Continuous recycling apparatus and related methods for decomposing solid-phase carbon-containing compositions

Abstract

A continuous-process apparatus having: a first decomposition chamber; a conveyor assembly configured to continuously transport solid-phase carbon-containing compositions from a first location outside of the first decomposition chamber to a second location inside of the first decomposition chamber; a first inert-gas assembly configured to saturate the first decomposition chamber with an inert gas; a first microwave generator configured to generate microwaves having a frequency ranging from 900 MHz to 930 MHz and having a power rating ranging from 90 to 110 kW; a first wave-guide assembly configured to guide microwaves generated by the first microwave generator from the first microwave generator into the first decomposition chamber; a solid-phase fluid-flow blocking component positioned within the first wave-guide assembly, wherein the solid-phase fluid-flow blocking component blocks fluid flow from occurring within the first wave-guide assembly; a first gas-phase-emissions collection assembly configured to collect gas-phase emissions from the first decomposition chamber; a second decomposition chamber that is releasably attached to the first decomposition chamber; and a third decomposition chamber that is releasably attached to the second decomposition chamber.

Description

[0001] TITLE OF THE INVENTION

[0002] Continuous Recycling Apparatus and Related Methods for Decomposing Solid-Phase Carbon-Containing Compositions

[0003] CROSS REFERENCE TO RELATED APPLICATIONS

[0004] This patent application claims priority to pending U.S. provisional patent application 63 / 764,811 filed on 2 / 28 / 2025 and titled, “Continuous Recycling Apparatus and Related Methods for Decomposing Solid-Phase Carbon-Containing Compositions.” The subject matter of U.S. provisional patent application U.S. 63 / 764,811 is incorporated by reference into this application. This patent application also claims priority to pending U.S. provisional patent application 63 / 764,788 filed on 2 / 28 / 2025 and titled, “Continuous Recycling Apparatus and Related Methods for Decomposing Solid-Phase Carbon-Containing Compositions.” The subject matter of U.S. provisional patent application U.S. 63 / 764,788 is incorporated by reference into this application.

[0005] This patent application also claims priority to pending U.S. provisional patent application 63 / 764,826 filed on 2 / 28 / 2025 and titled, “Continuous Recycling Apparatus and Related Methods for Decomposing Solid-Phase Carbon-Containing Compositions.” The subject matter of U.S. provisional patent application U.S. 63 / 764,826 is incorporated by reference into this application.

[0006] BACKGROUND OF THE INVENTION

[0007] There remains a need for improved safety and efficiency of a continuous-recycling apparatus that recycles polymeric carbon-containing compositions, e.g., shredded vulcanized rubber from used automotive tires, by decomposing the polymeric carbon-containing compositions into reusable products such as:

[0008] i) carbon-black particulates (that can be reused in automotive-tire manufacturing), ii) oil, andiii) syngas.

[0009] BRIEF SUMMARY OF THE INVENTION

[0010] A continuous-process apparatus having: a first decomposition chamber; a conveyor assembly configured to continuously transport solid-phase carbon-containing compositions from a first location outside of the first decomposition chamber to a second location inside of the first decomposition chamber; a first inert-gas assembly configured to saturate the first decomposition chamber with an inert gas; a first microwave generator configured to generate microwaves having a frequency ranging from 900 MHz to 930 MHz and having a power rating ranging from 90 to 110 kW; a first wave-guide assembly configured to guide microwaves generated by the first microwave generator from the first microwave generator into the first decomposition chamber; a solid-phase fluid-flow blocking component positioned within the first wave-guide assembly, wherein the solid-phase fluid-flow blocking component blocks fluid flow from occurring within the first wave-guide assembly; a first gas-phase-emissions collection assembly configured to collect gas-phase emissions from the first decomposition chamber; a second decomposition chamber that is releasably attached to the first decomposition chamber; and a third decomposition chamber that is releasably attached to the second decomposition chamber.

[0011] In an apparatus that continuously recycles used-tire shreds using microwave pyrolysis, and to decrease the probability of a harmful explosion while microwave pyrolysis is being conducted, there remains a need for improved safety features and systems. More specifically, upon the occurrence of a light-generating event, e.g., a spark within a chamber in which microwave pyrolysis is being conducted, that could cause an explosion resulting in the loss of human life, a more efficient and fail-safe system for preventing continued introduction of microwaves into a microwave-pyrolysis chamber is needed. Currently, the only known method for preventing or ceasing the continued introduction of microwaves into a microwave-pyrolysis chamber is to turn off a microwave generation unit(s)- thereby ceasing the generation of microwaves (that would otherwise enter a microwave-pyrolysis chamber).

[0012] Inventive embodiments are provided herein that can be used alone or in combination to prevent the continued introduction of microwaves into a microwave-pyrolysis chamber upon theoccurrence of a light-generating event within a microwave-pyrolysis chamber- and relative to currently known methods, decrease the probability of an explosive event during operation of the continuous recycling apparatus.

