may contain organic contaminants, chemicals, or residues that need to be properly treated before being discharged or recycled. The wastewater line directs this flow into the wastewater treatment unit 5, where the water undergoes purification and filtration processes. The wastewater line 4 is beneficial for managing the by-products of waste processing, particularly in facilities that handle organic, industrial, or composite wastethat produces significant amounts of liquid. By efficiently routing wastewater through the system, the line helps prevent contamination of dry waste streams, improving the effectiveness of solid waste processing and maintaining the integrity of the sorting and recycling operations. Additionally, proper management of wastewater is crucial for environmental compliance, ensuring that the plant can treat and release or reuse water in an environmentally responsible manner. Depending on the type of waste being processed, the wastewater line may incorporate additional filtration or containment systems to handle hazardous liquids before they reach the treatment unit.

[0157] Wastewater treatment unit 5 is configured to purify and treat the liquid waste that is collected from various stages of the waste processing operation, such as the autoclave system (3) or other moisture-generating processes. This unit typically employs a combination of physical, chemical, and biological treatment methods to remove contaminants from the wastewater. These processes can include filtration, sedimentation, chemical neutralization, and biological digestion, depending on the nature of the contaminants present in the wastewater. The treatment ensures that any harmful substances, such as organic pollutants, heavy metals, or chemicals, are neutralized or removed before the water is either discharged into the environment or recycled for use within the facility. Wastewater treatment unit 5 is beneficial for ensuring that the liquid by-products of waste processing are handled in an environmentally responsible manner. This unit helps the plant comply with environmental regulations by preventing untreated wastewater from being released into local ecosystems, which could otherwise lead to pollution and contamination of groundwater or surface water sources. Additionally, the ability to treat and recycle water within the facility contributes to resource efficiency, reducing the plant's overall water consumption and operational costs. Depending on the type of waste being processed, the wastewater treatment unit may be tailored with specific filtration technologies, chemical dosing systems, or advanced biological reactors to meet the demands of industrial, organic, or hazardous liquid waste.

[0158] Treated water line 6 is the conduit through which purified water exits the wastewater treatment unit 5 after undergoing the necessary filtration and purification processes. This line ensures that the treated water, now free from contaminants, is either discharged safely into the environment or redirected for reuse within the facility. Depending on the quality of the treated water, it may be used for non-potable purposessuch as cooling systems, cleaning, or further processing stages within the plant, thus promoting water recycling and reducing the facility's overall water consumption. The treated water line 6 plays a critical role in ensuring that the wastewater treatment system functions efficiently by providing a clear pathway for the purified water to be removed or repurposed. This prevents bottlenecks in the treatment process and helps the plant operate smoothly. Additionally, it ensures that any water released into the environment complies with environmental standards and regulations, reducing the plant’s environmental impact. In cases where the treated water is reused within the facility, the line contributes to the overall sustainability and resource efficiency of the plant. The design of the treated water line may vary based on the plant's specific needs, with options for storage tanks, monitoring systems, and valves to control water flow and quality.

[0159] Autoclaved waste line 7 is responsible for transporting waste that has been treated in the autoclave system 3 to the next stage of processing. After the waste has been sterilized and its volume reduced in the autoclave, it is carried through this line to either sorting systems, shredders, or other units for further processing. The autoclaved waste, now decontaminated and more uniform in size and composition, is ready for efficient handling by downstream sorting and recycling units. The autoclaved waste line 7 is beneficial for maintaining the flow of processed waste through the plant, ensuring that sterilized materials are quickly and efficiently transferred to the next stage without exposure to contamination or the external environment. This line supports a continuous and smooth operation within the plant, preventing bottlenecks and optimizing the waste management process. By transporting waste that has already been sterilized and compacted, it reduces the overall strain on downstream sorting systems, allowing them to operate more efficiently. Depending on the specific requirements of the plant, the autoclaved waste line may include conveyor belts, pneumatic systems, or chutes designed to handle the treated waste with minimal human intervention, ensuring safety and operational efficiency.

[0160] Sorting system 8 is responsible for separating and categorizing the autoclaved or pre-treated waste into different material streams based on physical, chemical, or material properties such as size, weight, magnetic response, or composition. Once the waste passes through the autoclaved waste line 7 or other pre-treatment processes, the sorting system engages multiple technologies (such as magnetic separators, windsifters, optical sorters, and screens) to divide the waste into fractions that can be directed to specific recycling, energy recovery, or disposal processes. The sorting system 8 is used in optimizing the efficiency of the entire waste management facility by ensuring that valuable materials, such as metals, plastics, organics, and high- calorific fractions, are correctly identified and recovered. This system minimizes the volume of waste sent to landfills by extracting materials that can be recycled or used for energy production. Depending on the specific types of waste being processed, the sorting system can be equipped with a combination of sensors (for material identification), automated mechanisms (such as air jets or conveyors), and manual sorting stations to handle both large volumes of waste and complex material streams. Optional configurations of the sorting system may include advanced technologies like near-infrared (NIR) sorting for plastics or eddy current separators for non-ferrous metals, making it adaptable to a wide range of waste processing needs.

[0161] Non-recyclables line 9 is responsible for directing waste materials that cannot be recycled or repurposed into a designated path for final disposal or energy recovery. After the waste passes through the sorting system 8, any materials deemed non- recyclable (such as contaminated or composite materials, certain plastics, or non- reusable fractions) are channelled into this line. The materials in the non-recyclables line are typically prepared for incineration, gasification, or other forms of waste-to- energy processing, ensuring that even non-recyclable waste is utilized for energy production rather than being sent directly to landfills. The non-recyclables line 9 is crucial for managing residual waste that cannot be sorted into recyclable or reusable categories. By isolating these materials, the plant minimizes contamination of recyclable streams and ensures efficient processing of non-recyclable fractions. The non-recyclables line plays a key role in waste-to-energy strategies, allowing the plant to convert otherwise unusable waste into electricity, heat, or other forms of energy, thereby reducing the overall environmental impact. Depending on the plant's setup, the non-recyclables line may feed directly into energy recovery units or, in cases where energy recovery is not viable, transport waste to landfill operations. Optional enhancements could include shredding or compacting systems within the line to reduce the volume of non-recyclable waste and improve the efficiency of energy recovery processes.

[0162] Waste line 10 is configured to transport selected waste that has been processed and sorted in the sorting system 8 and is destined for further thermal treatment. The waste line directs this material into the humidity adjustment unit 11 , where its moisture content is adjusted to optimize its performance in subsequent stages of the process, such as pyrolysis, thermolysis, or incineration. This line optionally includes both recyclable and non-recyclable materials that require thermal treatment or conversion into energy or valuable by-products within the reactor. The waste line 10 is beneficial for ensuring a continuous and controlled flow of materials into the reactor system, providing a feedstock that has been pre-sorted and adjusted for ideal moisture content. This preparation enhances the efficiency of the pyrolysis or thermolysis processes by preventing issues such as energy loss from excess moisture or incomplete material decomposition due to overly dry waste. The waste line’s role in transporting sorted materials from sorting system 8 through the humidity adjustment unit 11 ensures that the plant operates efficiently, with materials ready for consistent thermal processing. Depending on the plant’s design, the waste line may consist of conveyors, chutes, or other mechanisms that ensure a smooth, uninterrupted feed into the reactor.

[0163] Humidity adjustment unit 11 is designed to regulate the moisture content of waste material before it is fed into the reactor for thermal processes such as pyrolysis, thermolysis, or incineration. After the waste is sorted in sorting system 8 and transported via waste line 10, it enters the humidity adjustment unit, where moisture is either added or removed depending on the type of material and the specific requirements of the thermal treatment process. This may involve the use of dehumidifiers, dryers, or moisture injectors to ensure that the waste has the optimal moisture level for efficient conversion into gases, char, or other by-products. The humidity adjustment unit 11 is preferable for maximizing the efficiency and effectiveness of the reactor system. If the waste contains too much moisture, it can reduce the thermal efficiency, leading to energy losses and incomplete decomposition. Conversely, overly dry waste can lead to handling issues or inconsistent material flow. By precisely controlling the moisture content, the humidity adjustment unit ensures that the waste is in ideal condition for thermal treatment, improving energy recovery, and ensuring complete decomposition. Optional enhancements might include real-time moisture sensors and automated controls that adjust humidity levels based on thespecific requirements of different waste streams, optimizing the plant’s overall performance.

[0164] Excess water line 12 is responsible for removing and directing surplus water that has been extracted from the waste during the humidity adjustment process 11. When moisture is reduced in the waste to optimize its suitability for thermal treatment, the excess water needs to be efficiently collected and managed. The excess water line channels this water away from the humidity adjustment unit to either a wastewater treatment unit 5 or another designated area for proper handling, filtration, or disposal. The excess water line 12 is beneficial for maintaining the operational efficiency of the plant by ensuring that moisture removed from the waste does not interfere with other processes. It helps in maintaining a dry and controlled environment within the thermal treatment system, ensuring that the reactor operates with waste that has the ideal moisture content. Additionally, by managing and collecting the removed water, this unit prevents water from re-entering the waste stream or contaminating other areas of the plant. Depending on the plant's design, the excess water line may be connected to filtration systems that allow for recycling or safe discharge of the water, contributing to the facility's sustainability and regulatory compliance.

[0165] Pre-treated waste line 13 is responsible for transporting waste that has been processed in the pre-treatment section 2, including sterilization or volume reduction, to further stages of the plant, such as sorting or thermal processing. This line directs waste that has already been conditioned for subsequent steps, ensuring a smooth and efficient flow of materials from the pre-treatment system to the sorting system 8 or directly into the humidity adjustment unit 11 via waste line 10, depending on the plant’s configuration. The pre-treated waste line 13 plays a role in maintaining the continuity of operations within the plant, ensuring that the pre-treated waste is efficiently moved to the next relevant stage of processing. This line ensures that materials with reduced contaminants, pathogens, or moisture are ready for optimized sorting, recycling, or energy recovery processes. The pre-treated waste line also helps manage the distribution of materials based on their specific characteristics and processing needs, minimizing downtime and enhancing the throughput of the facility. Depending on the plant's layout, this line may consist of conveyor belts, pneumatic transport systems, or other mechanisms designed to handle the unique properties of the waste stream.

[0166] Gas production and treatment section 20 is a preferable component in the waste processing plant where the waste material undergoes thermal decomposition, such as pyrolysis or thermolysis, to produce useful gases like syngas (a mixture of hydrogen, methane, and carbon monoxide). This section comprises the pyrolysis and thermolysis unit 21 , which is responsible for breaking down the organic components of the waste at high temperatures in the absence of oxygen. The resulting gases are then collected and treated to remove impurities, such as tars, particulate matter, and other contaminants, before being directed for further use or storage. The gas production and treatment section 20 is optimal for converting waste into valuable energy products. The gases produced during thermal treatment can be used in energy recovery systems, such as gas turbines or engines, to generate electricity, heat, or other forms of energy. Additionally, by treating the gases within this section, the plant ensures that the emissions meet environmental regulations and that the gas is of high quality for energy applications. The section may include various components like gas scrubbers, filters, and separation units to refine and purify the produced gases, improving the overall efficiency and environmental sustainability of the waste-to-energy process.

[0167] Pyrolysis and thermolysis unit 21 is a core system for the thermal decomposition of waste materials. In this unit, waste is subjected to high temperatures in the absence (or limited presence) of oxygen, leading to the breakdown of organic compounds into simpler gases, liquids, and solid residues. Pyrolysis typically operates at lower temperatures than thermolysis, and both processes convert carbonaceous materials into products like syngas (a mix of hydrogen, carbon monoxide, and methane), liquid oils, and solid char. This unit serves as the optional heart of the gas production and treatment section 20, where waste is transformed into useful byproducts. The pyrolysis and thermolysis unit 21 is preferable because it enables the conversion of a wide variety of waste materials — such as plastics, biomass, and industrial waste — into valuable energy resources, while minimizing harmful emissions. The gases generated can be purified and used for energy recovery in turbines or other power-generating systems. Solid residues, like char, can be further processed or used in various applications, including soil enhancement or as a carbon-rich fuel. The efficiency of the pyrolysis and thermolysis processes depends on precise control of temperature, residence time, and the composition of the input waste, which is why thisunit is often equipped with advanced monitoring and control systems to optimize performance and ensure complete decomposition of the waste materials.

[0168] Fuel gas line 22 is responsible for transporting the gas produced in the pyrolysis and thermolysis unit 21 to downstream processes, where it can be treated, refined, or used for energy generation. This gas, typically a mixture of hydrogen, carbon monoxide, methane, and other hydrocarbons (syngas), is directed through the fuel gas line for further purification and processing in units such as gas cleaning systems or gas turbines for power generation. The fuel gas line is a critical component in ensuring the continuous and efficient flow of produced gases from the reactor to their next stage of use or storage. The fuel gas line 22 plays a beneficial role in maintaining the integrity and efficiency of the plant by ensuring that the produced gases are safely and efficiently transferred without leakage or contamination. Properly designed and maintained, this line ensures that the syngas can be directed to gas treatment units, where impurities are removed, and then utilized in gas turbines or other energy conversion devices to generate electricity or heat. The fuel gas line may include pressure monitoring, safety valves, and other control systems to handle the high- pressure and high-temperature gases, ensuring safe and efficient operation within the plant.

[0169] Solid rest line 23 is responsible for handling the solid by-products, or residues, that are left after the thermal decomposition of waste in the pyrolysis and thermolysis unit 21. These solid residues typically consist of char, ash, and other inorganic materials that are not converted into gases or liquids during the pyrolysis or thermolysis process. The solid rest line transports these materials away from the reactor to be further processed, stored, or utilized, depending on their composition and potential applications. The solid rest line 23 plays an important role in ensuring the continuous and efficient operation of the pyrolysis and thermolysis unit by safely removing the solid residues, preventing them from accumulating in the reactor and potentially disrupting the thermal process. The materials collected in the solid rest line may have various uses. Char, for example, can be used as a fuel, soil amendment, or in industrial processes. Additionally, by effectively managing the removal of these solid byproducts, the solid rest line helps maintain the overall cleanliness and efficiency of the plant, ensuring that all valuable by-products are utilized and minimizing waste.

[0170] Separation unit 24 is configured for separating and refining the different gas fractions produced during the pyrolysis or thermolysis process. Once the gases have been generated in the pyrolysis and thermolysis unit 21 and transported through the fuel gas line 22, they enter the separation unit 24, where they are divided into distinct components such as hydrogen, carbon monoxide, methane, and other hydrocarbons. This unit optionally utilizes methods like gas cooling, compression, or membrane filtration to isolate and purify each gas stream based on its molecular properties.

[0171] The separation unit 24 is preferable for improving the efficiency and usability of the gases produced in the plant. By effectively separating valuable gases like hydrogen and methane from impurities or less desirable components, the plant can optimize the use of each gas fraction for various applications, such as energy generation, chemical production, or further refining. Additionally, the separation unit helps ensure that the gas streams are free from contaminants that could damage downstream equipment or reduce the quality of the final products. This unit can also be designed to handle carbon dioxide capture, removing CO2 from the gas mixture for storage or industrial use, further enhancing the plant's environmental and economic performance.

[0172] Carbon dioxide export line 25 is configured to handle and transport carbon dioxide that has been separated from the gas stream in the separation unit 24. After the gases produced during pyrolysis or thermolysis are processed and purified, CO2 is extracted to prevent its release into the atmosphere and to optimize the energy content of the remaining fuel gases. The carbon dioxide export line directs the captured CO2 to storage facilities, or to other industrial applications where it can be used, such as in enhanced oil recovery, carbonation processes, or for conversion into value-added products like methanol. The carbon dioxide export line 25 plays a crucial role in both improving the environmental sustainability of the plant and enhancing its economic viability. By capturing and exporting CO2, the plant significantly reduces its greenhouse gas emissions, contributing to compliance with environmental regulations and reducing its carbon footprint. Moreover, captured CO2 can be sold or utilized in various industrial applications, transforming what would otherwise be a waste product into a valuable resource. This unit ensures that the plant operates efficiently by minimizing the environmental impact of its operations.

[0173] Low carbon dioxide fuel gas line 26 is responsible for transporting the purified gas mixture that remains after the carbon dioxide (CO2) has been removed in the separation unit 24. This gas, which contains a higher concentration of energy-rich components like hydrogen, carbon monoxide, and methane, is directed to the plant's energy conversion systems, such as gas turbines or engines, for efficient use in generating electricity, heat, or other forms of energy. By removing CO2, the gas mixture in this line has an improved calorific value, making it more suitable for energy production and reducing emissions when burned. The low carbon dioxide fuel gas line 26 is preferable for optimizing the plant's energy recovery processes by ensuring that the fuel gas delivered to optional combustion or energy conversion systems is as efficient and clean as possible. The removal of CO2 increases the energy density of the gas, allowing for more efficient combustion and reducing the production of greenhouse gases during energy generation. This unit ensures that the gas is transported safely and efficiently to its next stage, whether for direct energy generation, further refinement, or industrial use, or storage. The design of the low CO2 gas line 26 may include pressure controls, safety valves, and flow monitoring systems to ensure smooth and secure transport of the purified fuel gas.

[0174] Loop line 27 is responsible for reintroducing the further carbonaceous rest from the cracking unit 80 back into the bottom part of the pyrolysis unit 21. This reintroduction ensures that any unreacted or partially reacted carbonaceous material is subjected to further thermal treatment, maximizing the conversion efficiency of the feedstock. By creating a closed-loop system, loop line 27 allows for continuous recycling of carbonaceous material, ensuring that the carbon content is fully utilized. This process minimizes waste and enhances the overall yield of valuable gases such as hydrogen and methane. The inclusion of loop line 27 is beneficial for maintaining a high level of thermal efficiency within the pyrolysis unit, as it ensures that the feedstock is consistently exposed to the highest temperature zone first. This step reduces the amount of unreacted material, improves the quality of the produced gas, and contributes to a more sustainable and efficient operation. Additionally, loop line 27 helps in stabilizing the calorific value of the output gas, making it more suitable for energy production and other industrial applications. The design of loop line 27 may include mechanisms for controlling the flow rate and pressure of the carbonaceous rest, ensuring smooth and efficient reintroduction into the pyrolysis unit.

[0175] Gas turbine power plant 30 is optional. It is where the energy-rich gases produced and purified in the plant, e.g. gas production and treatment section 20, are converted into electricity and / or heat. The gases transported through the low carbon dioxide fuel gas line 26 are directed into a gas turbine, where they are combusted under controlled conditions to generate mechanical energy. This mechanical energy drives the turbine, which in turn powers a generator to produce electricity. In some configurations, the gas turbine power plant may also incorporate a combined heat and power (CHP) system to utilize excess heat for industrial processes or heating systems.

[0176] The gas turbine power plant 30 is beneficial for converting the chemical energy stored in the syngas produced from the waste into useful electrical energy, which can either be used to power the waste processing facility itself or be fed into the grid. By using the low carbon dioxide gas mixture, the power plant operates more efficiently and with fewer emissions compared to traditional fossil fuel-based systems. This unit enhances the overall sustainability of the waste-to-energy system by providing a clean energy output while minimizing waste and emissions. Depending on the plant’s configuration, the gas turbine power plant may be designed to handle fluctuations in gas composition, ensuring stable and continuous energy production even when the input gas varies.

[0177] Alternatives for converting the energy-rich gases produced during pyrolysis or thermolysis into usable energy include several technologies that can handle varying compositions of syngas while maximizing efficiency and minimizing emissions. For example: internal combustion engines, fuel cells, boiler and stream turbine systems, CHP units, or syngas-to-liquid conversions (Fischer-Tropsch process). Engines that can run on syngas and are particularly suited for smaller-scale waste-to-energy plants. Internal combustion engines convert syngas into mechanical energy, which is then used to drive a generator to produce electricity. This option is more flexible for plants with lower energy output needs and can efficiently handle varying gas compositions. Syngas can be fed into solid oxide or molten carbonate fuel cells, which convert the chemical energy of the gas directly into electricity with higher efficiency and fewer emissions compared to combustion-based technologies. Fuel cells are an excellent alternative for clean energy production, especially in settings where reducing pollutants and greenhouse gases is a priority. Hydrogen-enriched syngas is particularly suited for fuel cells. If the syngas is combusted in a boiler to produce steam, steam then drivesa steam turbine to generate electricity. This method, particularly when combined with a combined heat and power (CHP) system, allows for the efficient use of both electricity and heat. This system is well-suited for larger plants and industrial applications where the heat by-product can be repurposed. While CHP can be integrated with gas turbines, it can also work with other systems like boilers or engines. In CHP units, syngas is burned to produce both electricity and useful heat. This alternative improves overall energy efficiency by using the heat that would otherwise be wasted, making it ideal for facilities that require both power and thermal energy. Instead of directly generating electricity, syngas can be processed into liquid fuels such as diesel or methanol using the Fischer-Tropsch process. This method is ideal when the goal is to produce clean fuels for transportation or chemical feedstocks rather than electricity.

