US 11,674,087 B2
Microwave methods for converting hydrocarbon-based waste materials into oil and gas fuels
Brian Bauer, Sebastopol, CA (US); Jason Tanne, Vancouver, WA (US); Tyler Spott, Rohnert Park, CA (US); Frank Mayhew, Graton, CA (US); A. J. McInnis, San Jose, CA (US); Mathew Leis, Redwood City, CA (US); Christopher Cardinal, Sunnyvale, CA (US); and Tom Greer, Graton, CA (US)
Appl. No. 17/250,284
Filed by Resynergi, Inc., Rohnert Park, CA (US)
PCT Filed Jun. 28, 2019, PCT No. PCT/US2019/039985
§ 371(c)(1), (2) Date Dec. 28, 2020,
PCT Pub. No. WO2020/006512, PCT Pub. Date Jan. 2, 2020.
Claims priority of provisional application 62/691,514, filed on Jun. 28, 2018.
Prior Publication US 2021/0122980 A1, Apr. 29, 2021
Int. Cl. C10B 53/07 (2006.01); B01J 19/12 (2006.01); C10L 3/12 (2006.01); B01J 4/00 (2006.01); C10B 31/02 (2006.01); C10L 3/08 (2006.01); H05B 6/64 (2006.01)
CPC C10B 53/07 (2013.01) [B01J 4/001 (2013.01); B01J 19/126 (2013.01); C10B 31/02 (2013.01); C10L 3/08 (2013.01); C10L 3/12 (2013.01); H05B 6/647 (2013.01); C10L 2200/0423 (2013.01); C10L 2200/0446 (2013.01); C10L 2200/0469 (2013.01); H05B 2206/045 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A system for converting a carbon-containing feedstock into one or more useful materials, comprising:
a thermal reactor having a feedstock inlet and a gas and waste char output, said thermal reactor including,
a polygonal internal microwave cavity having exterior sides;
a cylindrical outer shell surrounding and encasing said polygonal internal microwave cavity on said exterior sides, said outer shell having a closed top with a feedstock inlet at the input end and a closed bottom with a gas and waste char outlet at the gas output end;
a plurality of microwave generators disposed outside of, and coupled to, said outer shell, one each of said microwave generators for each side of said polygonal internal microwave cavity, said microwave generators including waveguides disposed through said outer shell and said internal microwave cavity to direct and deliver microwave energy to the interior of said internal microwave cavity;
an inert gas source in fluid communication with said internal microwave cavity;
a plurality of heating elements disposed around said internal microwave cavity;
a vertically oriented microwave transparent ceramic sleeve generally centered in said internal microwave cavity and spanning between an inner side of said top and said bottom of said outer shell;
a mixing auger rotatingly and axially disposed in said ceramic sleeve;
a plurality of microwave-absorbing spheres contained within said ceramic sleeve and surrounding said mixing auger;
an outlet grate through which vaporized gases and waste char pass after processing in said thermal reactor;
a feedstock feed assembly in fluid communication with said feedstock inlet; and
a cooling and condensation system in fluid communication with said gas and waste char outlet.