[0013] Furthermore, in an apparatus that decomposes (and thereby recycles) a continuous feed stream of used-tire shreds using microwave pyrolysis, and to better improve the processing efficiency of decomposing the used-tire shreds, there remains a need to dynamically alter the cross-sectional thickness (or cross-sectional height) of the continuous feed stream of used-tire shreds while the used-tire shreds are within, and travelling through, a microwave-pyrolysis decomposition chamber. If a continuous feed stream of used-tire shreds has a cross-sectional thickness that is too thick or too thin relative to the required thickness to achieve maximum decomposition efficiency within a microwave-pyrolysis chamber, then maximum decomposition efficiency cannot be achieved. Currently there is no known method for dynamically altering the cross-sectional thickness of a continuous feed stream of used-tire shreds within a microwave-pyrolysis decomposition chamber or series of microwave-pyrolysis decomposition chambers. Inventive embodiments are provided that enable dynamic changing the cross-sectional thickness of a continuous feed stream of used-tire shreds while the continuous feed stream of used-tire shreds is conveyed through a microwave-pyrolysis decomposition chamber or series of microwavepyrolysis decomposition chambers.

[0014] There remains a need for an apparatus, which continuously recycles used-tire shreds using microwave pyrolysis, having at least one modularized decomposition-chamber unit attached to an exit end of a main or first decomposition unit. Currently, the only known apparatus for conducting continuous microwave-pyrolysis processing of a feed stream of used-tire shreds does not have this arrangement or capability. The advantages of this inventive configuration, z.e., of at least two stand-alone microwave-pyrolysis decomposition-chamber units connected in series, include: i) improved speed of maintenance due to the ability to simply replace an improperly performing microwave-pyrolysis decomposition-chamber unit with a new unit, and ii) the ability to introduce a plurality of decomposition units in series to arrive at the most efficient number of microwave-pyrolysis decomposition-chamber units needed to achieve decomposition of the continuous stream of solid-phase subject matter being decomposed.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0015] Fig. l is a sectional side view of an embodiment.

[0016] Fig. 2 is a sectional side view of an embodiment.

[0017] Fig. 3 is a sectional side view of an embodiment.

[0018] Fig. 4 is a sectional side view of an embodiment.

[0019] Fig. 5 is a sectional side view of an embodiment.

[0020] Fig. 6 is a sectional side view of an embodiment.

[0021] Fig. 7 is a sectional top view of an embodiment.

[0022] Fig. 8 is a sectional top view of an embodiment.

[0023] Fig. 9 is a sectional top view of an embodiment.

[0024] Fig. 10 is a schematic of a continuous feed-stream path of solid-phase compositions.

[0025] Fig. 1 la is a side view of an embodiment of an arrangement of first conveyor belt 302 and second conveyor belt 304 within decomposition chamber 200.

[0026] Fig. 11b is a side view of an embodiment of an arrangement of first conveyor belt 302 and second conveyor belt 304 within decomposition chamber 200.

[0027] Fig. 12a is a perspective view of an embodiment of microwave-blocking louvered vent 902 having louvers 904 in a closed-louvers position to thereby block microwaves.

[0028] Fig. 12b is a perspective view of an embodiment of microwave-blocking louvered vent 902 having louvers 904 in an open-louvers position to thereby allow microwaves to pass through louvered vent 902.

[0029] Fig. 13a is a perspective view of an embodiment of microwave-venting louvered vent 906 having louvers 904 in an open-louvers position to thereby allow blocked microwaves to vent from continuous recycling apparatus 100.Fig. 13b is a perspective view of an embodiment of microwave-venting louvered vent 906 having louvers 904 in a closed-louvers position to thereby prevent microwaves to venting from continuous recycling apparatus 100.

[0030] Fig. 14 illustrates an embodiment of a computing system configured with the example systems and / or methods disclosed, including control circuitry that controls operations of various components of the apparatus described herein.

[0031] Fig. 15 is a schematic showing an embodiment of modularized decomposition-chamber unit. Fig. 16 is a schematic showing a cross-sectional side view of a fluid-flow blocking component within a section of a waveguide assembly.

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] The teachings of U.S. 11,111,439 Bl are incorporated by reference into this patent-application specification.

[0034] Embodiments are directed to an apparatus configured to process a continuous feed stream of polymeric solid-phase carbon-containing compositions, e.g., chunks of shredded vulcanized rubber generated from used automotive tires. During processing, the continuous feed-stream compositions are decomposed and thereby transformed into the following reusable products: i) carbon-black particulates,

[0035] ii) oil, and

[0036] iii) a combustible liquid fuel source, e.g., gasoline or diesel fuel.

[0037] Very generally, continuous processing of the feed-stream compositions is achieved by employing a conveyor assembly that continuously transports a feed stream of polymeric solid-phase carbon-containing compositions, i.e., chunks of shredded used automotive tires, into and through a microwave-pyrolysis decomposition chamber. These chunks of shredded vulcanized rubber include both polymeric and non-polymeric components, i.e., a polymeric vulcanized rubber component and a non-polymeric carbon-black component. Upon entering the microwavepyrolysis decomposition chamber, decomposition and depolymerization begins.Depolymerization can be understood as occurring when the depolymerized molecules break away from a solid-phase composition and directly enter the gas phase- thereby forming a gasphase composition (made up of the depolymerized molecules) within a decomposition chamber. This gas-phase composition is then captured using a gas-phase-emissions collection assembly, condensed to form a liquid, and then separated (using known separation methods) to create the second and third reusable products identified above, i.e.,

[0038] ii) oil, and

[0039] iii) a combustible fuel source, e.g., gasoline or diesel fuel.