[0178] Electric power line 31 is configured for transmitting the electricity generated by the gas turbine power plant 30 or any optional alternative energy conversion systems, such as internal combustion engines or fuel cells. After the waste-derived syngas is converted into electrical energy, the electric power line transports this electricity either to power the waste processing facility itself or to the local power grid for external distribution. The electric power line ensures that the generated electricity is delivered to where it is needed, whether to supply the facility’s energy needs or to be sold to the grid. The electric power line 31 is essential for integrating the waste-to-energy process into the overall energy system of the plant or region. It ensures that the electricity produced from the waste is efficiently utilized or distributed, maximizing the economic and environmental benefits of the waste-to-energy conversion process. Depending on the scale of the plant, the electric power line may be connected to transformers, inverters, and grid synchronization systems to manage voltage, current, and power quality, ensuring smooth and stable power delivery. Additionally, the power line may include safety features such as circuit breakers and monitoring systems to protect both the plant and the grid from electrical faults.

[0179] Steam line 32 is responsible for transporting steam generated within the plant, typically as a by-product of thermal processes like pyrolysis, thermolysis, or energy conversion in the gas turbine power plant 30 or other energy systems. The steam line channels this steam to various parts of the facility where it can be used for additional processes, such as heating, drying, or providing energy for secondary turbines in a CHP system. This steam may also be used to preheat materials, drive mechanicalsystems, or be condensed back into water for recycling within the plant. The steam line 32 plays an important role in improving the overall energy efficiency of the waste processing facility by capturing and utilizing waste heat in the form of steam, which would otherwise be lost. This makes the plant more sustainable and cost-effective by reducing the need for external energy inputs. The steam line may also be connected to heat exchangers, boilers, or secondary turbines, allowing for further recovery of energy in the form of electricity or thermal energy. In some configurations, the steam can be exported to nearby industrial facilities or district heating networks, contributing to broader energy efficiency and sustainability goals.

[0180] Steam lines 33, e.g. comprising 33a and / or 33b, are configured similarly to steam line 32, but may refer to multiple steam distribution channels within the plant. These additional steam lines 33 transport steam generated during thermal processes to various sections of the facility for specific uses, including heating, drying, energy recovery, or other auxiliary processes. Like steam line 32, these steam lines help capture and redistribute waste heat, ensuring that energy produced during the waste- to-energy process is efficiently utilized. The steam lines 33 ensure that steam is effectively routed to different systems or machinery that require heat energy. This network of lines allows for the strategic reuse of steam in multiple areas of the plant, optimizing energy efficiency. By distributing steam across different sections, the plant can reduce external energy consumption and improve the overall sustainability of its operations. These lines may also serve separate steam consumers, such as secondary turbines, heat exchangers, or external industrial or district heating customers, providing a flexible and efficient solution for managing waste heat within and beyond the facility.

[0181] Startup gas line 39 is configured to supply an external source of fuel or gas to initiate the thermal processes within the pyrolysis and thermolysis unit 21 or other energy systems during startup. Before sufficient syngas can be produced from the waste material itself, the startup gas line 39 provides the necessary combustible gas, such as natural gas, propane, or other fuel, to ignite burners or heat exchangers and bring the system up to operational temperature. Once the required temperature is reached and the thermal decomposition of the waste begins, the system can gradually switch over to using the syngas produced in the reactor 40. The startup gas line 39 is essential for ensuring a smooth and efficient startup of the waste-to-energy system,especially in large-scale industrial operations where significant amounts of heat are required to initiate the thermal reactions in the reactor. By providing a controlled and reliable fuel source during the startup phase, this line helps avoid operational delays and ensures that the plant can quickly reach the necessary conditions for waste processing. The startup gas line may also include safety features such as pressure regulators and shutoff valves to ensure safe operation, and it can be automatically shut off once the system is fully self-sustaining on syngas.

[0182] Reactor 40 is the central component of the pyrolysis or thermolysis process where waste materials undergo thermal decomposition. Inside the reactor 40, organic materials are subjected to high temperatures in the absence (or limited presence) of oxygen, causing the breakdown of complex compounds into simpler gases, liquids, and solid residues (such as char). The reactor 40 is configured to operate under carefully controlled conditions, with heating elements and insulation to maintain optimal temperatures for efficient pyrolysis or thermolysis. The exact temperature, pressure, and residence time inside the reactor is optionally adjusted based on the type of waste being processed and the desired outputs (e.g., syngas, oils, or solid carbon materials). The reactor 40 plays a critical role in the waste-to-energy conversion process, e.g. when the waste-to-energy process is based on pyrolysis or thermolysis and not alternative food or material recycling. It is where the waste is transformed into valuable energy-rich products, such as syngas, which can be used for power generation, and solid residues like biochar, which can have various industrial or agricultural uses. The efficiency and design of the reactor directly impact the quality and quantity of the byproducts generated. Modern reactors often include advanced controls for temperature, pressure, and feedstock flow to ensure consistent performance. Additionally, the reactor can be equipped with features such as screw conveyors 50 for continuous feed and gas extraction systems to capture the produced gases for further treatment and utilization.

[0183] Optionally, reactor 40 has a double wall configuration to improve safety and temperature efficiency. A reactor 40 with a double wall configuration consists of an inner wall and an outer wall, creating a volume between the two walls. This design is dimensioned to withstand the operating pressure and temperature specific to the reaction, e.g. pyrolysis, process. The volume between the walls is filled with at least one gas that is not hydrogen or oxygen, such as an inert gas, nitrogen, or carbondioxide. This configuration is beneficial because it enhances the safety and integrity of the reactor. The presence of a non-reactive gas in the volume acts as a buffer, reducing the risk of explosive reactions and providing an additional layer of thermal insulation. Furthermore, the double wall setup optionally includes at least one sensor for detecting gas leakage, which is communicatively coupled to a control and safety system. This feature ensures real-time monitoring and immediate response to any potential breaches, thereby maintaining the reactor's operational safety and efficiency. The overpressure in the volume relative to the process pressure inside the inner wall also provides tension to the inner wall, enhancing its structural stability and prolonging the reactor's 40 lifespan.

[0184] Gas line 41 is configured for transporting the gases produced during the pyrolysis or thermolysis process in the reactor 40 to downstream processing units. These gases, primarily consisting of syngas (a mixture of hydrogen, carbon monoxide, methane, and other hydrocarbons), are generated when waste materials undergo thermal decomposition within the reactor. The gas line ensures that these volatile gases are safely and efficiently carried to the gas cleaning, separation, and treatment systems for further refinement, purification, or direct use in energy generation systems like gas turbines. The gas line 41 is beneficial for maintaining a seamless and safe flow of gases from the reactor to other parts of the plant. It helps prevent any loss of valuable gases, ensuring that the syngas is properly captured for energy recovery or chemical processing. The gas line may be equipped with pressure regulators, valves, and safety features to control the flow and pressure of the gases and to prevent leaks or other hazardous conditions. Proper management of the gas line is crucial to ensure that the syngas reaches the treatment units in a clean and efficient manner, ultimately enhancing the plant’s energy recovery efficiency and reducing emissions.

[0185] Mixing chamber 45 is designed to blend different gas streams, typically produced in the reactor 40 or other parts of the plant, to ensure a consistent and homogeneous gas composition before the gases are further processed or utilized. The mixing chamber helps to equalize variations in gas composition that might result from differences in feedstock, pyrolysis conditions, or other variables within the thermal decomposition process. By homogenizing the gas, it ensures that downstream processes, such as gas cleaning, separation, or energy recovery, can operate under stable and optimized conditions. The mixing chamber 45 plays a preferable role inimproving the efficiency and effectiveness of gas treatment and utilization systems. By ensuring a consistent mixture of gases, it helps to prevent fluctuations in performance, particularly in sensitive systems like gas turbines or fuel cells, which require steady gas quality for optimal operation. The chamber may include mechanical or static mixers that facilitate thorough blending, and may be equipped with sensors to monitor gas composition in real-time, allowing for adjustments if necessary. This ensures that the plant can maintain high levels of efficiency and reliability in the gas treatment and energy generation processes.

[0186] Heating jacket 46 is an optional external system that provides controlled heating to the reactor 40 or other processing units to maintain the necessary high temperatures for pyrolysis or thermolysis to occur. The heating jacket surrounds the reactor 40 and delivers heat through various means, such as electric heaters, circulating hot oil, or steam. This external heating system ensures that the waste material inside the reactor is consistently subjected to the optimal temperatures required for thermal decomposition without the introduction of oxygen, allowing for the breakdown of organic compounds into syngas, oils, and char. The heating jacket 46 is configured for maintaining precise temperature control within the reactor, which directly impacts the efficiency and quality of the pyrolysis or thermolysis process. By providing consistent and uniform heating, the jacket prevents cold spots or uneven thermal gradients that could lead to incomplete decomposition or reduced gas and char yields. The ability to control the temperature via the heating jacket also allows for adjustments based on the specific feedstock being processed, ensuring the reactor operates at its most efficient for a variety of materials.

[0187] Air line 47 is configured for supplying controlled amounts of air or oxygen to specific sections of the plant, typically for combustion processes or to aid in cooling and venting systems. In pyrolysis or thermolysis systems, which typically operate in low or no oxygen environments, the air line 47 may be used for secondary processes such as heating, safety measures, or for precise introduction of air when controlled combustion is required. The air line 47 is carefully managed to ensure that oxygen does not interfere with the thermal decomposition process within the reactor, where oxygen-free conditions are critical for producing syngas, char, and other by-products. The air line 47 is beneficial for managing airflow in areas where oxygen is needed without compromising the main pyrolysis or thermolysis reactions. It may be used tointroduce controlled air for burners in heating systems (such as the heating jacket 46), or for gas clean-up processes, ensuring the plant operates efficiently and safely. The air line 47 is typically equipped with valves, regulators, and sensors to control air pressure and flow, ensuring the proper balance of oxygen in specific areas while maintaining an oxygen-free environment where necessary, such as inside the reactor.

[0188] Flue gas line 48 is configured for transporting the exhaust gases, or flue gases, generated from combustion or thermal processes within the plant to appropriate treatment or emission control systems. These gases are produced when waste materials or other fuels are combusted in auxiliary units such as heating systems, boilers, or burners that support the pyrolysis or thermolysis process. The flue gas line directs these gases to units like scrubbers, filters, or other pollution control systems where harmful substances like particulates, sulfur compounds, or nitrogen oxides are removed before the gases are safely released into the atmosphere. The flue gas line 48 plays a beneficial role in managing the by-products of combustion and ensuring that the plant adheres to environmental regulations regarding air emissions. By effectively channelling flue gases to treatment systems, the line helps prevent the release of harmful pollutants and ensures that emissions are within acceptable limits. The flue gas line is typically equipped with temperature and pressure controls to handle the hot exhaust gases and may include sensors and valves to monitor gas flow, ensuring safe and efficient operation of the plant’s emissions control systems. Proper management of the flue gas line is essential for maintaining both the environmental performance and the operational safety of the facility.

[0189] Motor 49 is a mechanical, electrical, or kinetic component that provides the necessary power or kinetic energy to drive various systems and processes within the plant. In the context of pyrolysis and thermolysis, the motor 49 is optionally used to operate devices such as conveyors, pumps, mixers, or other machinery that requires rotational or linear motion to transport materials, agitate gases, or move components within the reactor 40 or surrounding systems. The motor 49 is preferably directly connected to units like the screw conveyor 50 to ensure continuous movement of waste materials through the reactor 40, ensuring steady feed rates and optimized processing. The motor 49 is beneficial for maintaining the mechanical and / or kinetic operations within the plant, particularly in systems or processes that require precise and / or continuous movement of materials or components. Its reliable operation ensures thatwaste is fed into the reactor at the correct rate, and that materials within the reactor are adequately agitated or conveyed to achieve optimal thermal decomposition. The motor is typically equipped with speed and power controls to adjust its performance based on the operational needs of the plant, and it may be linked to automation systems to ensure synchronized operation with other units.

[0190] Screw conveyor 50 comprises a device for moving waste materials through one or more stages of the pyrolysis or thermolysis process, such as moving, churning, or mixing, waste within the reactor 40. Optionally, the screw conveyor 50 consists of a rotating helical screw blade, housed within a cylindrical or U-shaped trough, that pushes waste materials along its length. In the context of pyrolysis or thermolysis, the screw conveyor is often used to transport waste from the feed inlet through the reactor 40, ensuring a continuous and controlled flow of material. The conveyor’s speed can be adjusted to regulate the residence time of the waste within the reactor, which is beneficial for optimizing the thermal decomposition process. The screw conveyor 50 is essential for maintaining consistent material flow, which is crucial for the reactor's efficiency and performance. By precisely controlling the rate at which waste is introduced and moved through the reactor, the screw conveyor helps ensure uniform exposure to heat, promoting thorough thermal decomposition. It also prevents blockages and ensures that materials are evenly distributed within the reactor, preventing cold spots or uneven processing. The screw conveyor’s 50 design allows it to handle a wide range of materials, from organic waste to industrial residues, making it a versatile and reliable component in the waste processing system.

[0191] The high temperature chamber 51 is a section of the reactor system where the waste materials are subjected to intense heat during the pyrolysis or thermolysis process. This chamber is designed to maintain high and stable temperatures, typically ranging from several hundred to over a thousand degrees Celsius, depending on the material and process requirements. Inside the high temperature chamber 51 , organic materials break down into simpler compounds such as syngas, oils, and solid residues like char. The chamber is insulated and heated using systems like the heating jacket 46, ensuring that the thermal conditions remain optimal for the decomposition reactions. The high temperature chamber 51 plays a preferable role in the efficiency and effectiveness of the waste conversion process, especially when optionally placed towards the bottom of the reactor for further efficiency gains. By maintaining thenecessary high temperatures, the chamber ensures that the waste undergoes complete and uniform thermal decomposition, maximizing the production of valuable by-products like syngas and minimizing the formation of unwanted residues or emissions. The high temperature conditions also help in cracking complex organic compounds into simpler, usable products, making it a key component in the waste-to- energy system. The design of the chamber is optimized to handle a continuous feed of waste from the screw conveyor 50 while ensuring even heat distribution and controlled reaction times.

[0192] Pyrolysis gas line 52 is configured for transporting the gases produced during the pyrolysis or thermolysis process from reactor 40, e.g. the high temperature chamber 51 , to downstream processing units for cleaning, separation, or utilization. These gases, often referred to as syngas, comprise of hydrogen, carbon monoxide, methane, other volatile compounds generated when organic waste materials are thermally decomposed in the absence or limited presence of oxygen, or a mixture thereof. The pyrolysis gas line ensures that these valuable gas(es) are efficiently channelled from the reactor to gas cleaning systems, such as scrubbers or filters, where impurities like tars, particulates, or acids are removed before the gases are used for energy generation or other applications. The pyrolysis gas line 52 is beneficial for maintaining the integrity and efficiency of the gas processing system. By safely transporting the raw syngas from the reactor to the treatment units, the line helps ensure that the gases are captured without leaks or losses, optimizing the plant’s energy recovery. Additionally, it allows for real-time monitoring and control of gas flow, pressure, and composition to maintain safe and efficient operation throughout the plant. The pyrolysis gas line may be equipped with valves, sensors, and safety mechanisms to regulate the flow of gas, ensuring that it is delivered under controlled conditions to the gas cleaning and utilization stages.

[0193] On or more mixing arms 53 are an optional addition to reactor 40, e.g. via the screw conveyer 50 or another component. For example, the mixing arms 53 are directly or indirectly controlled or moved by motor 49. In one embodiment, mixing arms 53 comprises a mechanical component located inside the reactor 40 or connected to the waste processing system that serves to agitate or mix materials during the pyrolysis or thermolysis process. These arms rotate or move in a controlled manner to ensure that the waste material is evenly distributed and exposed to heat within the hightemperature chamber 51. By maintaining consistent mixing, the mixing arms prevent material from clumping or settling, which could lead to uneven heating and incomplete decomposition of the waste. The mixing arms 53 are beneficial for ensuring the uniform thermal treatment of the waste. By constantly stirring the material, they help promote even heat distribution and prevent localized overheating or cold spots within the reactor. This uniformity is essential for optimizing the efficiency of the pyrolysis or thermolysis process, ensuring that all materials are thoroughly decomposed into gases, liquids, or solid by-products like char. The mixing arms are typically designed to handle various types of waste, from solid organic materials to more complex industrial or composite waste, ensuring smooth and continuous operation throughout the process.

[0194] Heating jacket 54 is an external thermal system used to provide heat to specific sections of the reactor, similar to heating jacket 46, but dedicated to parts of the reactor system requiring the highest temperatures, e.g. high temperature chamber 51. The heating jacket 54 surrounds the relevant chamber or conduit, providing consistent and controlled heat to ensure that the pyrolysis or thermolysis process remains at the optimal temperature. It operates by circulating a heating medium, such as steam, hot oil, or electrical heating elements, around the reactor to maintain the necessary temperature for the thermal decomposition of waste materials. The heating jacket 54 is essential for maintaining stable temperatures in the reactor, particularly in areas where precise thermal control is critical for maximizing the efficiency of pyrolysis or thermolysis. By ensuring that the reactor remains at the correct temperature, the heating jacket enables the waste material to undergo complete decomposition, which enhances the yield of valuable by-products like syngas and minimizes the formation of unwanted residues. The uniform heating provided by the jacket also helps prevent cold spots or thermal imbalances, ensuring consistent performance throughout the reactor. This component can be adjusted to fit the specific heating requirements of different reactor zones, optimizing the overall thermal process.

[0195] High temperature chamber outlet 55 is he exit point from the high temperature chamber 51 where the solid residues, gases, and any remaining materials are discharged after undergoing the pyrolysis or thermolysis process. This outlet is designed to handle the high temperatures and the mixture of by-products that result from the thermal decomposition of the waste. The gases are preferably directed intothe pyrolysis gas line 52 for further treatment and utilization, while solid residues, such as char or ash, are routed to subsequent units for handling, processing, or disposal, optionally including further processing in another reactor, e.g. reactor 40 or secondary reactor 60. The high temperature chamber outlet 55 ensures the efficient transfer of materials from the reactor after the thermal decomposition process is complete. Its design helps prevent blockages and ensures a controlled flow of both gases and solids out of the reactor. By safely transporting the by-products, the outlet enables a smooth transition to the gas cleaning, separation, and solid residue handling stages. The outlet may also be equipped with temperature control mechanisms and sealing systems to prevent the loss of heat and to ensure that no oxygen enters the high temperature chamber, maintaining the anaerobic or limited oxygen conditions required for pyrolysis or thermolysis.

[0196] Heating jacket 59 is another external thermal system designed to provide heat to specific sections of the reactor or associated units. Like other heating jackets in the system, its purpose is to maintain high and consistent temperatures needed for the pyrolysis or thermolysis process. By surrounding parts of the reactor or conduits with a circulating heating medium, such as hot oil, steam, or electrical heating elements, the heating jacket ensures that the thermal decomposition reactions occur at the optimal temperature for efficient breakdown of waste materials into syngas, oils, and char. The heating jacket 59 optionally improves performance by ensuring that relevant parts of the system receive consistent or targeted heat as required. This prevents temperature fluctuations, which could lead to incomplete decomposition or lower yields of syngas and other by-products. Like the other heating jackets in the system, it ensures that no cold spots or thermal imbalances affect the efficiency of the pyrolysis or thermolysis process. Additionally, the heating jacket helps protect the integrity of the reactor by maintaining the structural components at the right temperatures, minimizing wear and thermal stress on the system during operation.

