IP Library Granted Patent US 11,975,302
Granted Patent B2
US 11,975,302 · App. 18/089,114 · Granted May 7, 2024

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 AG RENEWABLES, LLC
B01J19/0013B01J8/0285B01J19/20C10J3/723C22C19/051
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 11,975,302
App. No.
18/089,114
Granted
May 7, 2024
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 (51)

1. A system for converting energy comprising:

a controller;

a reactor having inner walls operated by the controller, the reactor adapted to allow a continuous feed, phase-change process of a feedstock;

a pressure transition component adapted to allow continuous flow transition of vapor formed from the phase-change process from the reactor from positive pressure to negative pressure; and

a heater surrounding the reactor.

2. The system of claim 1 , wherein the pressure transition component includes a compensator adapted to allow for transition of vapor from a positive pressure from the reactor to negative pressure vapor removal.

3. The system of claim 2 , wherein the compensator includes a primary recirculator with an associated primary recirculator and a secondary compensator with an associated secondary recirculator, the primary and secondary compensators adapted to allow for condensation of the vapor removed.

4. The system of claim 2 , further comprising:

a scale;

a mixer;

a feedstock hopper metering stage;

an infeed sensor; and

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

5. The system of claim 4 , wherein the feedstock hopper metering stage includes metered sorbents and reagents adapted to pretreat feedstock prior to the feedstock being advanced to the reactor.

6. The system of claim 5 , wherein the metered sorbents and reagents include finely milled lime, trona, bentonite, sodium bentonite, sodium, or sodium bicarbonate.

7. The system of claim 4 , 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 vacuum buffer tank;

a regulator;

a vacuum pump;

a syngas buffer tank; and

a catalytic scrub.

8. The system of claim 7 , wherein the compensator, the vacuum buffer tank, the vacuum pump, and the syngas buffer tank are adapted to maintain a pressure with the reactor.

9. The system of claim 7 , wherein the vacuum pump includes a liquid ring compressor adapted to cool vapor advance from the reactor as it is being compressed.

10. The system of claim 7 , wherein the reactor includes an automated plunging system having multi-vapor discharge nozzles.

11. The system of claim 10 , wherein the multi-vapor discharge nozzles are integrated with the ceramic hot gas filter, the primary and secondary quenching stages, the multi-tub plunging condenser, or any combination thereof.

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

providing an energy conversion system according to claim 11 ;

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 through the pressure transition component from the positive pressure to a negative pressure in the energy-conversion system; and

supplying the quenched vapor to a vacuum buffer tank.

13. The method of claim 12 , 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.

14. The method of claim 13 , further comprising the step of advancing the reacted feedstock to a quench station.

15. The method of claim 14 , further comprising the step of advancing the quenched feedstock to an atmospheric fractioning unit.

16. The method of claim 15 , further comprising the steps of advancing the reacted feedstock to an automated plunging system.

Assignments (6)
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 Dec 27, 2022
From: NR-3, LLC
To: MONTAUK RENEWABLES, INC.
Reel/Frame 062212/0484 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Dec 27, 2022
From: MONTAUK RENEWABLES, INC.
To: MONTAUK AG RENEWABLES, LLC
Reel/Frame 062212/0492 →
Continuity (4)
Continuation 17409159 · Aug 23, 2021
Continuation 16622684
Provisional Application 62519213 · Jun 14, 2017
Related Publication 20230134703A1 · May 4, 2023