[0040] After the depolymerized molecules are no longer part of the chunks of shredded used automotive tires (i.e., used-tire shreds), what remains of the shredded used automotive tires is a carbon-black composition- carbon-black particulates having a rigid texture. These are the first of the reusable products identified above, i.e.,

[0041] i) carbon-black particulates.

[0042] With reference to both the figures and general understanding provided above, continuous recycling apparatuslOO (or apparatus 100) includes conveyor assembly 300 that is configured to continuously transport a stream of polymeric solid-phase carbon-containing compositions, e.g., used-tire shreds (that are chunks of used automotive tires), from outside of, into, and through the length of decomposition chamber 200. As a feed stream of used-tire shreds are continuously conveyed through decomposition chamber 200 using both first conveyor belt 302 and second conveyor belt 304, both of which are at least partially within decomposition chamber 200, used-tire shreds are decomposed or depolymerized while travelling through decomposition chamber 200.

[0043] Decomposition or depolymerization is achieved via microwave pyrolysis that occurs within decomposition chamber 200 using microwaves generated by microwave generator(s) 600 and guided into decomposition chamber 200 by wave-guide assembly 700. As shown in Fig 1, decomposition chamber 200 has three microwave-point-of-entry locations 708 at which microwaves are introduced into decomposition chamber 200 from wave-guide assembly 700. In embodiments, microwave generator(s) 600 are configured to generate microwaves having a frequency ranging from 900 MHz to 930 MHz and having a power rating ranging from 90 to 110kilowatts (kW). Inert-gas assembly 500 is configured to introduce an inert gas into decomposition chamber 200 via inert-gas introduction orifice(s) 502; in embodiments, inert-gas assembly 500 saturates decomposition chamber 200 with an inert gas so as to eliminate oxygen or ambient air from being within decomposition chamber 200. Operation of one or more of the components of the apparatus 100, such as conveyor assembly 300, gas assembly 500, microwave generator 600, wave-guide assembly 700, microwave-blocking assembly 900, for example, can be controlled by control circuitry, optionally implemented as a computing device 1400 described with reference to Fig. 14.

[0044] In embodiments, and as shown in Fig. 16, which is a sectional view of microwaves 602 passing through wave-guide assembly 700, fluid-flow blocking component 702 allows microwaves 602 to pass through wave-guide assembly 700 while at the same time blocking fluid flow, such as gas-phase fluid flow, within wave-guide assembly 700. By blocking fluid flow within waveguide assembly 700, fluid-flow blocking component 702 prevents gas-phase composition from travelling from decomposition chamber 200 into microwave generator 600. As a non-limiting example, a useful fluid-flow blocking component 702 can be manufactured from quartz.

[0045] Decomposition or depolymerization that occurs within decomposition chamber 200 transforms used-tire shreds into carbon-black particulates. As the solid-phase compositions are transformed within decomposition chamber 200, conveyor assembly 300 is configured to continuously convey the remaining decomposed solid-phase compositions, e.g.. the carbon-black particulates that remain after decomposition or depolymerization, out of decomposition chamber 200 and into carbon-black-particulate accumulation container orbin 1300.

[0046] To achieve continuous conveyance of solid-phase compositions, and as displayed in the path shown in the Fig. 10 schematic, conveyor assembly 300 includes a plurality of conveyor components arranged to work in coordination to transport solid-phase compositions, e.g., used-tire shreds, from first location 400 outside of decomposition chamber 200, i.e., first location 400 being shredded-rubber feed-stock bin 400, to second location 402 that is inside of decomposition chamber 200, and then after passing through the length of decomposition chamber 200, to third location 404 outside of decomposition chamber 200, e.g., third location 404 can be understood to be carbon-black-particulate accumulation chamber or bin 1300.In embodiments, and as shown in the figures, auger-driven conveyer component 301 is configured to continuously convey a stream of shredded and granular solid materials, e.g., used-tire shreds, from shredded-rubber feed-stock bin 400 to inclined conveyor component 312.

[0047] Inclined conveyor component 312 is configured to receive a stream of shredded and granular solid materials from auger-driven conveyer component 301 and continue to continuously convey the stream of shredded and granular solid materials to first conveyor-belt component 302 within decomposition chamber 200. As shown in Figs. Ila and 11b, first conveyor belt 302 is configured to receive a stream of shredded and granular solid materials from inclined conveyor component 312 and continue to continuously convey the stream of shredded and granular solid materials to second conveyor belt 304. Second conveyor belt 304 is configured to receive a stream of shredded and granular solid materials from first conveyor belt 302 and continue to continuously convey the stream of shredded and granular solid materials through an exit from decomposition chamber 200 and to third location 404, e.g., carbon -black-particulate accumulation chamber or bin 1300. In embodiments, after exiting decomposition chamber 200 on second conveyor belt 304, carbon-black particulates fall or gravity feed from second conveyor belt 304 into carbon-black-particulate accumulation container or bin 1300.