[0197] One or more secondary reactors 60 are configured to play a complementary role to the main pyrolysis and thermolysis unit 21 and / or primary reactor 40. These secondary reactors are optionally used to further process the intermediate products, such as gases, oils, or solid residues, generated from the primary reactor 40. The secondary reactors may carry out additional reactions, such as gasification, cracking of heavier hydrocarbons, or further thermal decomposition of solids, to increase theyield of valuable products like hydrogen-rich syngas, liquid fuels, or char. These reactors 60 preferably operate at different temperatures or pressures from the primary reactor 40, depending on the specific chemical transformations required. The secondary reactors 60 are important for maximizing the efficiency and output of the overall waste processing system. By providing an additional stage for refining the products from the primary reactor, they help ensure that all potential energy and material value is extracted from the waste. For example, heavier oils produced in the primary reactor might be further cracked into lighter, more valuable hydrocarbons, while char or ash could undergo additional gasification to produce more syngas. These reactors enhance the plant’s flexibility and adaptability, allowing it to handle a wide variety of feedstocks and optimize the production of different energy and material outputs.

[0198] Raw gas withdrawal line 61 is responsible for transporting the raw syngas produced in the primary pyrolysis and thermolysis unit 21 or secondary reactors 60 to the gas cleaning and treatment systems. This line carries the unprocessed syngas, which contains a mixture of valuable gases (like hydrogen, methane, and carbon monoxide) as well as impurities such as tars, particulates, and other by-products, from the reactors to the next stage where it can be purified and refined for further use in energy generation or chemical processing. The raw gas withdrawal line 61 is beneficial for ensuring that the syngas is efficiently and safely transported out of the reactor system. Proper management of this line helps prevent leaks or losses of valuable gases and ensures that the gas is delivered to treatment units in a controlled manner. This line may include sensors, valves, and pressure control mechanisms to monitor the flow and composition of the raw gas, ensuring optimal performance of downstream processes like gas cleaning, separation, and storage. The raw gas withdrawal line helps maintain the integrity of the gas processing system, improving the overall efficiency and effectiveness of the plant.

[0199] First Gas Cleaning Unit 62 is responsible for the initial purification of the raw syngas transported through the raw gas withdrawal line 61 . In the first gas cleaning unit, contaminants such as tars, particulates, sulfur compounds, and acids are removed from the gas stream to prevent damage to downstream equipment and to improve the quality of the syngas. The cleaning process may include filtration, scrubbing, or condensation techniques. The first gas cleaning unit 62 is critical forensuring that the raw syngas is clean enough to proceed to further treatment or utilization, such as in gas turbines or chemical synthesis. This step improves the efficiency and lifespan of the gas handling and utilization systems by preventing clogging, corrosion, or inefficiencies caused by impurities.

[0200] Wastewater line 63 transports wastewater generated during the gas cleaning processes, such as from the scrubbers or condensers used in the first gas cleaning unit. The wastewater may contain dissolved contaminants, tars, or particulates that need further treatment before being safely discharged or recycled. The wastewater line 63 ensures that contaminated water from the cleaning process is managed efficiently, preventing any cross-contamination with the gas stream or other plant operations. It typically directs the wastewater to the wastewater treatment unit 5 for purification.

[0201] The scrubbed raw gas line 64 carries the syngas after it has undergone its first cleaning in the gas cleaning unit. At this stage, the syngas has had its largest contaminants removed but may still need further purification depending on its intended use. The scrubbed raw gas line 64 is beneficial for ensuring the smooth flow of cleaner syngas to additional purification or separation units, ensuring that the gas is ready for further refinement or energy recovery applications.

[0202] Gas separation unit 65 separates different components of the syngas, such as hydrogen, methane, carbon monoxide, and other valuable gases. Various technologies, such as membranes, pressure swing adsorption PSA, or cryogenic separation, can be used to isolate the gas fractions based on their molecular properties. The gas separation unit 65 enhances the efficiency of the plant by isolating valuable gas fractions like hydrogen for industrial applications or power generation. This separation process is beneficial for maximizing the economic and energy value of the syngas.

[0203] The hydrogen-rich gas line 66 is responsible for transporting the hydrogen-rich fraction of the syngas that has been separated in the gas separation unit 65. The hydrogen-rich gas may be used in various industrial processes, energy generation, or stored for future use. The hydrogen-rich gas line 66 ensures the secure and efficient flow of this valuable gas to its next destination, whether for use in fuel cells, turbines, or chemical manufacturing.

[0204] Gas line 67 comprises a general-purpose gas line and transports the remaining gas fractions after hydrogen and other key components have been separated. The gases may still contain energy-rich components like methane and can be used for power generation or other applications. The gas line 67 ensures that the remaining gas is properly routed for further use, ensuring efficient energy recovery and utilization of all by-products from the pyrolysis or thermolysis process.

[0205] First light oil line 68 transports the light oils that are condensed from the gas stream during the gas cleaning and cooling processes. These oils may contain valuable hydrocarbons that can be used as fuel or chemical feedstocks. The first light oil line 68 ensures that these light oils are efficiently collected and directed to storage or processing units, where they can be refined or used directly as a product.

[0206] Solid line(s) 69 transports solid residues, such as char or ash, generated during the pyrolysis or thermolysis process. These materials may have value as fuel, soil amendments, or industrial raw materials. The solid lines 69 ensure the safe and efficient movement of solid by-products to handling or processing units, contributing to waste minimization and material recovery.

[0207] Conversion unit 70 is configured to further process intermediate gas or liquid products to enhance their quality or convert them into other valuable products. For instance, it may include systems for steam reforming, gasification, or cracking heavier hydrocarbons into lighter gases. The conversion unit 70 adds flexibility to the plant by enabling the refinement of intermediate products into more valuable forms, improving the overall yield of usable energy or materials.

[0208] Steam line 71 transports steam generated either from the thermal processes or from the conversion unit 70 to other parts of the plant for heating, drying, or driving turbines for power generation. The steam line 71 improves energy efficiency by repurposing steam as a useful by-product, contributing to the overall energy recovery in the plant.

[0209] Gas line 72, similar to other gas lines in the system, handles the flow of gases produced or refined in the plant. It may connect to various systems, such as turbines or chemical reactors, for energy production or further refinement. The gas line 72 ensures the secure transport of gas to its intended destination, optimizing the plant’s energy and material flow.

[0210] Cracked gas line 74 transports gas that has been cracked in the conversion unit 70. Cracking breaks down heavier hydrocarbons into lighter ones, resulting in a gas that is more energy-rich and suitable for fuel use. The cracked gas line 74 ensures that this refined gas is efficiently moved to power generation systems or further treatment, maximizing the value of the gas produced.

[0211] Second gas cleaning unit 75 provides an additional level of cleaning and purification for the syngas after it has been further processed or cracked. It removes any remaining impurities, ensuring the gas meets the necessary quality standards for use in power generation or chemical synthesis. The second gas cleaning unit 75 is preferable for ensuring that the final gas product is clean and free from contaminants that could hinder its use in sensitive applications, such as fuel cells or turbines.

[0212] Used water line 76 transports wastewater generated from various gas cleaning and cooling processes to a treatment unit for purification. It carries the used water from the gas treatment stages to be processed and recycled or safely discharged. The used water line 76 is key to managing water resources in the plant, ensuring that contaminated water is handled appropriately and does not interfere with other processes.

[0213] The second light oil line 77 handles the transport of light oils that have been condensed and separated in the later stages of the process. These oils can be used as fuels or chemical feedstocks. The second light oil line 77 efficiently directs this byproduct to storage or refining units, ensuring that all valuable fractions of the pyrolysis or thermolysis process are captured and utilized.

[0214] Heating collar 78 comprises a localized heating element used to maintain the temperature of specific parts of the reactor or pipelines. It ensures that certain sections of the plant remain at the required temperature to prevent condensation or blockages and to maintain optimal reaction conditions. The heating collar 78 is preferable for precision heating in areas where temperature control is beneficial, such as gas lines or sensitive components of the reactor.

[0215] Heating jacket 79, similar to 46 and 54, is an external thermal system used to provide consistent heating around a reactor or pipeline section. It ensures that the temperature is maintained for optimal thermal decomposition or gas flow. The heating jacket 79 plays a beneficial role in maintaining uniform heat distribution throughout thesystem, preventing energy losses and ensuring the efficiency of the pyrolysis or thermolysis process.

[0216] Cracking unit 80 breaks down heavier hydrocarbons, such as oils produced during pyrolysis, into lighter gases and liquids through thermal or catalytic cracking. The cracked products are typically more valuable and easier to use in energy applications or chemical synthesis. The cracking unit 80 enhances the plant’s efficiency by converting heavier, less valuable products into lighter fractions that have a higher market value and energy content, such as methane, ethylene, or other light hydrocarbons.

[0217] Beneficially, the cracking unit 80 is accessible for processes like reforming, which offers several key benefits and inventive aspects over known systems that typically have more rigid or limited post-processing capabilities for intermediate products like heavy oils or gases, including: enhanced product flexibility, integrated reforming for hydrogen production, increased energy recovery and process efficiency, minimized waste and by-products, and / or operational flexibility and scalability.

[0218] In traditional pyrolysis or thermolysis systems, heavier hydrocarbons generated from the initial thermal decomposition of waste often remain as-is, requiring separate, more specialized downstream processing for further conversion into lighter, more valuable products. The cracking unit 80 allows for the immediate further processing of these heavier oils and gases within the same plant, enabling them to be cracked into lighter fractions, such as methane, ethylene, or hydrogen-rich gases, in a continuous manner. This flexibility allows the plant to optimize the composition of output gases and liquids to meet varying industrial or energy needs. Traditional systems often lack this level of integration, requiring additional external units for further refining.

[0219] The ability to integrate reforming processes within the cracking unit allows for efficient hydrogen production, which is highly sought after for industrial uses, energy storage, and fuel cells. In contrast to known systems that typically separate hydrogen production into an entirely different system, the cracking unit (80) allows heavier hydrocarbons to be reformed directly into hydrogen-rich syngas within the same operational cycle. This streamlines the plant’s operations and maximizes hydrogen output without the need for additional reactors or complex piping systems for transporting intermediate products to separate reforming facilities.

[0220] Known systems often produce a mixture of heavy oils and tars that either require complex treatment or are combusted directly, leading to incomplete utilization of their energy potential. The accessibility of the cracking unit 80 for reforming or cracking allows the plant to extract more energy from the hydrocarbons produced during pyrolysis or thermolysis by breaking them down into lighter, more combustible gases. This process increases the overall energy efficiency of the plant, leading to higher yields of syngas, which can be used for power generation or chemical synthesis, improving the economic viability of the system.

[0221] By allowing the reforming or cracking of heavier hydrocarbons on-site, the cracking unit 80 minimizes the generation of unwanted by-products such as tar, which are problematic in known systems. In conventional setups, heavier tars and oils may accumulate, requiring separate disposal or complex additional treatment. The integrated cracking approach reduces the volume of waste by converting a larger portion of these heavier hydrocarbons into valuable products, thereby enhancing the sustainability of the waste-to-energy process.

[0222] The ability to use the cracking unit 80 for reforming adds an extra layer of operational flexibility. The plant can adjust the reactor and cracking unit parameters depending on the feedstock composition and desired outputs, allowing it to switch between producing light hydrocarbons, syngas, or hydrogen-rich gases. This versatility is particularly inventive compared to more rigid systems, as it allows the plant to adapt to changing market demands for different products, such as fuel gases or industrial feedstocks, without requiring significant retrofitting or additional infrastructure.

[0223] The cracking unit 80 being accessible for reforming and other post-processing techniques offers a highly inventive improvement over known systems by integrating further chemical processing into the main waste conversion cycle. This not only boosts energy efficiency and product yield but also simplifies operations, reduces waste, and enhances the economic and environmental benefits of the system. Other postprocessing techniques include catalytic reforming, which enhances the hydrogen and light hydrocarbon yields by using catalysts to break down heavier hydrocarbons, and methanation, where gases like carbon monoxide and hydrogen are converted into methane for use as synthetic natural gas (SNG). Additionally, Fischer-Tropschsynthesis can be used to convert syngas into liquid fuels such as diesel or synthetic oils.

[0224] The cracking unit 80 being accessible for catalytic reforming offers significant advantages and inventive improvements over traditional systems by allowing heavier hydrocarbons to be efficiently converted into lighter, more valuable products like hydrogen and methane directly within the plant. Catalytic reforming, using specialized catalysts, enhances the breakdown of heavier fractions into hydrogen-rich syngas and other light hydrocarbons, enabling the plant to optimize its output for energy production or industrial uses. Unlike known systems that often require separate facilities for reforming, integrating catalytic reforming into the cracking unit 80 streamlines operations, increases energy recovery, and boosts hydrogen production without the need for additional external processing.

[0225] The accessibility of the cracking unit 80 for catalytic reforming also maximizes process efficiency by converting energy-dense hydrocarbons into high-quality syngas while minimizing waste products such as tars or heavy oils. This integrated approach ensures more complete utilization of feedstock and enhances the plant's flexibility in adjusting outputs based on demand, such as producing hydrogen for fuel cells or methane for synthetic natural gas. In contrast to traditional systems, which are limited in handling heavier hydrocarbons, the inventive use of catalytic reforming within the cracking unit significantly boosts the overall economic and environmental performance of the waste-to-energy process.

[0226] A cracker unit 80 with a double wall configuration features an inner wall and an outer wall, creating an intermediate volume between them. This design is tailored to handle the specific operating pressures and temperatures encountered during the cracking process. The volume between the walls is filled with at least one gas that is not hydrogen or oxygen, such as an inert gas, nitrogen, or carbon dioxide. This configuration is inventive and beneficial as it significantly improves the safety and durability of the cracker unit. The non-reactive gas in the volume serves as a protective barrier, minimizing the risk of hazardous reactions and providing additional thermal insulation. The double wall design also incorporates at least one sensor for detecting gas leakage, which is connected to a control and safety system. This setup allows for continuous monitoring and rapid intervention in case of any leaks, ensuring the crackerunit operates safely and efficiently. Additionally, maintaining the volume at an overpressure relative to the process pressure inside the inner wall creates tension in the inner wall, enhancing its structural integrity and extending the cracker unit's 80 operational life.

[0227] The light oil recycle line 81 recycles light oils back into the reactor or other processing units for further refinement or cracking. It allows for better utilization of the light oil fraction, ensuring that no valuable hydrocarbons are wasted. The light oil recycle line 81 helps improve the overall efficiency of the plant by recirculating light oil back into the process, allowing for more complete conversion into useful products.

[0228] The exhaust line 82 carries exhaust gases, typically after they have been processed or treated, to the final emission control units or flue systems. These gases are often the by-products of the energy generation processes, such as from gas turbines or boilers. The exhaust line 82 ensures that emissions are safely and efficiently handled, leading to proper treatment or release, typically after passing through pollution control units to meet environmental standards.

[0229] The exhaust gas return line 83 recycles a portion of the exhaust gases back into the system, often for further energy recovery or to enhance combustion efficiency by reintroducing gases into the process. In some systems, exhaust gas recirculation EGR is used to control combustion temperatures and reduce emissions, particularly nitrogen oxides NOx. The exhaust gas return line 83 enhances the plant’s overall efficiency by allowing residual energy in the exhaust gases to be recaptured and used in subsequent processes, reducing waste and lowering emissions. By using exhaust gases in combustion or other thermal processes, the plant can improve energy efficiency and reduce the need for additional external fuel sources.

[0230] Char handling unit 90 is configured to manage the solid by-products, such as char, that are left over after the pyrolysis or thermolysis process. The char can be collected, stored, or transported for further use, such as in agricultural applications biochar or as a carbon-rich fuel source. The char handling unit 90 ensures that the solid residues from the reactor are efficiently managed, either for recycling into useful products or for safe disposal. Proper handling of char prevents bottlenecks in the reactor, facilitates efficient waste-to-energy conversion, and allows for the full utilization of the by-products.

[0231] The char line 91 is used to transport the char produced during pyrolysis or thermolysis from the reactor or char handling unit to storage or further processing. Char is often valuable as a fuel source, a soil amendment, or as a material for industrial applications. The char line 91 plays a beneficial role in moving the solid residues efficiently out of the reactor and ensuring that these by-products can be collected or further processed without interfering with the plant’s continuous operation.

[0232] The ash line 92 transports ash or other solid, non-combustible residues that result from the pyrolysis or thermolysis process. Ash is a by-product that may require disposal or, in some cases, can be used in construction materials or other industrial applications. The ash line 92 ensures the efficient removal and transport of ash, preventing it from accumulating in the reactor and ensuring that it can be safely handled or repurposed. Managing the ash is preferable for maintaining the reactor’s efficiency and cleanliness.

[0233] Uncontaminated char line 93 is configured for transporting char that has been verified to be free of volatile organic compounds (VOCs), e.g. after undergoing a multistage separation process. For example, the char produced in the pyrolysis or thermolysis reactor 40 is subjected to a heating unit where it is exposed to controlled temperatures designed to volatilize and remove any remaining VOCs. This thermal post-treatment ensures that VOCs are either broken down or released from the char, leaving behind purified solid carbon. Following this thermal process, the char is optionally passed through a mechanical separator that employs techniques such as density-based separation or air classification to segregate any remaining contaminated particles from the clean, VOC-free char. The uncontaminated char is then transported via uncontaminated char line 93 to its next stage of handling or utilization. This VOC- free char can be safely used in various applications, such as soil amendments, industrial processes, or as a carbon-rich fuel, without posing environmental or health risks. The primary benefit of this separation process is the improved quality and usability of the final char product, enhancing the marketability of the clean char and ensuring regulatory compliance.

[0234] Contaminated char line 94 is responsible for transporting char that has been identified as containing VOCs after the initial separation process. This char is directed to further processing to remove the VOCs and ensure it meets safety andenvironmental standards. The detection of VOC contamination in char is typically achieved using advanced analytical techniques such as gas chromatography (GC), mass spectrometry (MS), infrared spectroscopy, or thermal desorption analysis. These methods involve sampling the char and analyzing the emissions of VOCs when the material is heated, or using chemical sensors to detect specific organic compounds. Once identified, the contaminated char is transported via contaminated char line 94 to undergo additional thermal treatment or solvent-based desorption processes to remove the VOCs. This further treatment ensures that the char can be safely utilized or disposed of, preventing VOC emissions during handling or use. By isolating and treating contaminated char, the plant enhances the overall safety and regulatory compliance of the waste processing system, reducing potential hazards associated with VOC-laden materials and improving the quality of the final char product.

[0235] The supply line(s) 95 supply materials, fuels, or gases to various parts of the system to support the operation of the pyrolysis or thermolysis process. This could include the supply of startup gases, supplementary fuels, or any additional materials required for optimizing the reactor’s performance. The supply line(s) 95 are integral to ensuring that the necessary inputs are provided consistently and reliably throughout the system. These lines are beneficial for maintaining the continuous operation of the plant and for adjusting operational parameters as needed. Similar to supply line(s) 95, supply line(s) 96 and 97 are additional supply lines that deliver necessary materials, gases, or resources to other parts of the plant. The distinction between supply line(s) 95, 96 and 97 refers to different sources or types of supply, such as primary and secondary inputs or different categories of materials or gases used in the plant. The supply line(s) 96 and 97 support the plant’s overall operational stability by ensuring that the required resources are consistently fed into the appropriate sections of the system, helping to balance processes and optimize performance. The necessary resources for optimal efficiency and operation are preferably available at all stages of the process, providing flexibility and adaptability to adjust plant operations based on feedstock or output requirements. For example, water for scrubbing, and aqueous solutions of scrubbing chemicals are supplied through supply lines 95-97 to second gas cleaning unit 75.

[0236] Figure 2 is an illustration of one embodiment of the gas production and treatment unit 20 comprising the humidity controlling unit 11 . Figure 3A and Figure 3Billustrate embodiments of a reactor 40, optionally comprised within the treatment unit 20.

[0237] The skilled person would understand that not all aspects of Figure 2, Figure 3A or 3B are required, and each component / unit may be used individually or together with any other component of the Figures described herein for methods, systems, or processes related to transforming source material, e.g. MSW or plant matter, into a desired product, e.g. protein, fuel, hydrocarbons, or other sorted, separated, or liberated product.

[0238] Waste is introduced into the humidity controlling unit 11 , here illustrated as a drying unit, through waste line 10 as described above. Heat for drying the waste in the humidity controlling unit 11 may supplied to a heating chamber 11 b, as steam through line 33a, or as hot flue gas in flue gas line 48 from sources that will be further explained below. After being cooled, or while heating and drying the waste, the cooled exhaust is released through an exhaust gas release line 48a. For example, exhaust is cooled using cooling unit 610 and / or any cooling process described below.

