IP Library Granted Patent US 11,534,733
Granted Patent B2
US 11,534,733 · App. 17/409,159 · Granted Dec 27, 2022

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

Inventors: Martin Redeker (Pittsburgh, PA); Joseph P. Carroll, Jr. (Pittsburgh, PA)
Assignee: Montauk Renewables, Inc.
B01J19/0013B01J8/0285B01J19/20C10J3/723C22C19/051
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Quick Facts
Patent No.
US 11,534,733
App. No.
17/409,159
Granted
Dec 27, 2022
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 (31)

1. A system for converting energy comprising:

a controller;

a reactor having inner walls operated by the controller;

a drag conveyor in the reactor, the drag conveyor including a multi-pass drag chain adapted to allow a feedstock material to advance in opposing directions on the same drag chain; and

a multi-zone heater surrounding the reactor and the drag conveyor.

2. The system of claim 1 , further comprising an airlock having a steric acid high-temperature fluid bath forming a closed loop with the reactor.

3. The system of claim 2 , wherein the closed loop further comprises a multi-zone quench station having a quench oil filter and an oil preheated stage.

4. The system of claim 3 , wherein the closed loop further comprises an atmospheric fractioning unit.

5. The system of claim 4 , wherein the atmospheric fractioning unit comprises a heavy oil fractioning process, a re-boiler, a diesel storage, and an asphalt storage, wherein the multi-zone quench station includes a supply of diluting oil.

6. A method for converting energy, comprising the steps of:

providing an energy conversion system according to claim 1 ;

supplying feedstock material to the energy-conversion system;

processing the feedstock material;

supplying the processed feedstock material to the inlet of the reactor;

advancing the processed feedstock through the reactor while the reactor facilitates a phase-change process of the feedstock from solid to liquid to vapor;

maintaining through the heater accurate and consistent temperature within reactor;

maintaining a positive pressure in the energy-conversion system;

discharging from reactor outlets char and vapor obtained from the reacted feedstock;

removing particulates from the discharged vapor;

quenching the discharged vapor to prevent tar, grease, and/or wax build-ups;

after the quenching step, transitioning from the positive pressure to a negative pressure in the energy-conversion system; and

supplying the quenched vapor to a vacuum buffer tank.

7. The method of claim 6 , further comprising the steps of:

advancing the supplied vapor to a regulator;

removing liquid from the advanced vapor;

cooling the advanced vapor; and

performing a filter-less quenching gas clean-up operation on the advanced vapor; and

forming and discharging syngas.

8. The method of claim 6 , further comprising the step of advancing the reacted feedstock to a quench station.

9. The method of claim 8 , further comprising the step of advancing the quenched feedstock to an atmospheric fractioning unit.

10. The method of claim 6 , further comprising the steps of advancing the reacted feedstock to an automated plunging system.

Assignments (8)
RELEASE OF SECURITY INTEREST Recorded Mar 13, 2026
From: FIFTH THIRD BANK, N.A., SUCCESSOR BY MERGER TO COMERICA BANK
To: MONTAUK RENEWABLES, INC.
Reel/Frame 074072/0160 →
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 →
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 Dec 27, 2022
From: REDEKER, MARTIN; CARROLL, JOSEPH P., JR.
To: NR-3, LLC
Reel/Frame 062212/0474 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 4, 2022
From: MONTAUK RENEWABLES, INC.
To: MONTAUK AG RENEWABLES, LLC
Reel/Frame 059811/0259 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 4, 2022
From: NR-3, LLC
To: MONTAUK RENEWABLES, INC.
Reel/Frame 059811/0204 →
SECURITY INTEREST Recorded Jan 19, 2022
From: MONTAUK RENEWABLES, INC.
To: COMERICA BANK, AS AGENT
Reel/Frame 058696/0298 →
Continuity (3)
Continuation 16622684
Provisional Application 62519213 · Jun 14, 2017
Related Publication 20210379551A1 · Dec 9, 2021
Cited By (1)
US 12,415,170