[0048] Within decomposition chamber 200, a continuous feed stream of shredded and granular solid compositions, e.g., used tire shreds, can be understood to be a collection of shredded and granular solids piled on top of one another. Because of this, a continuous feed stream of shredded and granular compositions has a cross-sectional height and a cross-sectional width-both of which are perpendicular to the feed stream’s direction of travel. “Height” and “width” should be understood to have their conventional meanings. For ease of explanation, a feedstream cross-sectional “height” can also be understood to be a feed-stream cross-sectional “thickness.”

[0049] In embodiments, and as shown in Fig. Ila and Fig. lib, first conveyor belt 302 and second conveyor belt 304, both of which are at least partially located within decomposition chamber 200, enable altering a feed stream’s cross-sectional height or cross-sectional thickness from a first feed-stream cross-sectional thickness on first conveyor belt 302 to a second feed-stream cross-sectional thickness on second conveyor belt 304 (while the feed stream continuously travels through decomposition chamber 200). In embodiments, conveyor assembly 300 isconfigured to enable the feed-stream cross-sectional second thickness to be changed to a greater or lesser thickness than the feed-stream cross-sectional first thickness.

[0050] In an embodiment, and as shown in Fig. Ila and Fig. 11b, first conveyor belt 302 is positioned relative to second conveyor belt 304 to enable a continuous feed stream of shredded and granular solid compositions to fall or gravity feed from first conveyor belt 302 onto second conveyor belt 304; Fig. 1 lb teaches an embodiment that employs conveyor-belt transition slide 305 and Fig. Ila does not. In view of this relative configuration of conveyor belts 302 and 304, embodiments allow for first conveyor belt 302, second conveyor belt 304, or both conveyor belts to be a variable-speed conveyor belt 306. By creating a speed differential between first and second conveyor belts 302, 304, a feed stream’s cross-sectional thickness on second conveyor belt 304 will necessarily be different than the feed stream’s cross-sectional thickness on first conveyor belt 302. If the speed of second conveyor belt 304 is greater than that of first conveyor belt 302, then the feed stream’s cross-sectional thickness on second conveyor belt will be less than that of the feed stream’s cross-section thickness on first conveyor belt 302. Likewise, if the speed of conveyor belt 302 is less than that of first conveyor belt 302, then the feed stream’s cross-sectional thickness on second conveyor belt will be greater than that of the feed stream’s crosssection thickness on first conveyor belt 302.

[0051] Embodiments allow for changing the speeds of one or more of the variable-speed conveyor belts, i.e., first conveyor belt 302, second conveyor belt 304, or both, to achieve a desired cross-sectional thickness of the feed stream on second conveyor belt 304. Changing a feed-stream cross-sectional thickness within decomposition chamber 200 enables creating feed-stream cross-sectional thicknesses that result in improved microwave-pyrolysis decomposition efficiency(s). Still other embodiments allow for a plurality of, e.g., three or more, variable-speed conveyor belts 306 that are similarly configured to be used within decomposition chamber 200. These plurality-of-variable-speed-conveyor-belts embodiments allow for even more control over a feed stream’s cross-sectional thickness on any particular conveyor belt within decomposition chamber 200.

[0052] Additional embodiments are directed to light-sensing assembly 800 that is configured to emit a signal upon sensing visible light, e.g., using a photodiode, within decomposition chamber 200, wherein a light-having-been-sensed signal emitted by light-sensing assembly 800 is received bymicrowave-blocking assembly 900 that, upon receiving the emitted signal, causes microwaveblocking assembly 900 to perform a mechanical action that results in blocking microwaves generated by microwave generator 600. In embodiments, microwave blocking assembly 900 has at least one louvered vent having rotatable louvers 902 positioned within wave-guide assembly 700, along microwave transmission path between microwave generator 600 and decomposition chamber 200. Louvered vent having rotatable louvers 902 has a first open-louvers “microwaves-pass-through” position, illustrated in FIG. 12b, in which one or a plurality of louvers 904 or other adjustable partition allows microwaves to pass through the louvered vent 902 and continue to travel through wave-guide assembly 700 and into decomposition chamber 200. Louvered vent having rotatable louvers 902 also has a second closed-louvers “microwaves-are-blocked” position, illustrated in FIG. 12a, in which one or a plurality of louvers 904 or other adjustable partition are oriented to block microwaves from passing through louvered vent having rotatable louvers 902. The position and / or orientation of louvers 904 can be controlled as described herein through operation of computing device 1400 to selectively interrupt transmission of microwaves to decomposition chamber 200 responsive to detection of a light-generating event. For example, computing device 1400 can, in response to transmission of light-having-been-sensed signal emitted by light-sensing assembly 800, adjust louvers 904 from the open-louvers “microwaves-pass-through” position, illustrated in FIG. 12b, to the closed-louvers “microwaves-are-blocked” position, illustrated in FIG. 12a.

[0053] In an embodiment, louvered vent 902 has a spring-driven or tension element that causes louvered vent 902 to naturally rest in the first open-louvers “microwaves-pass-through” position, i.e., the naturally relaxed position of louvered vent 902 is in the first open-louvers “microwaves-pass-through” position. The second closed-louvers “microwaves-are-blocked” position is arrived at upon an electronic signal forcing louvered vent 902 to rotate its louver(s) into a closed-louvers position.