[0239] From the humidity controlling unit 11 , the waste is introduced into a primary reactor 40 via a humidified waste line 13, where the primary reactor 40 is optionally a standard pyrolysis or thermolysis reactor or the reactor of Figures 3A and 3B. The skilled person will understand that the illustrated reactor 40 may be one reactor or two or more reactors arranged in series or parallel. The same applies to all elements described below. Additionally, any reference to a pyrolysis reactor or process should be understood to encompass a thermolysis reactor or process, e.g. with modifications to apply the functionality associated with relevant disclosure.

[0240] Preferably, the waste is introduced towards the bottom of the reactor, e.g. as shown by waste line 13. However, this is not essential, as is shown by waste line 13a. Inputting waste towards the bottom of the reactor 40, where the temperature is highest, offers several technical benefits that improve the efficiency and effectiveness of the pyrolysis or thermolysis process. This method addresses a number of challenges inherent in traditional waste input systems and provides an inventive solution for maximizing thermal conversion, minimizing unreacted material, and ensuring a consistent quality of output gases and solids.

[0241] For example, introducing waste directly into the hottest part of the reactor ensures that the material is immediately exposed to the highest available temperature. This accelerates the breakdown of complex organic molecules and composite materials, leading to faster pyrolysis or thermolysis reactions. Since the bottom of the reactor operates at peak temperature (preferably around 1000°C), materials decompose more rapidly compared to entering through the cooler upper zones, resulting in higher throughput and processing efficiency. By introducing waste at the hottest point, the risk of incomplete thermal decomposition is significantly reduced. In traditional reactors, waste is introduced at the top or in cooler regions, which can lead to incomplete pyrolysis, with some material passing through without fully decomposing. The immediate exposure to high temperatures ensures that even heat-resistant materials like plastics, resins, and heavy hydrocarbons are fully converted into syngas and solid residues (char or ash).

[0242] The intense heat at the bottom of the reactor promotes not only pyrolysis but also secondary reactions like cracking, steam reforming, and gasification. These reactions improve the composition of the syngas, increasing the yield of valuable gases such as hydrogen, methane, carbon monoxide, and other light hydrocarbons. By immediately subjecting the waste to high temperatures, unwanted heavier hydrocarbons are cracked into lighter, more valuable fractions, enhancing the quality of the output gas. Introducing waste at lower, cooler points in the reactor can result in material sticking to the reactor walls or forming coke deposits and slag, which negatively impact reactor performance and require frequent maintenance. By inputting waste directly into the hottest zone, where thermal decomposition is instantaneous, the risk of material buildup is minimized. The high heat reduces the viscosity of molten residues, preventing them from adhering to reactor surfaces, thus ensuring smoother operation and reducing downtime for cleaning and maintenance.

[0243] Furthermore, by placing the input at the bottom, the reactor uses thermal stratification to its advantage. As gases rise, they pass through progressively cooler zones, allowing for efficient thermal transfer from the hot bottom to the cooler top regions. This controlled temperature gradient ensures that the volatile components in the gas are properly processed before extraction, optimizing both heat usage and gas quality.

[0244] This approach is especially beneficial as, while it departs from traditional reactor designs where waste is often introduced at the top or middle of the reactor, e.g. where temperatures are lower, conventional designs can lead to uneven heating, incomplete decomposition, and inefficient material flow, particularly for high-moisture or high- density wastes like composites or biomass. By altering the entry point of the waste and introducing it at the hottest zone, this system addresses the fundamental challenge of ensuring uniform and complete thermal decomposition across a wide range of feedstocks. For example, a problem this innovation solves is incomplete decomposition and poor gas quality often seen in conventional pyrolysis systems, particularly when dealing with mixed or complex wastes. In traditional setups, materials can exit the reactor partially processed, resulting in lower-quality syngas, more unconverted residues, and the need for reprocessing. By inputting waste into the hottest part of the reactor, the system ensures that all material is fully exposed to high temperatures immediately, leading to more efficient conversion and better-quality output gases and solids.

[0245] Waste from the humidity control unit 11 is introduced into the primary reactor 40 through the waste line 13 into a mixing chamber 45 at least partially surrounded or by a heating jacket 46 heated by a heating means, e.g. combustion of heating gas introduced through a heating gas line 41 and air that is introduced through an airline 47. For example, mixing chamber 45 is wholly or partially comprised within a heating jacket 46, heated using recycled heat generated from a reactor 40 or otherwise insulating the mixing chamber 45. Exhaust gas from the combustion is withdrawn through an exhaust release line 48.

[0246] A screw conveyor 50, operated by means of a motor 49, is arranged in the mixing chamber 45, the screw conveyor extending 50 into a high temperature chamber 51 . Optional mixing arms 53 may be connected to the axis of the screw conveyor, for mixing of the incoming waste with waste already partly processed in the mixing chamber.

[0247] The waste mixture in the mixing chamber is transported into the high temperature chamber 51 by means of the screw conveyor 50. In the high temperature chamber 51 the waste is further heated by a heating means via heating jacket 54, e.g. heated using heat recycling, combustion of heating gas, insulation, or alternativeheating means. Heating jacket 54 at least partially surrounds the high temperature chamber 51 , either instead of or in addition to heating jacket 46. For example, heating gas is introduced into the heating jacket 54 through a gas line 41 b, and air for the combustion is introduced through an airline 47b. A gas line 39 is provided to add natural gas into line 41 during start-up of the plant.

[0248] The total waste in the mixing chamber 45 and high temperature chamber 51 is thus heated in absence of oxygen to effect thermolysis and pyrolysis therein. The waste in the mixing chamber is heated both by the heating jacket 46 and pyrolysis and thermolysis gases generated in the mixing chamber and the high temperature chamber. At least a part of the gases generated through pyrolysis and thermolysis in the mixing chamber and high temperature chamber is withdrawn through a pyrolysis gas line 52 connected to the mixing chamber. The temperature in the mixing chamber is typically from 500 to 700 °C, whereas the temperature in the high temperature chamber is higher due to the additional heating, such as typically about 1000 °C. The pressure in the reactor 40 is typically about ambient pressure or slightly higher.

[0249] Due to the thermolysis and pyrolysis in the reactor 40, a substantial part of the original mass of the waste is converted to gas by well-known thermolysis or pyrolysis reactions. Small and large organic molecules such as synthetic or natural polymers or macromolecules, such as carbohydrates, fats, proteins, plastics etc., are thermally cracked, i.e. , molecules are split via different reactions to form smaller molecules. The humidity present in the waste, and / or water / steam added into the waste during introduction into the mixing chamber results in some steam cracking reactions to happen in the reactor as well as heat cracking. Due to the presence of water in the reactor 40, several reactions take place therein. First of all, the temperature causes thermolysis or pyrolysis of the hydrocarbon material introduced into the reactor, to give a solid char rest and gases, primarily hydrogen, methane, minor amount of lower hydrocarbons and tars, or higher hydrocarbons that will condensate at lower temperatures. Additionally, the water present in the reaction mixture in the reactor 50, will react with carbon according to the reactions:(1 ) C + H2O %carbon monoxide + H2 (gasification reaction)(2) CO + H2O %carbon dioxide + H2 (water gas shift reaction)

[0250] As mentioned above, a part of the generated gas may be withdrawn through line 52, as will be described in further detail below. The remaining mass of solid waste is withdrawn from the bottom part of the high temperature chamber 51 through a high temperature chamber outlet 55 and are directly introduced into a series of secondary reactors 60, here illustrated by one reactor 60.

[0251] Optionally, as shown in Figure 3B, reactor 40 comprises a plurality of reactors 40 operating in a series. For example, remaining mass of solid waste withdrawn through the high temperature chamber outlet 55 is fed into waste line 13 to be reprocessed. Additionally, or alternatively, a plurality of reactors 40 operate in parallel. Further optionally, any of heating jackets 46, 54, 59, 79 are shared or otherwise interconnected across a plurality of reactors 40.

[0252] The gas withdrawn trough line 52 is introduced into the first secondary reactor 60, to participate in the further breakdown of hydrocarbons in the secondary reactor 60. The secondary reactor(s) 60 have a common design being tubular reactor(s), provided with a screw conveyor both for mixing the solid material and the gas, and for carrying the remaining solid material through the reactor(s). Additionally, the reactors are provided a heating jacket 59 heated by combustion as for the primary reactor 40, for further pyrolysis and thermolysis of the remaining solid waste, and to ascertain that generated gas is released from the solid waste therein. The temperature in the secondary reactors is upheld at about the same temperature as in the high temperature chamber. Dependent on the specific plant, two or more secondary reactors 60 may be serially connected to provide maximum thermolysis and pyrolysis of the waste. The solid rest from the last secondary reactor 60 is withdrawn through a solids line 69 and is introduced into a conversion unit 70.

[0253] Gases generated and / or released from the solid carbonized waste, are withdrawn from the secondary reactors 60 through a raw gas withdrawal line 61 and are introduced into a first gas cleaning unit 62. The first gas cleaning unit 62 is provided for removal of tars, oils, and dust particles from the raw gas stream. The first cleaning unit 62 comprises a series of scrubbers where the gas is washed in a buffered liquid medium. Gas cleaning is detailed further below. The temperature of the raw gas is reduced in stages, from one scrubber to the next, to separate the condensate, andsolid particles from the gas. The temperature, pH and composition of the scrubbing media are controlled in a conventional way.

[0254] Wastewater from the scrubbers is removed from the first gas cleaning unit 62 through a wastewater line 63 and is introduced into the above-mentioned wastewater treatment unit 5.

[0255] Scrubbed raw gas, mainly comprising carbon monoxide, carbon dioxide and hydrocarbons having a boiling range below 170 °C, is removed from the first gas cleaning unit 62 via a scrubbed raw gas line 64 and introduced into a gas separation unit 65 comprising two membrane based separation units, one membrane unit to give a hydrogen enriched gas fraction that is withdrawn through a hydrogen rich gas line 66, and one membrane unit to give a hydrocarbon rich fraction that is withdrawn through a heat gas line 41 , to be used for firing for heat purposes as described above and a third raw gas fraction comprising a mixture of gases, mainly lower hydrocarbons, carbon monoxide, carbon dioxide, and some hydrogen, that is withdrawn through a gas line 67. The gas in line 67 is introduced into the above-mentioned conversion unit 70.

[0256] The solids introduced into the conversion unit 70 in line 69, are heated by combustion of heat gas in a heating jacket 79 and is reacted with the gas introduced through line 67, and steam introduced through a steam line 71 to further break down hydrocarbons in the gas, and for gasification of carbon in the solids, according to the “gasification” reaction:H2O + C = CO + H2 to add additional synthesis gas to the generated gas flow. Dependent on the amount of steam introduced through the steam line 71 , the generated carbon monoxide may be further converted to carbon dioxide and hydrogen, by the reaction:CO + H2O = CO + H2.

[0257] The conversion in the conversion unit 70 does, however, result in a higher concentration of hydrogen in the product gas and with steam reforming of CH in gas line 67, at the cost of gas used for heating the conversion unit 70.

[0258] Gas generated in the conversion unit 70 is withdrawn through a converted gas line 72, and is introduced into a second gas cleaning unit 75, were the gas is combinedwith the gas in the above described hydrogen rich gas line 66, and is scrubbed in a series of scrubbers, where the calcium hydroxide or sulphuric acid, and / or other chemicals, such as Ca(OH)2, and sulphuric acid, used for removal of unwanted elements in the gas, may be included in the scrubbing solution. Water for scrubbing, and aqueous solutions of scrubbing chemicals are added through supply lines 95, 96 and 97, respectively. Used scrubbing solution is removed through a used water line 76 and introduced into the wastewater unit 5.

[0259] The solid waste from the converter 70 is withdrawn through a solids waste line 23 and is optionally introduced into a char handling unit 90, where the solid material is separated into char, that is withdrawn through a char line 91 , and a mixture of char and ash that is withdrawn through an ash line 92. The char and ash are exported for the plant, sold / deposed, or further treated according to the disclosure further below.

[0260] Heating gas for heating jackets 46, 54, 59, 79 is introduced through lines 41 as described above. During normal operation the heating gas is withdrawn from the gas separation unit 65 as described above. Startup heating gas for starting up the plant, or supplementary gas in the case that the heating gas withdrawn from the gas separation has to be supplemented to give the required heating, may be introduced through a startup gas line 39. Oxidant, such as air, or other gas including oxygen, to obtain combustion and generation of heat in the heating jackets by combusting the heating gas, is added through the air line 47.

[0261] A first light oil fraction having a boiling range from about 170-350 °C at atmospheric pressure is withdrawn from the first gas cleaning unit 62 via a first light oil line 68 and introduced into a light oil recycle line 81 for introduction of light oils into the primary reactor 40. A second light oils fraction having a boiling range from about 100 - 200 °C at atmospheric pressure is withdrawn from the second gas cleaning unit 75 through a second light oil line 77 and is also introduced into the light oils recycle line 81 . The light oil fractions that are recycled into the primary reactor participates in the reactions in the primary reactor 40 and are further broken down as described above.

[0262] Raw fuel gas is withdrawn through the synthesis gas line 22 and may be introduced into the carbon dioxide separation unit 24 for removal of a substantial part of the carbon dioxide from the gas as described above, as described above.

[0263] Figure 4 illustrates a system architecture diagram for a waste sorting system.As noted above, not all units shown are required for a waste sorting system.

[0264] One waste sorting system comprising any of units 100-123 begins with the autoclave system 3, which sterilizes and reduces the volume of incoming waste. The autoclave 3 uses steam to treat the material, ensuring that pathogens and harmful substances are neutralized while preparing the waste for further sorting. Once sterilized, the waste moves through a sequence of mechanical and magnetic sorting units designed to separate different fractions based on material properties. The process begins with the magnetic separator 100, which extracts ferrous materials like iron and steel. After this, the waste is passed through various systems such as wind sifting separators 108, 113 and non-ferrous separators 115, which sort lighter materials like plastics, fibers, and non-ferrous metals. The system also includes advanced detection technologies such as near-infrared detection separators 116, which identify and separate specific polymers and other materials based on their molecular signatures. The goal is to divide the waste into recyclable fractions such as metals, plastics, and organic matter, as well as high-calorific value end products suitable for energy production.

[0265] According to one embodiment, after leaving the first magnetic separator 100, the waste is further sorted in a first screen 102, such as a finger screen, dimensioned to remove large items, such as items having a size >200 mm and stringy materials like wrapping foils, textile and rope, by allowing particle of <200 mm through the screen. The >200 mm fraction is collected in a large high calorific value fraction 103. The skilled person will understand that what is regarded as a large item in such a plant is dependent on the actual plant and that the given limit of 200 mm may differ from plant to plant. If deemed necessary, a sorting unit comprising a near infrared detection system may be arranged to remove any nylon and / or PVC from said fraction.

[0266] The <200 mm material passing through the first screen 102, is thereafter screened in a second screen 104, such as a Starscreen®, to give a <12 mm fraction, and a +12 mm fraction. The <12 mm fraction is introduced into a magnetic drum over belt separator 106, to separate an iron containing waste fraction that is combined with other iron containing fractions as will be described below. The non-ferrous fraction not being removed in the separator 106, is introduced into a non-ferrous separator 106,where the components are separated based on their density to give a non-ferrous heavy fraction that is combined with other non-ferrous heavy fractions as described in more details below. The lighter material is collected in a flock / fibre fraction 107.

[0267] The +12 mm fraction is introduced into a first wind sifting separator 108, where most of the less dense material is separated from the denser material by means of blowing air and gravity. Light materials, mostly comprising plastics in addition to some additional light materials are led into a light materials fraction 109. The light material fraction may be further sorted to separate different plastic and / or to separate plastic from non-plastic material.

[0268] The dense fraction from the first wind sifting separator 108 is introduced into a screening unit 110 separating material according to size, i.e. <50 mm and >50 mm. The <50 mm material is introduced into a magnetic drum over belt separator 111 , to separate a ferrous fraction that is handled as described below, and a non-ferrous fraction that is introduced into a non-ferrous separator, separating the dense material, typically metals, from less denser materials. The dense material is collected as described below, whereas the less dense material is introducing into a near infrared detection separator section 116 as will be described below.

[0269] The >50 mm material from the screening unit 110, is introduced into a second wind sifting separator 113. The less dense material from the second wind sifting separator 113 is combined with the less dense material from the first wind sifting separator 108, as described above. The dense material from the second wind sifting separator 113 is introduced into a magnetic drum over belt separator 114, to give a ferrous fraction that is combined with the ferrous material from the separators 105 and 111 as described above and introduced into a ferrous fraction 117.

[0270] The non-ferrous fraction from separator 114 is introduced into a non-ferrous separator 115, corresponding to separators 106 and 112, to give a dense fraction that is combined with the corresponding fractions from separators 106 and 112 and collected as a non-ferrous fraction 123.

[0271] The near infrared separator section 116 typically comprises several corresponding separators, optionally with a ferrous separator for a final separation of ferrous materials from the remaining waste. The infrared separators, e.g., four separators, are all corresponding separators that are adjusted for separation ofdifferent types of plastic materials. The skilled person understands how to adjust the detectors for separation of the different plastic types, based on their chemical composition that is detectable using near infrared detectors.

[0272] The near infrared separator section 116 may, if it comprises four infrared separators as indicated below, will be able to separate the introduced material into fractions as PCV in a fraction 118, nylon in a fraction 119, PET into a fraction 120, mixed plastics into a fraction 121 , a high calorific end product fraction 122, and optionally an additionally not shown metal fraction.

[0273] Recyclable materials such as the ferrous fraction 101 , 117, the non-ferrous fraction 123, the PVC fraction 118 and nylon fraction 119, are exported from the plant. The PVC fraction 118 may, however, be used internally for fuel gas generation, provided that the PVC amounts to less than about 1 % by weight of the total sorted MSW added. Even other fractions, such as the PET fraction 120 may be exported if all PET is not needed for the gas production.

[0274] Each unit in the sorting system has a specific operation that maximizes material recovery and efficiency. The magnetic separator 100, for example, uses a magnetic drum to extract ferrous metals from the waste stream, which is essential for both recycling and preventing metal contamination in downstream processes. The wind sifting separators 108, 113 use air flows to separate lightweight materials, such as plastic films and fibers, from heavier fractions like glass and metals. These units are beneficial because they allow for the effective sorting of waste without requiring complex manual intervention. Wind sifting separators 108, 113 can also be used instead of or alongside / in a process chain with comminutor 310 or cyclonic particle separator 200, such as for separating liberated protein. The non-ferrous separator 115 operates by inducing a magnetic field that repels non-ferrous metals, such as aluminium, ensuring these valuable materials are recovered for recycling. Alternative implementations for each unit may include different sorting techniques like eddy current separators for non-ferrous metals or optical sorting systems for plastics and other materials, depending on the specific requirements of the waste stream. Additionally, manual sorting could be used as a fallback option for materials that are not easily handled by automated systems.

[0275] The magnetic separator 100 is a unit designed to extract ferrous materials, such as iron and steel, from the waste stream using magnetic fields. It typically consists of a magnetic drum or over-belt separator that generates a strong magnetic field. As the waste material passes over or near the magnetic separator, the magnetic field attracts the ferrous materials, pulling them out of the main waste stream and separating them from non-magnetic materials. These ferrous metals are then directed to a collection area for recycling or further processing, while the non-ferrous materials continue along the sorting line for additional separation or treatment.

[0276] The benefit of the magnetic separator lies in its ability to efficiently and automatically remove ferrous metals from mixed waste streams, significantly reducing the need for manual sorting. This not only improves the speed and efficiency of the waste sorting process but also ensures that metals are recovered for recycling, which adds economic value and reduces environmental impact. Additionally, separating ferrous metals early in the process prevents them from contaminating other fractions of the waste, such as plastics or organics, which might degrade their quality. The magnetic separator 100 is a preferably component in many recycling and waste management systems due to its simplicity, reliability, and high throughput capacity. In alternative implementations, different configurations such as magnetic pulleys or cross-belt separators can be used depending on the specific requirements of the waste stream and processing facility.

