IP Library Granted Patent US 11,097,245
Granted Patent B2
US 11,097,245 · App. 16/622,684 · Granted Aug 24, 2021

Electric-powered, closed-loop, continuous-feed, endothermic energy conversion systems and methods

Inventors: Martin Redeker (Greensboro, NC); Joseph P. Carroll, Jr. (Greensboro, NC)
Assignee: Montauk Renewables, Inc.
B01J19/0013B01J8/0285B01J19/20C10J3/723C22C19/051
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Quick Facts
Patent No.
US 11,097,245
App. No.
16/622,684
Granted
Aug 24, 2021
Kind
B2
Abstract

Electric-powered, closed-loop, continuous-feed, endothermic energy-conversion systems and methods are disclosed. In one embodiment, the presently disclosed energy-conversion system includes a shaftless auger. In another embodiment, the presently disclosed energy-conversion system includes a drag conveyor. In yet another embodiment, the presently disclosed energy-conversion system includes a distillation and/or fractionating stage. The endothermic energy-conversion systems and methods feature mechanisms for natural resource recovery, refining, and recycling, such as secondary recovery of metals, minerals, nutrients, and/or carbon char.

Claims (42)

1. A system for converting energy comprising:

a controller;

a reactor having inner walls operated by the controller;

a shaftless auger in the reactor, the shaftless auger adapted to rotate in contact with the inner walls of the reactor; and

a heater surrounding the reactor and the shaftless auger.

2. The system of claim 1 , wherein the heater is a multi-zone heater that provides plural individually controlled heating zones within the reactor.

3. The system of claim 1 , wherein the heater is a catalytic heater.

4. The system of claim 1 , wherein the reactor is formed of carbon steel, stainless steel, or a specialized alloy.

5. The system of claim 4 , wherein the specialized alloy is Inconel.

6. The system of claim 1 , wherein the shaftless auger is a single penetration auger.

7. The system of claim 1 further comprising:

a scale;

a mixer;

a feedstock hopper metering stage;

an infeed sensor; and

an airlock, wherein the scale, the mixer, the feedstock hopper metering stage, and the infeed senor form a closed loop with the reactor.

8. The system of claim 7 , wherein the feedstock hopper metering stage includes a dryer.

9. The system of claim 8 , wherein the dryer is a bed dryer adapted for conduction drying.

10. The system of claim 9 , wherein the dryer is a bed dryer adapted for convection drying in combination with the conduction drying.

11. The system of claim 7 , wherein said feedstock hopper metering stage includes metered sorbents and reagents adapted to pretreat feedstock prior to the feedstock being advanced to the reactor.

12. The system of claim 11 , wherein said metered sorbents and reagents include finely milled lime, trona, bentonite, sodium bentonite, sodium, or sodium bicarbonate.

13. The system of claim 7 , wherein the infeed sensor is adapted to control feedstock bed depth and rate prior to feedstock being advanced to the reactor.

14. The system of claim 13 , wherein the infeed sensor includes a positive flow advancement sensor.

15. The system of claim 7 , wherein the airlock includes a conical auger adapted to remove air from feedstock prior to the feedstock advancing to the reactor.

16. The system of claim 7 , wherein the closed loop further comprises the components of:

a vapor pre-heating stage;

a ceramic hot gas filter;

a first quench stage;

a multi-tube plunging condenser;

a second quench stage;

a primary compensator with an associated primary recirculator;

a secondary compensator with an associated secondary recirculator;

a vacuum buffer tank;

a regulator;

a vacuum pump;

a syngas buffer tank; and

a catalytic scrub.

17. The system of claim 16 , wherein the primary and secondary compensators, the vacuum buffer tank, the vacuum pump, and the syngas buffer tank are adapted to maintain a pressure within the reactor.

18. The system of claim 16 , wherein the vacuum pump includes a liquid ring compressor adapted to cool vapor advancing from the reactor as it is being compressed.

19. The system of claim 16 , wherein the reactor includes an automated plunging system having multi-vapor discharge nozzles.

20. The system of claim 19 , wherein the multi-vapor discharge nozzles are integrated with the ceramic hot gas filter, the primary and secondary quenching stages, the multi-tube plunging condenser, or any combination thereof.

21. The system of claim 1 , further comprising a pressure transition component adapted to allow continuous flow transition of vapor advancing from the reactor from positive to negative pressure.

Assignments (7)
RELEASE OF SECURITY INTEREST Recorded Mar 13, 2026
From: FIFTH THIRD BANK, N.A., SUCCESSOR BY MERGER TO COMERICA BANK
To: MONTAUK ENERGY HOLDINGS, LLC; MONTAUK AG RENEWABLES, LLC
Reel/Frame 074072/0080 →
RELEASE OF SECURITY INTEREST Recorded Mar 13, 2026
From: FIFTH THIRD BANK, N.A., SUCCESSOR BY MERGER TO COMERICA BANK
To: NR-3, LLC
Reel/Frame 074072/0113 →
SECURITY INTEREST Recorded Mar 9, 2026
From: MONTAUK ENERGY HOLDINGS, LLC; MONTAUK AG RENEWABLES, LLC; NR-3, LLC
To: CCH1 MEH LENDER LLC
Reel/Frame 074016/0476 →
SECURITY INTEREST Recorded Jan 6, 2026
From: MONTAUK AG RENEWABLES, LLC; MONTAUK ENERGY HOLDINGS, LLC
To: COMERICA BANK
Reel/Frame 073377/0110 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 4, 2022
From: NR-3, LLC
To: MONTAUK RENEWABLES, INC.
Reel/Frame 059811/0235 →
SECURITY INTEREST Recorded Jan 19, 2022
From: NR-3, LLC
To: COMERICA BANK, AS AGENT
Reel/Frame 058694/0856 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Dec 13, 2019
From: REDEKER, MARTIN; CARROLL, JOSEPH P., JR.
To: NR-3
Reel/Frame 051279/0827 →
Continuity (2)
Provisional Application 62519213 · Jun 14, 2017
Related Publication 20210138424A1 · May 13, 2021
Cited By (1)
US 12,415,170