[0054] In an alternate embodiment, louvered vent 902 has a spring-driven or tension element that causes louvered vent 902 to naturally rest in the second closed-louvers “microwaves-are-blocked” position, i.e., the naturally relaxed position of louvered vent 902 is in the second closed-louvers “microwaves-are-blocked” position. The first open-louvers “microwaves-pass-through” positionis arrived at upon an electronic signal forcing louvered vent 902 to rotate its louver(s) into an open-louvers position.

[0055] In embodiments, one-or-more louvered vents 902 are arranged within wave-guide assembly 700 to effect complete blocking, z.e., prevention, of microwaves from entering decomposition chamber 200. As a non-limiting example, two-or-more louvered vents 902 may be positioned in series within wave-guide assembly 700 as an intentionally designed safety redundancy that contemplates a malfunction of one of the two-or-more louvered vents 902. If such a malfunction occurs, e.g., if one of the two-or-more louvered vents 902 fails to adopt a closed-louvers position upon light-sensing assembly 800 emitting a signal (as a result of sensing visible light within decomposition chamber 200), the remaining two-or-more properly functioning louvered vent(s) 902 will properly function and arrive at a closed-louvers position to thereby successfully block microwaves from entering decomposition chamber 200.

[0056] In additional embodiments, and because blocked microwaves that have been blocked by louvered vent(s) 902 may accumulate within wave-guide assembly 700, microwave-blocking assembly 900 is further configured to open microwave-venting door 906 (also referred to herein a microwave-venting louvered vent 906), the open position being illustrated in FIG. 13a, at substantially the same time that louvered vent(s) 902 arrive(s) at a closed-louvers or “blocking” position. By opening microwave-venting door 906 from a closed-door or closed-vent position, illustrated in FIG. 13b, the otherwise accumulating blocked microwaves are allowed to escape from wave-guide assembly 700 by travelling through microwave-venting door / vent 906 and into water sink 910 (FIG. 5) where microwaves are dissipated as heat into water in water sink 910. Microwave-venting door(s) 906 is positioned within wave-guide assembly 700 downstream from microwave generator 600 and upstream of microwave-blocking louvered vent(s) 902. Persons of ordinary skill in the art will be able identify useful locations of microwave-venting door(s) without having to exercise undue experimentation. In embodiments, microwave-venting door 906 makes up a portion of a wall section of wave-guide assembly 700; while microwave-venting door 906 is in the louvers-closed position, the wave-guide assembly 700 wall section is solid and microwaves are enabled to travel through wave-guide assembly towards, and eventually into, decomposition chamber 200. And while microwave-venting door 906 is in the louvers-openposition, microwaves are enabled to exit from wave-guide assembly 700 and dissipate as heat into water sink 910.

[0057] In embodiments in which microwave-venting louvered vent 906 is a vent having rotatable louvers (versus a door), microwave-venting louvered vent(s) 906 can be understood as being the same kind(s) of louvered vent(s) employed for microwave-blocking louvered vent(s) 902; although the two different louvered vents are used for separate purposes, the functionality of the two separate louvered vents, i.e., microwave-venting louvered vent 906 and microwave-blocking louvered vent(s) 902, may be similarly understood.

[0058] At substantially the same time as a signal is emitted by light-sensing assembly 800 (z.e., upon sensing a light-emitting event within decomposition chamber 200), and microwaves are being blocked by microwave-blocking louvered vent(s) 902, microwave-venting louvered vent(s) 906 assumes an open-louvers position from a closed-louvers position to thereby allow the microwaves that are being blocked to exit wave-guide assembly 700 and dissipate into water sink 910. In embodiments, a signal from light-sensing assembly 802 that causes louvered vent 902 to rotate its louvers into a closed-louvers position and thereby block microwaves from entering decomposition chamber 200, can be the same signal that causes microwave microwave-venting louvered vent(s) 906 to arrive at an open-louvers position that allows blocked microwaves to travel and dissipate into water sink 910.

[0059] Fig. 14 shows a schematic representation of computing device 1400 configured with computerexecutable instructions that, when executed, control performance of one or more of the processes described herein. The exemplary computing device 1400 may be a computer that includes processor 1402, memory 1404, and input / output ports 1406 operably connected to each other by bus 1408. In one example, computing device 1400 may include logic 1410 configured to control operation of one or more of the components of the apparatus 100, such as conveyor assembly 300, gas assembly 500, microwave generator 600, wave guide assembly, microwave-blocking assembly 900, for example. In different examples, logic 1410 may be implemented in hardware, a non-transitory computer-readable medium with stored instructions, firmware, and / or combinations thereof. While logic 1410 is illustrated as a hardware component attached to bus 1408, it is to be appreciated that in other embodiments, logic 1410 could be implemented in processor 1402, stored in memory 1404, or stored in disk 1412.In one embodiment, logic 1410 or computing device 1400 is a means (e.g., structure: hardware, non-transitory computer-readable medium, firmware) for performing the actions described. In some embodiments, computing device 1400 may be a server operating in a cloud computing system, a server configured in a Software as a Service (SaaS) architecture, a smartphone, laptop, tablet computing device, and so on.