[0277] The first iron fraction 101 is a designated output from the magnetic separator 100, and is optional any additional or alternative output from the magnetic separator 100. After the magnetic separator attracts and removes ferrous materials from the waste stream, these materials are directed into the first iron fraction 101 collection area. This fraction typically contains a mix of ferrous metals such as iron and steel, which have been separated based on their magnetic properties. The first iron fraction 101 is beneficial because it isolates valuable recyclable metals early in the waste sorting process, allowing these materials to be efficiently directed toward recycling facilities where they can be processed and reused. By isolating ferrous materials, the system improves the purity of other waste fractions (e.g., plastics, non-ferrous metals), preventing contamination and enabling further sorting processes to operate more efficiently. In some implementations, the first iron fraction 101 optionally undergoes additional refining steps, such as passing through a secondary magnetic separator ormetal refining process, to ensure that the collected metals are free from impurities and can be directly recycled or further processed into steel or other metal products.

[0278] First screen 102 is a beneficial component in the waste sorting system that functions to separate materials based on size. It typically consists of a mesh or grid through which smaller particles can pass, while larger items are retained on the surface. The screen size, or mesh aperture, is specifically selected based on the type of materials being processed and the desired separation criteria. As waste material passes over the screen, finer materials such as dust, small organic particles, or small pieces of plastic fall through the mesh and are directed into a separate collection or processing stream, while larger materials continue along the sorting line for further treatment. A benefit of the first screen 102 lies in its ability to quickly and efficiently sort waste into different size fractions, which is essential for optimizing subsequent sorting processes. By filtering out smaller particles early on, the system reduces the overall volume of material that needs to be processed by downstream units, improving efficiency and throughput. Additionally, separating smaller fractions helps prevent clogging and wear in more sensitive equipment, such as air separators or conveyors. This unit also ensures that large, potentially valuable materials like metals or bulky plastics remain in the sorting system for further separation and recycling. Alternative implementations of this system may include vibrating screens or trommel screens, depending on the specific materials and process requirements.

[0279] Calorific value faction 103 is a specific category of sorted material that is rich in organic and carbonaceous content and has a high energy potential. This fraction typically includes materials such as plastics, paper, wood, and other combustible waste that, once separated from non-combustible components, can be directed toward energy recovery processes like incineration, pyrolysis, or gasification. The sorting process leading to this fraction may involve several steps, including screening, densitybased separation, and wind sifting, all designed to isolate materials with a high calorific value from inert or non-energy-yielding materials. The benefit of the calorific value fraction 103 lies in its ability to harness the energy contained within waste materials, which can be converted into electricity, heat, or syngas through various waste-to- energy technologies. By efficiently isolating this fraction, the system ensures that valuable energy sources are not lost in landfills, thus reducing waste volume and contributing to sustainable energy production. Moreover, the recovery of this fractionreduces the need for fossil fuels in energy generation, helping to lower greenhouse gas emissions. This approach also aligns with modem waste management practices aimed at diverting waste from landfills and maximizing resource recovery through energy production. Optional enhancements to this system could include more advanced sorting techniques, such as near-infrared detection, to ensure that only high- energy materials are included in this fraction.

[0280] The second screen 104 operates similarly to the first screen 102, but is used to further refine the sorting process by separating materials based on a different size range or specific criteria. The second screen 104 typically follows after initial separation, acting on the materials that have already passed through or been retained by the first screen. It is designed with a mesh or grid aperture size that differs from the first screen 102, either smaller or larger, depending on the desired output fractions. As waste materials pass over the second screen, particles that meet the size requirements are sifted through and collected for further processing or disposal, while larger or nonconforming materials continue along the sorting line. The second screen 104 provides an additional layer of precision in the sorting process, enabling the system to better separate materials into fractions that can be more efficiently handled by subsequent units. This step is particularly useful for capturing smaller fractions that may not have been separated by the first screen 102, ensuring that the system operates at optimal efficiency by reducing contamination and improving the quality of sorted materials. The second screen 104 also allows for a more thorough division of materials based on specific characteristics, such as separating fine organic matter for composting or energy recovery, while larger, more valuable recyclables like metals and plastics are retained for further refinement. Depending on the plant's needs, alternative implementations of this unit could involve trommel screens or vibrating screens for enhanced sorting based on particle shape and size distribution.

[0281] Separator 105 is a general-purpose unit used in the sorting system to divide waste materials based on their physical properties, such as density, size, weight, or composition. This unit could be a mechanical separator, such as an air classifier or gravity-based separator, depending on the specific waste stream being processed. The separator 105 works by applying a physical force — such as air flow, vibration, or centrifugal force — that acts differently on various materials. For example, lightweight materials such as plastics or paper may be lifted or blown away by air currents, whileheavier materials like glass, metals, or dense organics remain in place or follow a different path. A benefit of the separator 105 lies in its ability to efficiently and accurately divide the waste stream into distinct categories for further processing, recycling, or disposal. By isolating specific types of materials, such as high-value recyclables or energy-rich organic matter, the separator enhances the overall efficiency of the sorting process and reduces the need for manual intervention. Additionally, this unit helps improve the purity of the sorted fractions by minimizing cross-contamination between different materials, which is crucial for maximizing the quality and value of the recycled products. Optional alternative implementations of this separator could include advanced technologies like eddy current separators for nonferrous metals, or optical sorters that use sensors to identify and separate materials based on their chemical composition or colour, depending on the specific waste being handled.

[0282] Magnetic drum over belt separator 106 is configured to extract ferrous metals from the waste stream through a continuous and efficient process. This unit consists of a magnetic drum positioned above a conveyor belt. As the waste material passes along the conveyor, the magnetic field generated by the drum attracts ferrous metals like iron and steel. These metals are lifted out of the waste stream and held against the surface of the drum. As the drum rotates, the ferrous materials are carried over the top of the drum and deposited into a separate collection area, while non-magnetic materials continue along the conveyor belt. The magnetic drum over belt separator 106 is highly beneficial because it offers continuous, automated removal of ferrous materials from mixed waste streams without the need for manual sorting. Its design allows for high throughput, making it particularly effective in large-scale waste processing facilities. By removing ferrous metals early in the process, this unit helps prevent damage or interference with downstream sorting units, improving the overall efficiency of the plant. Additionally, recovering ferrous metals for recycling adds economic value and reduces the volume of waste sent to landfills. Optional alternatives for this unit could include using different strengths of magnetic fields or implementing multiple drums in series to enhance the separation of varying sizes and types of ferrous materials.

[0283] Flock / fibre fraction 107 is a designated output from the sorting process that isolates lightweight materials such as fibres, textiles, and flock (fine particles of materiallike dust or lint). These materials are typically separated from the heavier components of the waste stream through units like wind sifting separators (108, 113), which use air currents to lift and segregate lightweight particles. The flock / fibre fraction (107) consists of materials that are non-recyclable but often have a high surface-area-to- mass ratio, making them ideal candidates for further processing, such as energy recovery through combustion or conversion to alternative fuel sources like refuse- derived fuel (RDF). Beneficially, the flock / fibre fraction 107 is used in optimizing the waste-to-energy process. By isolating these lightweight, high-calorific materials, the system ensures that this fraction is efficiently utilized for energy production while reducing the amount of material sent to landfills. Additionally, separating out this fraction helps prevent clogging and contamination in subsequent sorting processes, which are typically designed to handle denser, more valuable recyclables like metals or plastics. Optional implementations of this system could involve enhanced air separation technologies, such as variable-speed fans or cyclonic separators, to further refine the separation process and ensure that the flock / fibre materials are optimally sorted.

[0284] First wind sifting separator 108 is a sorting unit that uses air flow to separate materials based on their weight and aerodynamic properties. As waste materials enter the wind sifting separator, a controlled stream of air is directed through the waste, lifting lighter materials such as plastics, paper, and fibres while heavier materials, like metals and glass, remain unaffected and continue through the system. The lighter materials are carried into a separate collection area, while the heavier fractions are directed for further sorting or processing. The first wind sifting separator 108 is beneficial because it efficiently separates lightweight materials from the waste stream without requiring manual sorting, significantly improving the speed and accuracy of the overall process. This unit is particularly effective for recovering high-volume, low-density materials like plastics and fibres, which can be sent for recycling or used in waste-to-energy applications. By separating these materials early in the sorting process, the system ensures that valuable recyclables are captured while minimizing contamination of heavier materials, leading to higher purity in both streams. Optional alternative implementations could involve adjusting the strength and direction of the air flow or integrating additional wind sifting stages to further refine the separation of different lightweight materials, enhancing the plant’s overall efficiency and output quality.

[0285] Light materials fraction 109 is a designated collection of materials separated from the waste stream that are characterized by their low density and weight. These materials, such as plastics, paper, films, and certain fibres, are typically isolated using systems like the wind sifting separators 108, 113 or cyclonic particle separators 200, which use air flow or centrifugal force to lift and segregate lightweight items from heavier fractions like metals or glass. The light materials fraction is directed to a specific collection area for further processing, which may include recycling, energy recovery, or preparation for alternative fuel production. A benefit of the light materials fraction 109 is its role in reducing landfill waste by recovering valuable, low-density materials that can be repurposed or transformed into energy. By efficiently separating these materials from heavier waste components early in the sorting process, the system ensures that recyclables like plastics and paper are diverted from landfills and redirected toward appropriate recycling or waste-to-energy facilities. This fraction also plays an important part in optimizing the calorific value of materials for processes like pyrolysis or incineration, as many light materials have a high energy potential. Optional variations could include refining this fraction further by adding additional sorting technologies like optical or density-based separators to capture specific types of light materials, such as different grades of plastics or composite materials.

[0286] Screening unit 110 is configured to separate materials based on size. The screening unit typically consists of a mesh or perforated surface through which smaller particles can pass while larger items remain on top for further processing. As waste moves across the screening surface, the smaller, finer materials — such as dirt, small organic matter, or small pieces of plastic — are separated out and directed to a different collection stream, while larger materials continue along the sorting line. The screening unit 110 provides significant benefits by efficiently sorting materials into size-based fractions, optimizing downstream processing. This unit enhances the overall efficiency of the waste management system by ensuring that only appropriately sized materials are directed to more advanced or specialized sorting processes, such as wind sifting or magnetic separation. Additionally, it helps to prevent clogging or damage to more sensitive equipment by removing small particles early in the process. This unit is especially useful in systems handling a variety of waste types, where both large and small materials need to be separated quickly and effectively. Alternative implementations of the screening unit could involve vibrating screens or trommelscreens, which offer greater flexibility in handling different types of waste and allow for finer control over the size of materials being sorted.

[0287] Magnetic drum over belt separator 111 is a specialized system designed to extract ferrous metals from a mixed waste stream. This unit operates by using a conveyor belt that moves waste beneath or around a rotating magnetic drum. The magnetic field generated by the drum attracts ferrous materials, such as iron and steel, pulling them away from non-magnetic materials. As the magnetic drum rotates, the captured metals are carried to a separate discharge point, where they are released into a collection bin or further processing area, while the non-magnetic materials continue on the conveyor for additional sorting. The magnetic drum over belt separator 111 offers several benefits, including continuous, automated separation of ferrous metals, which improves the efficiency of the sorting process by removing metals early and ensuring they are recovered for recycling. This helps reduce contamination in subsequent sorting stages, such as plastic or organic material separation. Recovering metals also adds economic value by diverting recyclable ferrous materials from landfills to metal recycling streams. In terms of alternative implementations, the magnetic drum’s strength can be adjusted based on the specific characteristics of the waste stream, and multiple magnetic drums can be used in series to enhance separation efficiency, especially for smaller ferrous particles or varying waste compositions.

[0288] Separator 112 is configured to distinguish between different materials within a waste stream based on specific physical or chemical properties. This unit typically functions by utilizing technologies such as air classification, gravity separation, or even density-based sorting, depending on the materials being processed. The waste material is introduced into the separator, where forces like air currents, centrifugal forces, or vibrations are applied to divide lighter, less dense materials (such as plastics and fibres) from heavier items (like metals, glass, or dense organic matter). The separated materials are then directed to different collection points or further treatment processes. The separator 112 is beneficial because it adds an additional layer of refinement to the waste sorting process, ensuring that materials are categorized more precisely for recycling, reuse, or disposal. By efficiently segregating materials based on their physical properties, this unit optimizes the overall efficiency of the waste management system, reducing contamination in valuable material fractions and improving the quality of the recycled products. The flexibility of the separator allows itto handle a wide range of materials, making it highly adaptable for various waste streams, from domestic refuse to industrial by-products. Alternative implementations may include using optical or electromagnetic separation methods, depending on the specific waste being handled, to increase precision in material sorting and recovery.

[0289] Second wind sifting separator 113 is an advanced sorting system that uses controlled air currents to further refine the separation of light and heavy materials after an initial sorting stage. In this unit, waste materials are exposed to a directed airflow that lifts and carries lighter fractions such as plastic films, paper, and fibres into one collection area, while denser materials, including metals, glass, and organic waste, fall into another collection stream. The air velocity and direction are carefully calibrated to achieve an efficient and precise separation based on the weight and aerodynamic properties of the materials. The second wind sifting separator 113 enhances the sorting process by providing a more detailed refinement of materials after the initial wind sifting or other sorting operations. It ensures that lightweight recyclables are captured and directed for further recycling or energy recovery, while heavier, non-recyclable fractions are isolated. This additional stage of separation improves the purity of both light and heavy fractions, maximizing the value and usability of the recovered materials. The system is particularly effective for handling mixed waste streams where fine-tuning the separation of materials is necessary. Optional configurations might include adjustable air flow rates or multiple separation stages to handle different material densities or sizes, further optimizing the sorting process for specific waste streams.

[0290] Magnetic drum over belt separator 114 is configured to separate ferrous metals from mixed waste streams using a continuous, automated process. This unit operates by passing the waste material over a conveyor belt that moves underneath or around a rotating magnetic drum. As the waste travels on the belt, the magnetic drum attracts ferrous materials such as iron and steel from the non-magnetic portion of the waste stream. The magnetic force holds the metals against the drum as they are transported to a discharge point, where they are separated and deposited into a collection area. Meanwhile, non-magnetic materials continue along the conveyor for further sorting. The magnetic drum over belt separator 114 is highly beneficial because it efficiently recovers ferrous metals, ensuring that valuable recyclables are extracted early in the process. By removing metals from the waste stream at this stage, the system reducesthe risk of contamination in subsequent separation processes, such as sorting plastics, fibres, or organic materials. This also prevents damage to other processing equipment and maximizes the purity of the recyclable materials. The ability to continuously remove metals without manual intervention increases the overall throughput of the system, making it ideal for high-capacity waste processing facilities. Alternative implementations could involve stronger or variable magnetic fields to capture smaller or more difficult-to-separate ferrous particles, depending on the specific characteristics of the waste being processed.

[0291] Non-ferrous separator 115 is a specialized system configured to remove nonferrous metals, such as aluminium, copper, and brass, from a mixed waste stream. This unit typically uses an eddy current separator, which operates by generating a strong magnetic field that induces eddy currents in the non-ferrous metals. These currents create a repelling force that causes the metals to be ejected from the waste stream and directed into a separate collection area. Non-metallic materials, which are unaffected by the eddy currents, continue on their path for further sorting or disposal. The non-ferrous separator 115 plays a beneficial role in the efficient recovery of valuable non-ferrous metals, which are often more difficult to separate than ferrous metals due to their lack of magnetic properties. This unit ensures that non-ferrous metals are effectively removed from the waste stream, preventing them from contaminating other materials like plastics or organic matter. Recovering non-ferrous metals not only adds economic value by diverting valuable recyclables from landfills but also reduces environmental impacts by facilitating the recycling of metals that require significant energy to produce. Alternative implementations could include optical sorting systems or sensor-based technologies for more precise separation of specific non-ferrous metals, depending on the waste stream composition and desired outcomes.

[0292] Near-infrared (NIR) detection separator section 116 is an advanced sorting technology that uses near-infrared spectroscopy to identify and separate different types of materials based on their chemical composition. The NIR separator works by shining near-infrared light on the waste stream as it moves through the system. Different materials reflect or absorb the infrared light at distinct wavelengths, which allows the system to recognize various types of plastics, such as PET, PVC, or polypropylene, as well as other materials like paper or textiles. Once the material isidentified, an automated mechanism, typically air jets or mechanical diverters, sorts the materials into their respective collection bins. The NIR detection separator 116 offers significant benefits in precision sorting, particularly for plastics and other visually similar materials that are difficult to differentiate manually or with more basic mechanical systems. By using spectral analysis, this unit can quickly and accurately sort high-value materials, improving the quality and purity of the recyclables and making them more suitable for further processing or direct reuse. The system significantly reduces contamination in recycling streams, ensuring that sorted materials meet the necessary standards for recycling industries. This unit is particularly useful in facilities that handle large volumes of mixed plastic or polymer-based waste, such as packaging, and can be configured to separate multiple material types in a single pass. Optional alternative implementations could include expanding the wavelength range or integrating it with other detection technologies, like visible light or X-ray, to increase the sorting capability for more complex waste compositions.

[0293] Ferrous fraction 117 represents the collection of ferrous metals such as iron and steel that have been separated from the waste stream by magnetic separators. After passing through the magnetic drum or over-belt separators, these metals are directed into the ferrous fraction 117, which serves as the final collection point for all ferrous materials before they are sent for recycling. The benefit of this fraction is that it isolates valuable recyclable metals early in the process, ensuring they are not mixed with other waste materials, thereby improving the quality of the recovered metals and enhancing the overall efficiency of the recycling process.

[0294] PVC fraction 118 is the portion of the waste stream where polyvinyl chloride (PVC) materials are collected after sorting. This separation is often achieved using technologies like near-infrared (NIR) detection separators (116), which can specifically identify PVC based on its unique spectral properties. By isolating the PVC fraction, the system ensures that this material, which requires specialized recycling processes due to its chlorine content, is handled separately from other plastics, preventing contamination and allowing for proper treatment or recycling.

[0295] Nyon fraction 119 is a designated output for nylon materials, which are typically separated using advanced sorting technologies like near-infrared spectroscopy. Nylon has distinct chemical properties that make it identifiable through such technologies. Bycreating a separate nylon fraction, the system allows for the recycling of this material, which is commonly found in textiles, carpets, and industrial products, and helps prevent it from contaminating other plastic or textile waste streams.

[0296] PET fraction 120 is the collection point for polyethylene terephthalate (PET) materials, a type of plastic commonly used in beverage bottles and packaging. PET is highly recyclable, and separating it into its own fraction ensures that it can be processed efficiently in recycling facilities. Like the PVC and nylon fractions, the PET fraction is typically sorted using NIR detection systems (116) or other optical sorting technologies that can accurately identify and isolate this type of plastic based on its spectral signature.

[0297] Mixed plastic fraction 121 is a category that includes various types of plastics that are not easily separated into distinct categories like PET or PVC. This fraction may consist of a mixture of low-value plastics, such as polyethylene or polypropylene, that are more challenging to recycle individually. These plastics can either be sent for further processing into alternative products like refuse-derived fuel (RDF) or handled through a mechanical or chemical recycling process, depending on the facility's capabilities.

[0298] High calorific end product fraction 122 is a collection of materials that have a high energy content and can be used for energy recovery processes like incineration or gasification. This fraction typically includes materials like certain plastics, textiles, and other carbon-rich waste that cannot be recycled but can be converted into energy. The benefit of isolating this fraction is that it maximizes the energy recovery potential of the waste stream while minimizing the amount of material sent to landfills.

[0299] Non-ferrous fraction 123 is the collection point for non-ferrous metals, such as aluminium, copper, and brass, that have been separated using technologies like eddy current separators (e.g. 115). These metals are valuable for recycling and are isolated from the waste stream to prevent contamination and ensure they are recovered efficiently. The non-ferrous fraction allows recycling facilities to process these metals separately, improving the overall economic viability of the waste sorting process.

[0300] For configuring a simple waste sorting system, only a few units are employed to achieve basic separation. The waste would first undergo sterilization in the autoclave system 3 to reduce pathogens and prepare it for further processing. Following this, themagnetic separator 100 would extract ferrous metals from the waste stream. After the removal of metals, a wind sifting separator 108 could be used to isolate lightweight materials such as plastics and fibres from heavier fractions like organic matter or glass. These simple units ensure the most critical materials are separated for recycling, and the remaining waste can be directed to energy recovery processes or landfills with minimal environmental impact. This basic system focuses on maximizing resource recovery while minimizing the number of processing steps and required resources.