[0060] The means may be implemented, for example, as an ASIC (application-specific integrated circuit) programmed to perform the processes described herein. The means may also be implemented as stored computer executable instructions that are presented to computing device 1400 as data 1414 (e.g., process parameters) that are temporarily stored in memory 1404 and then executed by processor 1402.

[0061] Logic 1410 may also provide means (e.g., hardware, non-transitory computer-readable medium that stores executable instructions, firmware) for performing the operations regarding the processes described herein.

[0062] Generally describing an illustrative configuration of computing device 1400, processor 1402 may be a variety of various processors including dual microprocessor and other multi-processor architectures. Memory 1404 may include volatile memory and / or non-volatile memory. Nonvolatile memory may include, for example, ROM, PROM, and so on. Volatile memory may include, for example, RAM, SRAM, DRAM, and so on.

[0063] Components such as light-sensing assembly 800 and storage disk 1412 may be operably connected to computing device 1400 via, for example, input / output (I / O) interface (e.g., card, device) 1406 and input / output port 1406. Disk 1412 may be, for example, a magnetic disk drive, a solid-state disk drive, a floppy disk drive, a tape drive, a Zip drive, a flash memory card, a memory stick, and so on. Furthermore, disk 1412 may be a CD-ROM drive, a CD-R drive, a CD-RW drive, a DVD-ROM, and so on. Memory 1404 can store instructions for execution of a process 1420 and / or data 1414, for example. Disk 1412 and / or memory 1404 can store an operating system that controls and allocates resources of computing device 1400.

[0064] Computing device 1400 may interact with input / output (I / O) devices via I / O interfaces 1416 and input / output ports 1406. Input / output devices may be, for example, a keyboard, a microphone, a pointing and selection device, cameras, video cards, displays, disk 1412, network devices 1418,and so on. Input / output ports 1406 may include, for example, serial ports, parallel ports, and USB ports.

[0065] Computing device 1400 can operate in a network environment and thus may be connected to the network devices 1418 via I / O interfaces 1416, and / or I / O ports 1406. Through network device(s) 1418, computing device 1400 may interact with a network. Through the network, computing device 1400 may be logically connected to remote computers. Networks with which the computing device 1400 may interact include, but are not limited to, a LAN, a WAN, and other networks.

[0066] In one or more embodiments, the disclosed methods or their equivalents are performed by either: computer hardware configured to perform the method; or computer instructions embodied in a module stored in a non-transitory computer-readable medium where the instructions are configured as an executable algorithm configured to perform the method when executed by at least a processor of a computing device.

[0067] While for purposes of simplicity of explanation, the illustrated methodologies in the figures are shown and described as a series of blocks of an algorithm, it is to be appreciated that the methodologies are not limited by the order of the blocks. Some blocks can occur in different orders and / or concurrently with other blocks from that shown and described. Moreover, less than all the illustrated blocks may be used to implement an example methodology. Blocks may be combined or separated into multiple actions / components. Furthermore, additional and / or alternative methodologies can employ additional actions that are not illustrated in blocks.

[0068] The following section’s content includes definitions of selected terms employed herein. These definitions include various examples and / or forms of components that fall within the scope of a term and that may be used for implementation. These examples are not intended to be limiting. Both singular and plural forms of terms may be included within these definitions.

[0069] References to “one embodiment,” “an embodiment,” “one example,” “an example,” and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element orlimitation. Furthermore, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, though it may.

[0070] “Computer-readable medium” or “computer storage medium,” as used herein, refers to a non-transitory medium that stores instructions and / or data configured to perform one or more of the disclosed functions when executed by at least a single processor. Data may function as instructions in some embodiments. A computer-readable medium may take forms, including, but not limited to, non-volatile media or volatile media. Non-volatile media may include, for example, optical disks, magnetic disks, and so on. Volatile media may include, for example, semiconductor memories, dynamic memory, and so on. Common forms of a computer-readable medium may include, but are not limited to, a floppy disk, a flexible disk, a hard disk, a magnetic tape, other magnetic medium, an application specific integrated circuit (ASIC), a programmable logic device, a compact disk (CD), other optical medium, a random access memory (RAM), a read-only memory (ROM), a memory chip or card, a memory stick, solid-state storage device (SSD), flash drive, and other media from which a computer, a processor or other electronic device can function with. Each type of media, if selected for implementation in one embodiment, may include stored instructions of an algorithm configured to perform one or more of the disclosed and / or claimed functions.

[0071] “Logic,” as used herein, represents a component that is implemented with computer or electrical hardware, a non-transitory medium with stored instructions of an executable application or program module, and / or combinations of these to perform any of the functions or actions as disclosed herein, and / or to cause a function or action from another logic, method, and / or system to be performed as disclosed herein. Equivalent logic may include firmware, a microprocessor programmed with an algorithm, a discrete logic (e.g., ASIC), at least one circuit, an analog circuit, a digital circuit, a programmed logic device, a memory device containing instructions of an algorithm, and so on, any of which may be configured to perform one or more of the disclosed functions. In one embodiment, logic may include one or more gates, combinations of gates, or other circuit components configured to perform one or more of the disclosed functions. Where multiple logics are described, it may be possible to incorporate the multiple logics into one logic. Similarly, where a single logic is described, it may be possible to distribute that single logic between multiple logics. In one embodiment, one or more of these logics are correspondingstructure associated with performing the disclosed and / or claimed functions. Choice of which type of logic to implement may be based on desired system conditions or specifications. For example, if greater speed is a goal, then hardware would be selected to implement functions. If a lower cost is desired, then stored instructions / executable application would be selected to implement the functions.

[0072] Additional embodiments are directed to continuous recycling apparatus 100 having at least one modularized decomposition-chamber unit 1500 releasably connected to exit end 202 of decomposition chamber 200. Releasably connecting modularized decomposition-chamber unit 1500 to exit end 202 of decomposition chamber 200 allows for a continuous feed stream of polymeric solid-phase carbon-containing compositions to be exposed to additional microwave pyrolysis within modularized decomposition-chamber unit 1500 beyond that provided by decomposition chamber 200.

[0073] In an embodiment, at least one modularized decomposition-chamber unit 1500 is connected to exit end 202 of decomposition chamber 200. In other embodiments, two or more modularized decomposition-chamber units 1500 are connected in series (i.e., each modularized decomposition-chamber unit 1500 following the other), wherein the first is connected to exit end 202 of decomposition chamber 200. In some instances, decomposition chamber 200 alone may be insufficient to fully decompose a feed stream of solid-phase compositions in a single pass. Because of that, additional microwave-pyrolysis regions or zones may be needed to completely decompose a feed stream of solid-phase compositions in a single pass. In such a scenario, at least one modularized decomposition-chamber unit 1500 is releasably connected to exit end 202 of decomposition chamber 200 to thereby arrive at a one-pass apparatus configuration. If more than one modularized decomposition-chamber unit 1500 is needed to arrive at a single-pass configuration, then a first modularized decomposition-chamber unit 1500 is connected (or releasably attached) to exit end 202 of decomposition chamber 200 and a second modularized decomposition-chamber unit 1500 is connected (or releasably attached) to exit end 15202 of the first modularized decomposition chamber 1500. Additional modularized decomposition chamber units 1500 may be added in series to achieve any desired single-pass configuration.

[0074] Modularized decomposition-chamber unit(s) 1500 at least includes: modular decomposition chamber 15200; at least one conveyor belt 15300 configured to receive a continuous feed streamof solid-phase compositions from a conveyor belt 1501 exiting decomposition chamber 200; inert-gas introduction orifice 15502 that enables flooding modular decomposition chamber 15200 with an inert gas supplied from an inert-gas source 15500. Inert-gas source 15500 can be independent of inert-gas source 500 provided to decomposition chamber 200, or plumbed into inert-gas source 500 provided to decomposition chamber 200 using a fluid coupler 15501.

[0075] Fluid coupler 15501 can be a quick-connect coupler that is compatible to mate with a corresponding male connector adapter provided to inert-gas source 500 provided to decomposition chamber 200, for example. Engagement between fluid coupler 15501 and corresponding male connector establishes a continuous fluid-flow pathway through which inert gas can be conveyed between decomposition chamber 200 and modularized decompositionchamber unit(s) 1500, allowing for expansion of continuous recycling apparatus 100 without requiring a separate and independent inert -gas source. A male connector adapter 1502 can optionally be provided to inert-gas source 15500 to facilitate fluid communication with inert-gas source 15500 of another modularized decomposition-chamber unit(s) 1500 connected in series, downstream of modularized decomposition-chamber unit 1500 shown in FIG. 15.

[0076] Modularized decomposition-chamber unit 1500 can also include microwave generator 15600 and wave-guide assembly 15700. Embodiments of microwave generator 15600 can optionally be independent of microwave generator 600 (FIGs. 3 and 4), operable to generate microwaves conveyed to decomposition chamber 15200 by wave-guide assembly 15700 without contribution from microwave generator 600. According to other embodiments, wave-guide couplers 1505 can be provided to operatively connect wave-guide assembly 15700 to wave-guide assembly 200, and optionally wave-guide assembly of another modularized decomposition-chamber unit 1500 connected in series, downstream of modularized decomposition-chamber unit 1500 shown in FIG. 15.

[0077] Modularized decomposition-chamber unit 1500 also includes light-sensing assembly 15800; and gas-phase-emissions exit-orifice assembly 151000 configured to channel gas-phase emissions out of decomposition chamber 15200 and to pre-existing external condensation assembly 1100 that is a component of recycling apparatus 100. In embodiments, modularized decompositionchamber unit(s) 1500 also includes microwave-blocking assembly that includes microwave-blocking louvered vent 15902, blocked-microwave venting louvered vent 15906, and water sink 15910.

[0078] Each of the components identified immediately above with respect to modularized decomposition-chamber unit(s) 1500, can be understood as being the same components or similar kinds of components identified above with respect to continuous recycling apparatus 100. Components in modularized decomposition-chamber unit 1500 can also be understood to function in the same manner as their counterparts described above with reference to continuous recycling apparatus 100. Persons of ordinary skill in the art will be able to select useful modularized decomposition-chamber unit 1500 components without having to exercise undue experimentation.