[0301] A more complex waste sorting system optionally employs all the available units to maximize efficiency, material recovery, and environmental protection. In this system, the waste first passes through the autoclave system 3 for sterilization before moving into the magnetic separator 100 to remove ferrous metals. The waste is then divided into multiple fractions using a series of units such as the first wind sifting separator 108 for light materials like plastics, the magnetic drum over belt separators 111 , 114 for further refining ferrous materials, and the non-ferrous separator 115 for recovering valuable non-ferrous metals. Advanced detection systems like the near-infrared detection separator 116 ensure precise sorting of plastics, separating polymers such as PVC, PET, and nylon. The screening units 110, 104 and additional wind sifting separators 113 help refine the final product, separating high-calorific fractions suitable for energy production from low-value residues. By integrating all these units, the plant achieves a high degree of material recovery while minimizing environmental impact and reducing landfill use. This fully automated and precise system allows for the recycling of diverse materials and the generation of valuable by-products like high- calorific end products.

[0302] For alternative waste sorting systems tailored to different waste streams, domestic waste sorting focuses on separating common household materials like plastics, paper, metals, and organic matter. The system would include units such as the magnetic separator 100 for metals, wind sifting separators 108 for plastics and papers, and possibly a composting line for organic materials. Industrial waste sorting would be more complex, requiring the separation of hazardous materials such as chemicals, which might involve additional units like chemical detection systems and safe containment lines for toxic substances, along with advanced separators for metals and plastics. Agricultural and food waste sorting would focus on organic material recovery, utilizing basic sorting units like the magnetic separator 100 and wind siftingseparators 108 for packaging removal, but with added composting and digestion units to process organic matter into biogas or compost. For complex waste streams such as chemical or medical waste, the system would integrate the autoclave system 3 for sterilization, along with additional containment and separation units specifically designed for hazardous materials, including high-efficiency particulate air (HEPA) filters, hazardous waste containment units, and chemical neutralization chambers to ensure safe handling and processing. These tailored systems provide the flexibility to address different waste challenges while maximizing material recovery and ensuring environmental safety.

[0303] Figure 5A illustrates a specific embodiment of the present invention where a cracking unit 80 is arranged for receiving and cracking the first and the second light oil fractions in lines 68 and 77. The skilled person would understand that not all aspects of Figure 5A are required, and each component may be used individually or together with any other component of the Figures described herein for methods, systems, or processes related to transforming source material, e.g. MSW or plant matter, into a desired product, e.g. protein, fuel, hydrocarbons, or other sorted, separated, or liberated product.

[0304] In the cracking unit 80, the hydrocarbons are thermally / catalytically cracked by heating the cracking unit with exhaust gas from the heating collars 46, 54 from the primary reactor 40 that is withdrawn through an exhaust gas line 82 and introduced into a heating collar 78 surrounding the cracking unit 80. The spent exhaust gas from the heating collar 78 is returned into the above-described exhaust line 48 through an exhaust gas return line 83.

[0305] The light oil fraction is thermally cracked in the cracking unit to produce synthesis gas, mainly comprising hydrogen, carbon monoxide, and carbon dioxide. The cracking in the cracking unit is not complete. The light oils that are not cracked in the cracking unit are withdrawn through a light oils recycle line 81 , to be recycled into the primary reactor as above described.

[0306] The synthesis gas generated in the cracking unit 80 is withdrawn through a cracked gas line 74 and introduced into the first gas washing section 62 as a part of the gas to be washed and separated therein.

[0307] Table 1 below gives typical values for kind of matter, mass flow, temperature, and pressure in different lines in an example waste handling plant according to the embodiment of present invention illustrated in Figure 5A, for handling of MSW, where the resulting gas is intended for a gas turbine for generation of electric power and district heating and / or cooling. Any missing values can be substituted for industrystandard values as known by a person skilled in the art. Any value here is listed as an example only, and the skilled person would understand that further values not listed here are also applicable. For example, ranges of plus or minus 10% of the listed would be optimal, ranges of plus or minus 25% of the listed values are potentially still operational, while ranges of plus or minus 50% may represent a loss of functionality.

[0308] Table 1

[0309] It can inter alia be seen from table 1 that the total mass is reduced by about 80% by weight. The amount of solids is i.e. dependent on the conversion in the conversion unit 70, as the weight of the carbonaceous rest may be substantially reduced by conversion of carbon by the gasification reaction mentioned above. In addition to this substantial reduction of weight, and correspondingly, volume, the solidmaterial exported from the plant has valuable properties making it possible to sell the product at the marketplace. The solid waste may be used in agriculture for soil improvement, and / or find use in different industrial applications. If there is no marked for the solid waste, it may be safely deposed, which is not the case for the MSW before treatment.

[0310] The input waste in line 10 may vary over time, a variation that may influence on the WOBBE-index. Stabilization of the WOBBE index may be accomplished by one or more measures, such as limiting the inhomogeneous feed stock into the gas production and treatment unit 20 through line 13, adjusting the humidity of the feed stock in line 13, adjusting the conversion seventy in the conversion unit 70 to influence the ratio of hydrogen to carbon monoxide to carbon dioxide produced therein, actively controlling the carbon dioxide capture in the carbon dioxide capture unit 24, and adjusting the cracking seventy of light oils in the cracking unit 80.

[0311] The present invention is described with reference to a specific plant and a specific embodiment. The skilled person will know how to adjust the parameters, dependent on the incoming waste, to obtain a fuel gas in line 26 that is suitable for other uses than for a gas turbine according to the state of the art. The fuel gas in line 26 comprises a mixture of carbon monoxide, hydrogen, carbon dioxide, and lower hydrocarbons, such as methane, ethane, propane, and butane. The produced fuel gas may be further separated to give individual fractions of one, two or more of the gases in the mixture. The gasification and thermolysis unit may also be operated at a higher temperature, and / or by introduction of more steam to cause more steam reforming to shift the products further against hydrogen and carbon dioxide.

[0312] It is assumed that gas turbines that can accept relatively pure hydrogen as fuel will be available within a few years. The skilled person will know how to adjust the parameters in different parts of the plant to obtain a produced gas in line 26 that mainly comprises hydrogen at the expense of carbon monoxide, which has a far lower calorific value than hydrogen.

[0313] With the produced gas in line 67 and line 72, that mainly comprises hydrogen carbon monoxide and carbon dioxide, Methanol can be produced for its further use in fuel cells according Figure 5B.

[0314] Correspondingly, the skilled person will understand how to adjust the parameters of operation of the plant if the intended use for the fuel gas produced is to produce other products from the fuel gas, instead of generating electrical power and hot water for district heating and / or cooling. The plant will then be adjusted to produce a fuel gas mixture that is optimal for the intended purpose, such as fuel gas for a Fischer Tropsch plant for synthesis of higher hydrocarbons.

[0315] Figure 5B illustrates a specific embodiment of the present invention where a Hydrogen-rich gas can be obtained in a single phase or in two phases, and methanol will be obtained as product.

[0316] In a single phase the gasification of the carbonaceous solid would occur at the same time as steam reforming in conversion unit 70.

[0317] In two phases, the char gasification is carried out in unit 70 and, additionally or alternatively, the catalytic steam reforming of methane and light hydrocarbons with an extra supply of steam in separation unit 24 between 700-900 °C (Figure 5B).

[0318] This gas rich in hydrogen, carbon monoxide, and carbon dioxide would be taken to the heat recovery and gas preparation zone for the synthesis of methanol (Figure 6) in a reactor with CuO-ZnO-AI2O3catalysts, Temperature between 240-270 °C, Pressure 40-45 bar. A CuO-ZnO-AI2O3catalyst is a mixed metal oxide catalyst primarily composed of copper oxide (CuO), zinc oxide (ZnO), and aluminum oxide (AI2O3). These catalysts are highly efficient due to the synergistic effects between the copper's catalytic activity, zinc's promoting behaviour, and alumina's structural support.

[0319] Alternative catalysts to traditional zeolites, e.g. for one or more cracking units, include nickel-based catalysts, alumina-supported catalysts, and metal oxides such as TiO2, Fe2O3, or MgO. Nickel-based catalysts enhance hydrogen production and reduce coking, while alumina-supported catalysts offer stability and high thermal resistance. Metal oxides like titanium dioxide and magnesium oxide provide effective cracking with reduced carbon deposition, making them suitable for converting complex feedstocks like waste plastics into valuable hydrocarbons. Additionally, mesoporous silica catalysts can improve product yield by offering higher surface areas for active sites and better diffusion of large molecules. These examples are non-limiting, and the skilled person would understand that alternative catalysts are applicable.

[0320] The conversion to hydrogen reaches 80% and after separation by distillation methanol is obtained with a purity of up to 99.3% molar.

[0321] The reactions that would take place are:CO + 2H2= CH3OH, and / orCO2 + 3H2= CH3OH + H2O.

[0322] Figure 6 describes a methanol production unit scheme. Excess of water and temperature, present in the gas coming from the conversion unit, is removed at the heat recovery and gas conditioning subunit. The skilled person would understand that not all aspects of Figure 6 are required, and each component may be used individually or together with any other component of the Figures described herein for methods, systems, or processes related to transforming source material, e.g. MSW or plant matter, into a desired product, e.g. protein, fuel, hydrocarbons, or other sorted, separated, or liberated product.

[0323] Figure 6 comprises a conversion unit, e.g. conversion unit 70, where a feedstock, e.g. from solid line 69, undergoes a chemical transformation, such as cracking, pyrolysis, or synthesis. In pyrolysis, this could be the unit where hydrocarbons are thermally decomposed into smaller molecules, producing gases, liquids, and solids. After the conversion, the produced gases are optionally cooled to condense liquids or bring the system to a manageable temperature. One or more cooling units 610 lower the temperature of the output stream from the conversion unit, allowing easier handling and separation of different phases.

[0324] The cooled stream enters the flash separator 611 , where volatile components (gases) are separated from non-volatile components (liquids and solids) due to pressure reduction or rapid cooling. This allows the recovery of different products, such as fuel gases or oils. One or more compressors 612 increase the pressure of the gaseous products separated in the flash separator. This step helps move the gases through the system or to prepare them for further reactions under specific pressure conditions. The compressor 612 increases the pressure of the gas stream, but it also raises the temperature. Instead of wasting this heat, it can be harnessed for downstream applications.

[0325] After compression, the gas may be cooled again to bring it to the appropriate temperature for downstream processing. This helps control the temperature before entering the next stage, which could be another reactor or separation unit.

[0326] The mixer 613 combines different streams (e.g., the gas stream from the cooling unit with other reactants) before the mixture enters the next reactor. In a methanol production plant, for example, this could be the point where gases like hydrogen and carbon dioxide are mixed for subsequent reactions. For example, the mixer helps maintain a substantially stable WOBBE-index or calorific value for input to one or more reactors 40. In the reactor(s) 40, a chemical reaction takes place, such as the synthesis of methanol from syngas (a mixture of CO, CO2, and H2). This is a beneficial unit where catalysts are often used to enhance the reaction.

[0327] The product stream from the reactor optionally passes through a flash separator 611 , which isolates gases and liquids once more. This helps separate unreacted gases from the liquid product (e.g., methanol or other hydrocarbons) and allows the recycling of unreacted gases, e.g. via unreacted gas line 617. Unreacted gas line 617 comprises any gaseous components that did not condense in the flash separator. For example, the unreacted gas comprises any of hydrogen, carbon dioxide, carbon monoxide, or other light hydrocarbons or inert gases, e.g. depending on the feed composition. Unreacted gas line 617 feeds unreacted gas back to the mixer 613 to be combined with fresh reactants, increasing overall efficiency and minimizing waste. By recirculating unreacted gases, the process ensures that these valuable components have another chance to participate in the reaction. Optionally, flash separator 611 also outputs unwanted components via a purge line 618, e.g. to remove unwanted components from the system that could build up and / or negatively affect the reaction efficiency or product quality. The purge line 618 optionally comprises inert gases, such as nitrogen or argon, light hydrocarbons or low-value gasses, or accumulated impurities. Purging helps maintain optimal reaction conditions and prevents excessive inert or harmful gases from affecting the reactor's performance.

[0328] An optional value 615 controls the flow rate and pressure of the stream moving toward the next process unit. Valves are optionally used throughout chemical processes and between units or within units described herein to regulate the pressure and flow of streams between different units.

[0329] The water / methanol separator unit 614 is configured for separating methanol from water after the reaction. Methanol and water are often produced together, and water / methanol separator unit 614 employs techniques like distillation or phase separation to purify the methanol, e.g. to over 98% Mol.

[0330] For example, reformed gas is fed to the reactor at 40-45 bar and 240-270 °C. A purge line is needed because of inert components in the stream. Total conversion at the reactor is 85-86% molar in methanol, approximately. Methanol is separated from water in a distillation column with a purity 98-99% molar.

[0331] Optionally, flash separator 611 , compressor 612, and cooling unit 610 comprise a heat recovery system 616. Heat recovery system 616 is configured to maximize energy efficiency by capturing and reusing heat from the process, thereby reducing energy consumption and minimizing waste. For example, during processing in the flash separator 611 , hot gases can carry a significant amount of thermal energy that would typically be lost if vented or cooled without recovery. Similarly, compressing gases generates a substantial amount of heat due to the compression process itself. This heat is typically seen as waste in standard processes but can be captured as part of the heat recovery system 616. After compression, the gas needs to be cooled to make it suitable for the next stages of the process (e.g., further reactions or condensation). This is typically done using a cooling unit, often involving a heat exchanger.

[0332] In heat recovery system 616, instead of dissipating this heat into the environment, the cooling unit 610 captures the heat from the hot compressed gas and transfers it to a medium (such as water, air, or another process stream). This recovered heat can then be used elsewhere in the plant. The heat is optionally used to preheat the incoming raw materials (like reactants) entering the conversion or reactor unit, reducing the energy required to bring the system up to the necessary reaction temperature. The recovered heat is additionally or alternatively used to generate steam, which can be utilized elsewhere in the process (e.g., in turbines or other heating requirements).

[0333] By implementing a heat recovery system 616, the plant significantly reduces energy consumption. Instead of needing to supply additional heat externally (e.g., burning fuel), the process can use its internal energy more efficiently. It also reducesthe cooling load of the system, as the cooling unit 610 no longer needs to dissipate all the thermal energy; much of it is captured for reuse, improving overall plant efficiency.

[0334] As described above, the solid waste from the converter 70 is withdrawn through a solids waste line 23 and is optionally introduced into a char handling unit 90, where the solid material is separated into char, that is withdrawn through a char line 91 , and a mixture of char and ash that is withdrawn through an ash line 92.

[0335] According to another aspect of the present invention, the char is further treated. First, optionally, in a comminutor system and second, after the optionally first treating, in a cyclonic particle separator, as described in the following. The skilled person would understand that any features described in relation to above aspects can be combined or otherwise interchanged with aspects below.

[0336] Figure 7 shows a cyclonic particle separator 200 for processing a fluid comprising solid particles. The skilled person would understand that not all components of Figure 7 are required, and each component may be used individually or together with any other component of the Figures described herein for methods, systems, or processes related to transforming source material, e.g. MSW or plant matter, into a desired product, e.g. protein, fuel, hydrocarbons, or other sorted, separated, or liberated product.

[0337] The cyclonic particle separator comprises a rotor 220, at least one electromagnetic coil 217 as well as at least one ultra-sound generator 216, and a main chamber 210. The main chamber comprises at least one section of non-conducting material. The rotor 220 is arranged to induce a rotation of the fluid in the chamber 210 and the electromagnetic coil / s 217 and ultrasound generator / s 216 are arranged to generate a pulsed magnetic field in cooperation with ultrasound waves in the fluid in the chamber 210. Depending on the material processed and its response, this can be done together or individually in connection to the at least one section of non-conducting material of the cylindrical wall. The pulsed magnetic field is arranged to induce a weak pulsating magnetic field through the rotating fluid mix. This pulsating field will gently vibrate even weak magnetic particles, thereby liberating any conglomerated particles of same or different sizes from each other. The effect of ultra-sound is similar for other or same type materials. This material effect of either force or combination of forces canbe visualized like a group of people in a queue shivering lightly on cold day while waiting for the bus to arrive.

[0338] Here, “processing” refers broadly to the act letting the fluid mix undergo a series of steps with a specific aim, such as the aim of separating and sorting the solid particles comprised in the fluid.

[0339] The main chamber 210 may be substantially cylindrical in shape. It may also comprise substantially cylindrical and conical sections. Herein, the terms “cylinder”, “cylindrical”, and “conical” are to be interpreted widely. For instance, a radius of the substantially cylindrical chamber 210 may vary along the central axis of the chamber 210, and a cross section of the chamber 210 at a point along the central axis may not be perfectly circular. An end of the chamber 210 is taken to be a point along the central axis where the chamber ends. The chamber end is a separate formed piece, end cap 225 with one outlet at the bottom of the funnel shaped interior bottom formed as shown in Figure 7. The end cap is screwed on to the main chamber with threads and can be twisted and adjusted up or down. This movement of the end cap allow the distance and size of the lower space to be increased or decreased giving an adjustable process parameter for sorting and separation of heavy particles of a specific material mix.

[0340] The cyclonic particle separator 200 may also comprise an impeller 215, connected to the rotor 220 by a means of connection such that if the impeller 215 starts to rotate, the movement is extended to the rotor 220.

[0341] During operation, the fluid with solid particles mix is introduced into the cyclonic particle separator through an inlet 211 near a first end of the main chamber 210. The fluid may at this point flow with a flow rate induced by an apparatus external to the cyclonic particle separator, such as a slurry pump. On contact with the impeller 215, kinetic energy is transferred from the fluid to the impeller 215, which starts to rotate. As described above, this induces causes the rotor 220 to rotate, which in turn induces a rotation in the fluid. The fluid will thus move in a spiral pattern along the central axis of the chamber 210. The rotation speed of the central rotor 220 is adjusted and controlled by the pressure of the incoming fluid mix as well as the shape and number of vanes of the impeller. These of each other dependent selection also become an important process parameter for certain materials.

[0342] The rotor 220 may comprise a plurality of holes 221a, 221 b arranged to admit solid particles and fluid into an interior cavity 222. As mentioned above, due to the rotation induced in the fluid, heavier solid particles will be pushed in a radial direction towards the walls of the chamber 210 while lighter solid particles remain closer to the center. The outer shape of the cyclone rotor is such that the medium density particles are trapped in their fluid as the passes the rotor 220, light particles can thus enter through the plurality of holes 221 a, 221 b into the interior cavity 222. The interior cavity 222 connected to the outlet 213, thus allowing for extraction of light particles mixed in the fluid through a first outlet 213. This light particle stream is light particles in relation to the other two fluid streams and can vary greatly both in size and weight. The term “light” shall only be a qualifier when compared with other solids processed at the same time.

[0343] After the fluid passes the rotor 220 it reaches a second end of the main chamber 210. At this turning point the flow of the fluid will be redirected along the central axis of the chamber 210 towards the first end of the chamber 210. As described above, heavier particles will be unlikely to follow the main flow of the fluid at the turning point, instead being collected at the second end of the chamber. The heavier particles may be extracted from the chamber through a second outlet 214.

[0344] Here, particle density is referred to using relative terms such as “heavier” and “lighter”. The absolute weight of the particles that are considered “heavier” or “lighter” will for example depend on the weight distribution of the particles in the fluid. Absolute weights of heavier and lighter particles can be found through experimentation.

[0345] The fluid flowing inside the hollow space of the central axis of the chamber 210 towards the second (bottom) end of the chamber may comprise particles of medium and heavy density in the general fluid stream. The fluid containing the medium weight particles may be extracted through a third outlet 212 through the hollow cyclone shaft at the first end of the apparatus.

[0346] Thus, the particle separator may be arranged to separate the slurry stream fluid into at least a second and third output stream. The first output stream may be extracted at a first outlet 212 and the second output stream may be extracted at a second outlet 214, the first 212 and second outlet 214 being arranged in different positions on the particle separator. The main volume of fluid is then released via the third outlet 213.The solid particles in the first, second, and third output streams have different densities for similar sized solid particles in the fluid stream.

[0347] In particular, the particle separator may be arranged to separate the fluid into three output streams extracted at a first 213, second 214, and third 212 outlet. The first213, second 214, and third 212 outlets may be arranged in different positions on the particle separator. The solid particles in each output stream have different density.

[0348] It is understood that not all particles in one output stream will have exactly the same weight. Rather, the weight of the particles may fall in a range that is different for each output stream, or the median or mean particle weight may be different for each output stream.