[0079] In embodiments, decomposition chamber 200 is configured to mechanically link, and thereby create a substantially airtight seal, with modularized decomposition-chamber unit 1500. In additional embodiments, a first modularized decomposition-chamber unit 1500 is configured to mechanically link, and thereby creates a substantially airtight seal, with a second modularized decomposition-chamber unit 1500. Modularized decomposition-chamber unit 1500 can also be operationally coupled to decomposition chamber 200 by a wired or wireless data / control connection so computing device 1400 can control operation of modularized decompositionchamber unit 1500 in a manner analogous to the control of decomposition chamber 200. For example, computing device 1400 can issue a command to change a transmission status of microwave-venting louvered vents 906, 15906 at substantially the same time that louvered vents 902, 15902 are adjusted, responsive to a signal from light-sensing assembly 800 or light-sensing assembly 15800. Likewise, computing device 1400 can optionally control operation of microwave generator 600, 15600 to establish desired wavelengths within decomposition chambers 200, 15200, respectively.

Claims

CLAIMSWhat is claimed is:

1. A continuous-process apparatus comprising:a first decomposition chamber;a conveyor assembly configured to continuously transport solid-phase carbon-containing compositions from a first location outside of the first decomposition chamber to a second location inside of the first decomposition chamber;a first inert-gas assembly configured to saturate the first decomposition chamber with an inert gas;a first microwave generator configured to generate microwaves having a frequency ranging from 900 MHz to 930 MHz and having a power rating ranging from 90 to 110 kW; a first wave-guide assembly configured to guide microwaves generated by the first microwave generator from the first microwave generator into the first decomposition chamber;a solid-phase fluid-flow blocking component positioned within the first wave-guide assembly,wherein the solid-phase fluid-flow blocking component blocks fluid flow from occurring within the first wave-guide assembly;a first gas-phase-emissions collection assembly configured to collect gas-phase emissions from the first decomposition chamber;a second decomposition chamber that is releasably attached to the first decomposition chamber; anda third decomposition chamber that is releasably attached to the second decomposition chamber.

2. The apparatus of claim 1, wherein the conveyor assembly is further configured to continuously transport solid-phase carbon-containing compositions from the second location inside of the first decomposition chamber to a third location inside of the second decomposition chamber.

3. The apparatus of claim 2, further comprising:a second inert-gas assembly configured to saturate the second decomposition chamber with an inert gas;a second microwave generator configured to generate microwaves having a frequency ranging from 900 MHz to 930 MHz and having a power rating ranging from 90 to 110 kW; a second wave-guide assembly configured to guide microwaves generated by the second microwave generator from the second microwave generator into the second decomposition chamber;a solid-phase fluid-flow blocking component positioned within the second wave-guide assembly,wherein the solid-phase fluid-flow blocking component blocks fluid flow from occurring within the second wave-guide assembly; anda second gas-phase-emissions collection assembly configured to collect gas-phase emissions from the second decomposition chamber.

4. The apparatus of claim 3, wherein the solid-phase fluid-flow blocking component in the first wave-guide assembly includes polytetrafluoroethylene.

5. The apparatus of claim 3, wherein the solid-phase fluid-flow blocking component in the first wave-guide assembly includes quartz.

6. The apparatus of claim 3, wherein the solid-phase fluid-flow blocking component in the first wave-guide assembly blocks gas-phase fluid flow.

7. The apparatus of claim 3, wherein the first wave-guide assembly is further configured to polarize the microwaves generated by the first microwave generator and introduce polarized microwaves into the first decomposition chamber.

8. The apparatus of claim 1, wherein the first gas-phase-emissions collection assembly is further configured to guide gas-phase emissions to a first condensation assembly that is configured to condense the gas-phase emissions into at least one liquid-phase composition or at least one liquid-phase emulsion.

9. The apparatus of claim 1, further comprising an additional solid-phase fluid-flow blocking component within the first wave-guide assembly.

10. The apparatus of claim 9, wherein the additional solid-phase fluid-flow blocking component includes quartz.

11. The apparatus of claim 9, wherein the additional solid-phase fluid-flow blocking component includes polytetrafluoroethylene.

12. The apparatus of claim 1, wherein the first inert-gas assembly is further configured to saturate the first decomposition chamber by continuously introducing inert gas into the decomposition chamber via an inert-gas introduction orifice.

13. The apparatus of claim 1, further comprising a light-sensing assembly configured to emit a signal upon sensing visible light within the first decomposition chamber,wherein a signal emitted by the light-sensing assembly is received by a microwave-blocking assembly that, upon receiving the signal, is configured to perform a mechanical action that blocks microwaves generated by the first microwave generator and thereby prevents the blocked microwaves from entering the first decomposition chamber.

14. The apparatus of claim 13, wherein the microwave-blocking assembly includes a louvered vent having rotatable louvers.

15. The apparatus of claim 13, wherein the microwave-blocking assembly includes a mechanical element that slides or rotates to effect at least a partial blocking of microwaves generated by the first microwave generator and thereby prevents the at least partially blocked microwaves from entering the first decomposition chamber.

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