[0349] The weight of the particles in each output stream, as well as the fraction of the particles included in each output stream, will for example depend on the flow rate of the fluid and the rotation rate of the impeller 215 and the rotor 220 as well as the size of chamber 223. The cyclone separator wall and the end piece 214 have threads allowing the end piece to be further screwed on to the cyclonic separator wall. Such parameters can be adjusted through routine experimentation until a desired weight distribution is reached for the particles in each output stream. As an example, the flow rate may be adjusted until the lightest 10-30 % of the particles are extracted via the first outlet 213 and the heaviest 5-10 % of the particles extracted via the second outlet214. The distance between the cone shaped bottom of outlet 214 and the bottom of rotor 220 creates a hollow space 223. The hollow space 223 can be adjusted so that what is classified as heavy particles can further be trimmed based on specific density of these heavy particles. A more abrupt turn of the fluid is accomplished when the distance between the bottom end of the rotor 220 and the top of the bottom cone 225 is shorter.

[0350] Particles in a fluid may cluster together to form aggregates of two or more particles. In the cyclonic particle separator described above a pulsed magnetic field and / or ultrasound is used to induce a vibration in the particles. The response of particles to the magnetic field and / or ultrasound will depend on whether the particles comprise ferromagnetic, paramagnetic, or diamagnetic materials. Particles comprising ferromagnetic materials such as iron, nickel or rare earth metals will respond strongly to a magnetic field and may therefore vibrate strongly in response to a pulsed magneticfield. Particles comprising paramagnetic materials such as aluminum will respond less strongly, and particles comprising diamagnetic materials such as copper will respond weakly to the magnetic field, and yet other materials will better respond to ultra-sound vibrations or possibly a combination of the two.

[0351] Within a cluster, the particles will generally adhere quite weakly to each other. The vibration induced by the magnetic field and / or ultrasound will cause a strain in the cluster, leading to it breaking apart at the boundaries between the particles. In addition, vibrating clusters may collide with other clusters, increasing the chance of the clusters breaking apart. The pulsed magnetic field and / or ultra-sound thus liberates the particles in such clusters from each other. The movements of these conglomerates can be described as humans shivering in a cold weather. As the individual particles in a cluster may be of different size, composition, and weight, liberating them from each other is beneficial for correct sorting of the particles based on density.

[0352] As an example, consider a cluster consisting of a three (3) equal sized particles. One (1 ) of iron oxide and two (2) of silica oxide attached to each other. Their combined density would be a weight of 2.77 grams per cubic centimeter and register together with similar sized particles of aluminum. Instead of correct value for silica dioxide of 1.54 grams per cubic centimeter and 5.24 grams per cubic centimeter for iron oxide. The conglomerated cluster would also be larger than individual parts, and if the particles are not liberated from each other the entire cluster may be sorted incorrectly. However, the pulsed magnetic and / or ultrasound field would induce a strong movement in the ferromagnetic iron oxide, introducing a strain into the cluster and liberating the three particles. The heavy iron oxide could still be extracted among the heaviest fraction of particles at the second outlet 214, but the lighter silica oxide particles might be extracted among the lightest fraction of particles at the third outlet or possibly among the middle density particles in the first outlet 212. Liberation of particles from the cluster thus aids in sorting particles with different mineral content into different output streams based on their relative, to each other, density. The closer these particles are in physical size the finer these cuts can be made. Such physical size screening is well known in prior art.

[0353] For example, liberation refers to the process of effectively separating and extracting particles or components from a mixed stream or material. Cyclonicseparators, such as cyclone dust collectors or hydrocyclones, utilize centrifugal force to separate particles based on their size, density, and other physical properties. Liberation occurs when particles are freed or released from the mixed material and are separated according to their characteristics. This separation process allows for the recovery and recycling of valuable components or materials from a mixed stream. Liberation is beneficial for achieving high efficiency in recycling processes, as it enables the extraction of specific components for reuse or further processing while minimizing waste.

[0354] It should be noted that even if a cluster of particles comprises only one ferro- or paramagnetic particle, the pulsed magnetic field and / or the ultrasound will still induce a vibration into the entire cluster.

[0355] The pulsed magnetic field is generated using at least one electromagnetic coil 217 arranged in connection to the chamber 210. If several of electromagnetic coils are used, they may be arranged to encircle the chamber 210. The ultrasound generators may be arranged in a similar fashion both around and along the chamber 210.

[0356] To generate the pulsed magnetic fields, the electromagnetic coil 217 is supplied with an alternating current and / or voltage. The frequency if of the alternating current or voltage may be adjusted based on knowledge of the magnetic properties of the solid particles or through experimentation. As an example, the frequency may be about 10 Hz and adjusted upwards based on the actual fluid flow speed through the cyclone.

[0357] The magnetic field strength will be affected by e.g., the number of coils used, the magnitude of the current, and the number of turns in each coil. These parameters may be adjusted based on knowledge of the magnetic properties of the solid particles or through experimentation.

[0358] For the pulsed magnetic field to extend into the main chamber 210, at least a section of the main chamber 210 must be made of a non-conducting material. Herein, non-conducting refers to a material that is not classed as an electric conductor. A nonconducting material may have an electrical conductivity of below 10000 (Qm)-1 , preferably it may have an electrical conductivity below 0.001 (Qm)-1 . As an example, at least a section of the chamber 210 could be made of a non-conducting plastic such as polyvinyl chloride or polypropylene. As another example, at least a section of the chamber 210 could be made of a ceramic material.

[0359] In some cases, a source material to be sorted in the cyclonic particle separator 200 is obtained in the form of extended pieces of solid material. An extended piece of solid material could be a piece that is too large to be reliably suspended in a fluid, or a piece that is larger than a few tenths of a millimeter. In this case, the source material may be comminuted in a comminutor before processing in the cyclonic particle separator. Comminutors are known in prior art. For a proper optimized performance of the aforementioned separator, it is important that certain kinds of comminution equipment are used. The absolute best sorting will occur on materials liberated and micronized along natural boundaries as compared with technologies that crush materials with force.

[0360] Here, a source material is taken to mean any substance that is comminuted and subsequently sorted in the cyclonic particle separator. According to the first part of the present invention, the source material will typically consist of multiple char components or component materials, and it is desirable to separate said component materials. According to one example, the source material could be char from the char handling unit 90, and the component materials may be minerals such as silica oxide, iron oxide and aluminum oxide. According to another example, not part of the invention, the source material could be packaging and other recyclable products that contain paper, plastic and metallic parts, and the paper, metal, and plastic are then component materials. According to yet another example, not part of the invention, the source material could be slag or dross from an ore treatment process, and the component materials may be minerals such as silica oxide, iron oxide and aluminum oxide.

[0361] Therefore, there is also herein disclosed a system for processing a source material, the system comprising a comminutor 310, Figure 9A and at least one cyclonic particle separator as described above.

[0362] Optionally, the system may also comprise a mixing apparatus for mixing the comminuted particles with a fluid such as a liquid or a gas prior to processing in the cyclonic particle separator. The system may further comprise an apparatus for feeding the fluid comprising the solid particles into the cyclonic particle separator. The apparatus may be a pump, optionally a pump suitable for pumping a fluid consisting of solid particles suspended in a liquid (e.g., a slurry pump). Methods and devices for mixing particles with fluids and for pumping a fluid into a chamber are known in the art.

[0363] The comminutor comprised in the system described above may be a comminutor which comprises a spinnable shaft 381 and two or more processing chambers 382, separated by segmented plates 383. Each processing chamber 382 comprises a rotor disc 384 attached to the shaft 381 and one or more vortex generators 385 placed in a side wall 386 apex corner of the processing chambers 382. The source material is fed into the comminution reactor 310 and particles are liberated from the source material by means of a chaotic vortex flow of the source material and the liberated products generated in the processing chambers 382.

[0364] A comminutor as described above is an example of a Librixer comminutor, the components and operating principles of which are shown in Figure 9A. During operation, a mixture of source material and air enters an entrance opening 371 of the comminutor 310. In the first upper of two or more vertical processing chambers 382, the mixture is spun outwards and will create a circular source material curtain restrained by the polygon shaped walls. The source material curtain spins in either a clockwise or a counterclockwise direction initiated by the vertical rotor assembly consisting of as many rotors as there are processing chambers. The source material flow is restrained by an odd number of flat wall segments, not shown in the schematic drawing. In each apex corner between two flat wall segments, a vortex generator 385 is placed setting up two small vortexes counter to the main flow. The main source material flow curtain interacts with these smaller vortexes consisting of a fluid, most commonly air, and source material in such way that brittle materials are stressed apart along natural boundaries. More flexible materials or fractions of a material, such as fibers, tend to go through relatively un-harmed.

[0365] The horizontal view in Figure 9A show one rotor disc. For simplicity, all rotor vanes 387 are straight in the image, although other shapes are also possible. The described source material curtain is established as a circular boundary just inside an inscribed circle created by the inner parts of the apex-comer-placed vortex generators 385. These vortex generators 385 are for clarity just indicated with an oval formed member. As the source material curtain restrained by the processing chamber walls reaches a vortex generator 385, a portion of the fluid stream is folded back on itself creating a small counter rotating vortex (i.e., counter to the main curtain rotation direction). The Coanda effect drags part of the initial vortex fluid over to the back side of the generator, creating a second slightly weaker vortex on the back side of the vortexgenerator 385. These two small vortexes are indicated by two small bent arrows in Figure 9A. For clarity only two such vortexes are indicated, but each generator sets up two respective vortexes. The vortex generators 385 may be shaped from the Greek letter omega, or to a shape similar to two spoons placed “back-to-back”, and many others optimizing the performance to different source materials.

[0366] The chaotic interference between these small counterrotating vortexes and the main source material flow curtain is one key component in the liberation function of the Librixer system. Each vortex is influenced by the lower pressure in the processing chamber below. As the particles are getting liberated and less dense or smaller, they eventually are sucked down into the next chamber where the processing is repeated in a similar fashion until the very last chamber.

[0367] Herein, particle sizes are referred to using relative terms, such as small, medium, and large. It is appreciated that absolute size values can be determined by straight forward experimentation. In the present disclosure, relative sizes are deemed more appropriate in order to not obscure the general inventive concept.

[0368] Since the Librixer comminutor liberate and micronize a source material along natural boundaries, the resulting particles will consist predominantly of a single component, possibly with smaller amounts of other components. As an example, if the Librixer comminutor is used to process slag from a mineral extraction process, comprising a mix of different minerals, each resulting particle will consist predominantly of a single mineral. Subsequent processing in the cyclonic particle separator can then be used to separate and sort particles comprising predominantly of different minerals into different outlet streams, thus separating e.g., char, silica oxides, iron oxides and aluminum oxides. Another example, not part of the invention, could be in a recycling process treating a mix of e.g., paper, plastic, and metal, where particles comprising mostly either paper, plastic, or metal could be sorted into different outlet streams.

[0369] The Librixer comminutor 310 has several operating parameters, comprising rotation direction (clockwise or counterclockwise), rotation speed of the rotor disc 384, and feed rate of the source material into the comminution reactor 310 expressed in volume per hour. These operating parameters may be adjusted in dependence of the source material to be processed, e.g., through experimentation.

[0370] There is also herein disclosed a method, shown in the flowchart in Figure 10A, for processing a fluid comprising solid particles using a cyclonic particle separator, where the cyclonic particle separator comprises a rotor 220, at least one electromagnetic coil 217 and / or at least one ultrasound generator, and a main chamber 210. The main chamber 210 comprises at least one section of non-conducting material. The method comprises, after comminution 400 and size fractionation 401 into two or more size fractions 410, 411 , 412 or as many as needed. Thereafter, if suitable, mixing the fractionated solids with a fluid 402 and feeding the fluid into the cyclonic particle separator, inducing a rotation of the fluid in the chamber by the rotor 220, and generating, by the electromagnetic coil 217 and / or ultrasound generator 216, a pulsed magnetic field and / or an ultrasound pulse in the particle separator in connection to the at least one section of non-conducting material. The pulsed magnetic field and / or ultrasound is arranged to vibrate the solid particles, thereby liberating the solid particles from each other.

[0371] As previously described, feeding the fluid into the cyclonic particle separator may be accomplished through a feeding means such as a pump. Such feeding means are known in the art.

[0372] The method may also comprise separating the fluid into at least a first and second output stream, the first output stream being extracted at a first outlet 212 and the second output stream being extracted at a second outlet 214, the first and second outlet being arranged in different positions on the particle separator, wherein the solid particles in the first and second output stream have different average weights.

[0373] The method according to any previous claim, where the method comprises separating the fluid into three output streams extracted at a first (213), second (214) and third (212) outlet, the first (213), second (214) and third (212) outlets being arranged in different positions on the particle separator, wherein the solid particles in each output stream have different density 420, 421 , 422.

[0374] Furthermore, the method may also comprise further sorting any one or all 420, 421 , 422 of the solid particles of at least one outlet stream by means of methods such as magnetic separation, spiral separation, filtering, or electrostatic separation, or by feeding the at least one outlet stream into a second cyclonic particle separator 404.

[0375] Depending on the contents of an output stream, the fluid in the outlet stream may undergo further treatment. As an example, an output stream may be put through a spiral separator to further separate particles with different specific weights, or magnetic particles may be extracted using a magnetic separator. Other methods such as filtering may also be applied. Such sorting methods are known. As another example, an output stream could be fed into a second cyclonic particle separator. The second cyclonic particle separator may be configured similarly or differently to the first and may be used to further separate and sort the particles of the output stream by density. For instance, one output stream of the first cyclonic particle separator may comprise mainly two types of particles of slightly different composition and slightly different density, that could not be efficiently separated in the first cyclonic particle separator due to the presence of significantly lighter or heavier particles. A second cyclonic particle separator could then be arranged to separate the two types of particles by their density in the absence of the lighter or heavier particles that were removed by the first cyclonic particle separator 403.

[0376] Alternatively, or additionally, the method for processing solid particles using a cyclonic particle separator 200 is performed as shown in Figure 10B. Figure 10B comprises obtaining a fluid comprising the solid particles at a main chamber 210, inducing a rotation of the fluid in the main chamber 210 using a rotor 220, and vibrating the solid particles, thereby liberating the solid particles from each other. Liberating the solid particles is performed by performing (a) and / or (b): (a) generating a pulsed magnetic field in the main chamber 210 using an electromagnetic coil 217, wherein the main chamber 210 comprises at least one section of non-conducting material; (b) generating an ultra-sound vibration using an ultra-sound generator 216. Optionally, the method further comprises separating the liberated solid particles based on size and / or density via the use of any of the first outlet, the second outlet, or the third outlet (e.g. any of outlets 212, 213, 214) of the cyclonic particle separator 200.

[0377] In a cyclonic particle separator (e.g. cyclonic particle separator 200), using a pulsed magnetic field or ultrasound vibration to influence solid particles offers significant advantages over traditional methods that rely on centrifugal force alone. A pulsed magnetic field applies periodic magnetic forces to particles, particularly those with magnetic susceptibilities, such as metallic or magnetizable components. This selective influence can greatly enhance the separation of magnetic particles, forcingIll them toward the cyclone walls or into different fractions, which is especially useful in processes requiring the separation of metals or specific minerals from non-magnetic materials. Additionally, the magnetic forces can break up particle agglomerates, improving dispersion and preventing particles from sticking together due to static charges or weak van der Waals forces. This reduction in agglomeration ensures more effective separation, allowing smaller or lighter particles to be correctly classified. Moreover, the pulsed magnetic field enables finer control over particle trajectories, which is beneficial in complex mixtures where particles differ by size, density, and magnetic properties. This can increase the throughput of the cyclonic particle separator 200 by reducing material build-up and preventing blockages that would otherwise slow down the process.

[0378] Ultrasound vibration involves the application of high-frequency sound waves to agitate the particles within the cyclonic particle separator 200. This method significantly improves particle dispersion, breaking up clumps and preventing premature settling, which ensures that particles are separated more effectively according to size and density. Ultrasound waves also reduce the boundary layer effect, which is the thin layer of particles that may stick to the cyclone walls and hinder separation. By disrupting this layer, ultrasound helps recover more of the light particles and minimizes product loss. The continuous agitation caused by ultrasound can also increase the rate of separation, allowing particles to settle into their respective streams — heavy particles (“heavies”), middle particles, or light particles — more quickly. This not only improves throughput but also reduces overall processing time. Furthermore, the use of ultrasound minimizes fouling and clogging within the separator, particularly when dealing with sticky or oily materials like tars or oils, ensuring consistent operation and reducing the need for maintenance.

[0379] Compared to traditional cyclone separation, which depends solely on centrifugal forces to separate particles based on size and density, these enhanced methods address several limitations. Conventional cyclones often struggle with the separation of fine or sticky particles, as these tend to clump together or adhere to the cyclone walls. Additionally, traditional methods may be less effective when separating particles with overlapping size or density characteristics. The introduction of a pulsed magnetic field or ultrasound vibration provides greater control over particle dynamics, improving the accuracy of classification and allowing for more efficient processing ofchallenging materials. Both methods also help reduce the frequency of maintenance by preventing clogging and fouling, making them highly advantageous for operations dealing with a variety of feedstock compositions.

[0380] Optionally, a plurality of cyclonic particle separators could be used in sequence, e.g. as illustrated in Figure 11 , where a plurality of particle separators, e.g. cyclonic particle separator 200, are used in series and parallel in a hybrid sequence. The skilled person would understand that series and parallel sequences, and hybrids thereof, are optional implementations of a plurality of particle separators.

[0381] Figure 11 optionally comprises one or more flotation units 619. Flotation is a particle separation method used at flotation units 619 that uses space, e.g. air bubbles, to separate fine solid particles from liquids or gases. Additionally, or alternatively, floatation unit 619 acts as storage, e.g. a silo.

[0382] Optionally, heavy particles 620 are output from an outlet of the cyclonic particle separator 200, e.g. outlet 212. Middle particles 622 are output from a different outlet, e.g. outlet 213. Light particles 621 are output from a different outlet again, e.g. 214. Heavy, middle, and light refers to the size, density, and weight of the particles produced from the previous process(es). These fractions are preferably separated based on differences in physical properties, particularly weight and aerodynamic behaviour, through centrifugal forces inside the cyclonic particle separator 200.

[0383] The heavy particles 620 are the largest and densest particles produced, e.g. during a pyrolysis reaction. These particles are typically the first to be separated in a cyclone separator, where the centrifugal forces push them to the outermost wall of the cyclone due to their higher inertia. Optionally, heavy particles 620 comprise char, unconverted solid materials, metal oxides, or ash. Further optionally, heavy particles 620 are removed for disposal or recycled, e.g. char is used for fuel or reprocessed.

[0384] The light particles 621 are the lightest, least dense particles produced in the pyrolysis reaction. These particles are carried by the gas flow and tend to remain in suspension for longer, making them harder to separate by centrifugal force. Optionally, light particles 621 comprises light hydrocarbons, very fine solid particulates, e.g. ultrafine char particles too small or light to settle with the heavy particles 620, or tar / VOCs / oils / liquids that condense into fine droplets, depending on the feedstock. Preferably, the light particles 621 undergo a separation process at flotation unit 619.For example, fine particulates are separated from gases or liquids by injecting air or gas, forming bubbles that float light particles to the surface. The light particles 621 are collected as a froth, and the gases or liquids are purified. Any light hydrocarbons in the gaseous stream might eventually be sent to condensation units to produce liquid fuels or flared off, while the fine particulates are collected for further processing or disposal.

[0385] Middle particles 622 are particles that fall between the heavies and lights in terms of size and density. They aren't as heavy as the char or ash particles, but they are not as light as the fines or gases. Middle particles 622 are partially separable in a cyclonic particle separator 200 and may require further processing. Optionally, middle particles 622 comprise small solid particles, such as small char fragments of solid hydrocarbons, larger aerosol droplets, such as oil mist, or intermediate-size particles, such as organic compounds that are still in the process of breaking down. Middle particles 622 are preferably sent to another separator (e.g., a secondary cyclone) for further size or density fractionation. This ensures that each fraction is as refined as possible. The output from this second separator could either be combined with heavies, or sent to further cracking or processing units.

[0386] This and similar configuration can be used for alternative purposes, e.g. to separate protein, fibre, and / or starch. Plant fibres are typically larger, more fibrous, and dense compared to proteins and starches. Fiber, such as cellulose, lignin, or other structural plant materials, does not break down easily and tends to be heavier. These fibres are often more robust in size and weight, causing them to be the first particles pushed to the outer walls of the cyclonic particle separator 200 and settle at the bottom or in outlet 212. Heavy particles 620 would comprise fibres. Middle particles 622 would comprise starch, where starch granules are generally smaller and lighter than fibre but denser than proteins. They tend to settle in the middies fraction in the cyclone separator 200. Proteins tend to form finer, less dense particles compared to fibres and starches. Because of their smaller size and lighter mass, they tend to remain in suspension longer and are carried away with the airflow in the cyclone. Therefore, light particles 621 would comprise proteins.

[0387] The method may also comprise, prior to feeding the fluid into the first or only cyclonic particle separator, generating the solid particles comprised in the fluid by comminuting a source material in a comminutor as a slurry.

[0388] The method may also comprise sorting the solid particles according to a size of the solid particles and selecting solid particles in a predetermined size range for sorting in the cyclonic particle separator.

[0389] During processing in the cyclonic particle separator, one significant factor in determining which outlet stream a particle ends up in is the density of the particle. If the particles fed into the cyclonic particle separator are of approximately the same size, the weight differences between the particles will be primarily due to differences in density or specific weight, which in turn are dependent on differences in the component materials comprised in the particle. As an example, a particle comprising mostly iron oxide is going to be heavier than a particle of the same volume comprising mostly silica oxide. Sorting the solid particles according to size and selecting particles in a predetermined size range for processing thus makes it more efficient to sort the particles according to density, and thereby according to component materials, in the cyclonic particle separator.

[0390] Sorting of particles according to size may for example be done by methods such as sieving or different forms of mechanical screening. Such alternative or additional methods are known in the art.

[0391] As an example, the comminuted particles could be sorted into size ranges comprising particles with a diameter smaller than 50 microns, particles with a diameter between 50 and 75 microns, and particles larger than 75 microns. The particles in each size range could then be processed separately, e.g., by using one cyclonic particle separator to sort particles in each size range.

[0392] The method may also comprise that the comminutor 310 comprises a spinnable shaft 381 and two or more processing chambers 382, separated by segmented plates 383. Each processing chamber 382 comprises a rotor disc 384 attached to the shaft 381 and one or more vortex generators 385 placed in a side wall 386 apex corner of the processing chambers 382. The source material is fed into the comminutor 310, and particles are liberated from the source material by means of a chaotic vortex flow of the source material and the liberated particles generated in the processing chambers 382.

[0393] According to aspects the fluid may comprise a liquid, and solid particles suspended in the liquid, forming a slurry. As an example, the liquid may be water. Asanother example, the liquid may be an oil. The liquid could also be solvent such as ethanol. The slurry could, as an example, consist of 65 to 95 % liquid and 5 to 35 % particles by volume, although other compositions are possible. Suitable slurry compositions may be found through routine experimentation. According to other aspects, the fluid may comprise a gas and solid particles suspended in the gas. According to one example, the gas may be air. According to another example, the gas may be an inert gas. Generally, the purpose of the fluid is to carry the solid particles through the cyclonic particle separator. As such, it may be necessary to choose the fluid to ensure that the heavier particles have sufficient buoyancy in the fluid to be carried along. The buoyancy depends on the difference in weight between the particle and an amount of fluid of the same volume. Using a liquid may thus be advantageous for heavier particles consisting e.g., of metal oxides, while a gas may be sufficient for the lighter particles consisting e.g., of plastic or char according to the invention.

[0394] The method may also comprise, prior to feeding 402 the slurry into the cyclonic particle separator, mixing the solid particles with liquid to form the slurry. Methods and devices for mixing solid particles and a liquid to form a slurry are known in the art.

[0395] According to aspects, the solid particles may comprise waste material from a process in which minerals are extracted from an ore. If the extraction method relies on smelting this waste material can take the form of dross, i.e. , lighter impurities floating on top of the molten ore or suspended within it, or slag, which is generally a glasslike substance comprising silica and metal oxides. If the process in which minerals are extracted from an ore is hard rock mining, the waste material could be tailings. The solid particles may also comprise waste material from coal mining processes, such as coal fines.

[0396] According to other aspects, the solid particles may comprise recycled materials, for example recycled packaging made from metal, paper, and plastic. According to yet other aspects, the solid particles may comprise food products.

[0397] The method, or parts of the method, may be executed by one or more control units arranged to control the cyclonic particle separator, the comminution reactor 310, or any mixing apparatus 402 or apparatus 402 for feeding a fluid into a container comprised in the system.

[0398] Optionally, the system may also comprise a mixing apparatus 402 for mixing the comminuted particles with a fluid such as a liquid or a gas prior to processing in the cyclonic particle separator. The system may further comprise an apparatus 402 for feeding the fluid comprising the solid particles into the cyclonic particle separator.

[0399] As described above, one embodiment of the present disclosure provides a method for processing a fluid comprising solid particles. Specifically, the method is performed using a comminutor and cyclonic particle separator as described herein. For example: the cyclonic particle separator comprises a rotor, at least one electromagnetic coil and / or at least one ultra-sound generator, and a main chamber, where the main chamber comprises one or more sections of non-conducting material; and the comminutor comprises a rotor, a plurality of segmented plates, and a plurality of vortex generators.

[0400] The method comprises: generating the solid particles comprised in the fluid by comminuting a source material in a comminutor; feeding the fluid into the cyclonic particle separator; inducing a rotation of the fluid in the cyclonic particle separator chamber by the rotor; and vibrating the solid particles by either (a) using the electromagnetic coil to generate a pulsed magnetic field, and / or (b) using the ultrasound generator to generate a pulse in the particle separator in connection to the one or more sections of non-conducting material, thereby liberating the solid particles from each other.

[0401] Preferably, the liberated solid particles comprise liberated products. For example, the method further comprises outputting, or otherwise extracting, one or more liberated products. Therefore, the method for processing a fluid comprising solid particles comprises a method for generating, liberating, or extracting liberated products from a source material. The skilled person will understand that the fluid optionally comprises air, such that a fluid comprising solid particles is one or more solid or liquid materials in air, and hence the source material is optionally the one or more solid materials.

[0402] For example, the method is suitable for any of the following: the source material comprises vegetable matter and the liberated product comprises starch and / or protein;the source material comprises clothes, clothing, fabric, or clothing fabric and the liberated product comprises cotton, plastic(s), and / or metal(s); or the source material is associated with wind turbine blades, e.g. the source material comprises a section of a wind turbine blade, and the liberated product comprises epoxy and / or glass fiber.

[0403] Further non-limiting examples of source materials include any of:Food stuffs or organic matter, e.g. Alfalfa, Algae, barley, beans, Blueberry, Broccoli, BSG, Buckwheat, Cahoun Nut, Carob, Cheese, Chia, Chickpeas, Cinnamon, Cocoa, Cocoa (press cake), Coffee, Coffee beans, Cohune, Corn, Com (protein), Com leaf (seroctin), Cranberry, Date Culls, DDGS, Echinacea, Field beans, Flax, Flax Seed, Ginseng, Grape, Grapes (seeds, skin), Hemp, Hemp Seeds, Hemp Stalk, Kava Kava, Larch Tree (chips), Lentils, Lupins, Malt (grains), Mesquite, Mushrooms, Nutmeg, Oats, OSG, Palmetto, Peanuts (dry roasted, raw, skins), Peas, Pepper coms, Quinoa, Rapeseed, Red Beans, Rice (whole brown, protein, white, Rice Hull (ash), Rye, Saw Palmetto, Sesame, Soy Beans (whole, protein powder), St. John Wort, Straw, Sugar, Sugar Cane, Sunflower, Tea (black, green), Walnut shells, Walnuts, Wheat, Wheat (whole), celecoxib (Celebrex), Creatine, Lesstanol or Policosanol, Loxoprofen sodium, HGH complete, or Phystosterol;Minerals or materials, e.g. Alunite, Arizona Black Sand, Copper ore, Copper slag, Gypsum, Mica, Oil Shale, Talc, Trona, or Various crude ores;Chemical materials or compounds, e.g. Ammonium Bicarbonate, Ammonia Sulfate, Calcium Citrate, Cement (clinker), Char, Graphite (carbon), Magnesium Citrate, Melamine Cyanurate, MonoAmmoniumPhosphate, Needle Coke, Polyacrylamide, Potassium Persulfate, Sodium Benzoate, Sodium Bicarbonate, Sodium Chloride, Sodium Triphosphate, or Titanium Dioxide;Recyclable materials, e.g. Aluminum Cans UBC, Aluminum Punch Outs, Aluminum Dross, Aluminum Siding (sized), Asphalt Shingles, Laminated Automotive Glass, Char or carbon (burned tires), Crtscreens, Hemp Fabric, High Grade Circuit Boards, Recycle Refrigerator Fractions, Glass Flakes, Hydraulic Hose, Injet Pellets, Lunar Dust simulant, Polyetherether Ketone(PEEK), PVC Plastic, Polycarbonate, Poly Rope, Polyethermide, Rubber Tread, Rubber Tires (radial), Titanium Dioxide, Wollastanite, or Vestowax; and / orOther material comprising desired solid particles for liberation, e.g. Amino Acid cake, Antler (deer), Crab Shells, Diatoms, Mussels (dry), Pink Salmon Fish Waste, or Shark Cartilage.

[0404] The above materials listed are examples and the methods, systems, and hence apparatus described herein are not limited to any of the above.

[0405] For example, the cyclonic particle separator 200 and comminutor 310 are operated in a series as shown in Figure 12. Optionally, either cyclonic particle separator 200 or comminutor 310 operate independently, e.g. both a cyclonic particle separator 200 and a comminutor 310 are not required. Further optionally, multiple comminutors 310 are operated in a series, in parallel, or as a hybrid series / parallel configuration. Any further or prior disclosure of comminutor 310 should therefore be understood to be applicable to a plurality of comminutors 310.

[0406] Figure 12 comprises one or more separators, e.g. cyclonic particle separator 200, and a plurality of comminutors 310, optionally operating in a series configuration. A source material 623 is input to one or more comminutors 310, where the output is preferably input to a further comminutor 310. The solid particles output from comminutors 310 and / or separators comprise liberated product 625. The liberated product is optionally further separated to extract or sort one or more desired substances from the liberated product 625. For example, source material 623 comprising plant matter such as legumes is input to the comminutor 310. Protein concentrate is formed as protein is liberated from the source material 623, and the solid particles 624 and / or liberated product 625 comprise protein (e.g. liberated product 625a) and broken-down fibrous mass (e.g. liberated product 625c). The protein, e.g. for pea protein concentrate, is therefore extracted from the source material using one or more comminutors 310 or separators. For example, the pea protein concentrate is then added to fibres, e.g. fibres from spent wheat or other suitable food mass or organic matter, to form a texturized protein product.

[0407] According to an additional or alternative embodiment, the comminutor comprised in any of the systems or methods described above may be a comminutor as described in relation to Figures 9A-D.

[0408] Figures 9A-D illustrate system architecture diagrams for the comminutor 310 and rotor(s) 384. Specifically, Figure 9B shows comminutor 310 according to embodiments disclosed herein and Figures 9C-D show rotors 384 within comminutor 310 according to embodiments disclosed herein. The disclosure of Figures 9A-D are optionally applied to any of the above disclosure in relation to Figure 9A or where reference is otherwise made to comminutor 310.

[0409] Figures 9A-D comprise comminutor 310, which further comprises a spinnable shaft 381 and two or more processing chambers 382 (not labelled here), separated by segmented plates 383. Each processing chamber 382 comprises a rotor disc 384 attached to the shaft 381 and one or more vortex generators 385 placed in a side wall 386 apex corner of the processing chambers 382. A vortex generator 385 comprises either first flow generator portions 506A and 506B or a second flow generator 507. The source material is fed into the comminution 310 via entrance opening 371 , as shown by entry flow 501 , and particles are liberated from the source material by means of a chaotic vortex flow of the source material. The liberated products are generated in the processing chambers 382, and the liberated products are extracted or otherwise output from comminutor 310 via exit opening 502, as shown by exit flow 503.

[0410] According to one embodiment, the comminutor 310 is an example of an improved Librixer comminutor. During operation, a mixture of source material and fluid, e.g. air or mixing fluid, enters an entrance opening 371 of the comminutor 310. In the first upper of two or more vertical processing chambers 382, the mixture is spun outwards and will create a circular source material curtain restrained by the polygon shaped walls. The source material curtain spins in either a clockwise or a counterclockwise direction initiated by the vertical rotor assembly consisting of as many rotors 384 as there are processing chambers 382.

[0411] One or more, or preferably all, processing chambers 382 are configured such that the rotor 384 is closer to the upper segmented plate 383, i.e. the segmented plate 383 above the rotor 384, and further from the lower segmented plate 383, i.e. the segmented plate 383 below the rotor 384, as shown in Figure 9B. Beneficially, positioning the rotor 384 closer to the upper segmented plate 383 results in a high pressure flow 504 above the rotor 384 and a low pressure flow 505 below the rotor 384, e.g. respective to average pressure within the comminutor 310. Therefore, thespeed and flow of material through the comminutor 310 is increased, which not only decreases the time taken for materials to be liberated, but also increases the efficiency of liberation, and comminutor 310 is capable of liberating a wider and more diverse range of materials in comparison to a typical Librixer-based comminutor.

[0412] For example, source material within comminutor 310 is in optimal dispersion for a cyclonic flow due to the above-described positioning of rotor 384 relative to upper and lower segmented plates 382, such that airflow is used to separate or otherwise liberate components or other solid particles of the source material. In a further example, a first distance between the upper segmented plate 383 and the rotor blade 384, shown as distance A in Figure 9B, is less than a second distance between the lower segmented plate 383 and the rotor blade 384, shown as distance B in Figure 2.

[0413] Furthermore, a traditional Librixer-based comminutor, where the rotor 384 is placed approximately centrally between segmented plates 383, often generates turbulent flow between the rotor 384 and upper segmented plate 383, which slows down the material flow and decreases efficiency. Comminutor 310 as described herein does not generate such turbulent flows, and hence results in further increases to speed and efficiency over traditional Librixer-based comminutors.

[0414] The source material flow is preferably restrained by an odd number of flat wall segments of side wall 386, as shown in Figures 9C-D. In one or more apex comers, or preferably each apex corner, i.e. between two flat wall segments, a vortex generator 385 is placed setting up two small vortexes counter to the main flow. The main source material flow curtain interacts with these smaller vortexes consisting of a fluid, e.g. air, and source material in such way that brittle materials are stressed apart along natural boundaries. More flexible materials or fractions of a material, such as fibers, tend to go through relatively un-harmed.

[0415] According to one embodiment, the vortex generator 385 comprises first flow generator 506 (not labelled), comprising a first flow generator portion 506A and a first flow generator portion 506B, as shown in Figure 9C. First flow generator portions 506A and 506B are configured to operate together to manipulate how material flow interacts with the smaller vortexes. First flow generator portion 506A is configured to direct material flow towards the apex corner, resulting in a high pressure flow, e.g. increasing the material flow speed. First flow generator portion 506B is configured to directmaterial towards the rotor 384, resulting in a low pressure flow 505, e.g. decreasing the material flow speed. Beneficially, directing material flow using first flow generator 506 results in fewer blockages and improved flow. While other vortex generators 385 can result in blockages and creation of unwanted heat, first flow generator 506 prevents such inefficiencies and energy loss. Theref...

Claims

PATENT CLAIMS1. A method for producing gas or biochar from municipal solid waste (MSW), the method comprising: controlling the humidity of an MSW feed comprising carbonaceous material to be within a predefined humidity range, thereby generating a humidity controlled MSW feed, by: adding water or steam to increase humidity of the MSW feed; or drying the MSW feed to decrease humidity; producing a raw pyrolysis gas and a carbonaceous rest by introducing the humidity controlled MSW feed into a unit for pyrolysis, wherein at least a bottom part of the unit for pyrolysis is heated; introducing the carbonaceous rest and steam into a cracking unit configured to crack the carbonaceous rest, thereby producing a further gas and a further carbonaceous rest; introducing the further carbonaceous rest from the cracking unit into the bottom part of the unit for pyrolysis; and separating or cleaning output from the unit for pyrolysis, resulting in hydrogen gas or other combustible gas, hydrocarbon oil, or produced char.

2. The method of claim 1 , wherein the MSW is sorted such that the MSW feed of MSW comprises a desired quantity of carbonaceous material.

3. The method of claim 1 or 2, wherein introducing the further carbonaceous rest from the cracking unit into the bottom part of the unit for pyrolysis results in remaining carbonaceous rest, and the remaining carbonaceous rest is introduced into a further unit arranged downstream or in parallel to the cracking unit or unit for pyrolysis.

4. The method of claim 3, wherein the further unit comprises: a further unit of pyrolysis, and remaining carbonaceous rest is introduced into the bottom part of the further unit of pyrolysis; or a further cracking unit, and remaining carbonaceous rest is introduced into the part of the further cracking unit near where steam is injected.

5. The method of any preceding claim, wherein carbonaceous rest comprises solid or liquid carbonaceous rest.

6. The method of any preceding claim, wherein produced char is cooled using a cooling unit.

7. The method of claim 6, further comprising controlling produced char for VOC contamination, wherein produced char without VOC contamination is separated from produced char contaminated with VOC.

8. The method of claim 7, wherein produced char contaminated with VOC is separated according to size, such that at least one larger char particle size part is associated with less VOC contamination in comparison to at least one smaller char particle size part.

9. The method of claim 8, wherein produced char contaminated with VOC is separated according to weight sequentially or in parallel to separation according to size.

10. The method of any of claims 7-9, wherein produced char is regenerated by thermal regenerating or solvents for desorbing VOC from produced char contaminated with VOC, resulting in clean biochar.11 . The method of any of any preceding claim, further comprising: sorting the MSW into at least two groups of MSW, each group of MSW associated with different calorific value with respect to combustion; and combining the MSWfrom one or more groups of the at least two groups of MSW, such that the MSW feed is associated with a stable calorific value over a time period.

12. The method of any of any preceding claim, further comprising: sorting the MSW into at least two groups of MSW, each group of MSW associated with different types of source material; and combining the MSWfrom one or more groups of the at least two groups of MSW, such that the MSW feed is associated with a stable composition over a time period.

13. The method of claim 11 or 12, wherein sorting or combining the MSW is performed using one or more feeders and based on weight data of the MSW.

14. The method of claim 13, wherein the one or more feeders comprise belts or rotating conveyors associated with variable speed controllers, such that controlling speed of the one or more feeders controls the calorific value or the composition of the MSW feed over the time period.

15. The method of any preceding claim, further comprising autoclaving the MSW feed.

16. The method of any preceding claim, further comprising: subjecting the MSW feed to torrefaction; and pelletizing the MSW feed.

17. The method of any preceding claim, wherein the predetermined humidity range is:10-30% humidity content by weight;15-25% humidity content by weight; or approximately 20% humidity content by weight.

18. The method of any preceding claim, wherein the unit for pyrolysis or catalyst unit comprises a catalyst, and the method further comprises reforming or replacing the catalyst.

19. The method of claim 18, wherein the catalyst is reformed or replaced: periodically with respect to operation time; or based on a measured functionality of the catalyst.

20. The method of claim 18 or 19, wherein reforming or replacing comprises: taking out the catalyst through an opening for catalyst removal in the unit for pyrolysis or catalyst unit; and introducing a reformed catalyst or new catalyst into the unit for pyrolysis or catalyst unit.

21. The method of any of claims 18-20, wherein the catalyst is reformed using steam or cleaning liquid.

22. The method of any preceding claim, wherein the unit for pyrolysis or catalyst unit is operated at approximately atmospheric pressure.

23. The method of any preceding claim, wherein hydrogen gas is extracted from the top part or near the top part of the unit for pyrolysis.

24. The method of claim 23, wherein hydrogen gas is extracted to maintain an operation pressure of the unit for pyrolysis.

25. The method of any preceding claim, wherein the unit for pyrolysis comprises one or more reactors.

26. A unit for pyrolysis or cracking configured for use in the method of any preceding claim, wherein the unit comprises: an inner wall and an outer wall, thereby providing a double wall configuration, such that there is a volume between the inner wall and the outer wall; wherein the inner wall and the outer wall is dimensioned for an operating pressure and temperature of the unit; wherein the volume comprises at least one gas that is not hydrogen or oxygen; and at least one sensor for detecting leakage of the at least one gas communicatively coupled to a control and safety system.

27. The unit of claim 26, wherein the at least one gas comprises an inert gas, nitrogen, or carbon dioxide.

28. The unit of claim 26 or 27, wherein the volume is at overpressure relative to a process pressure inside the inner wall, thereby providing tension to the inner wall.

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