A retort involves a stack of retort units arranged to process coal or other raw material by heating the coal in a heating compartment and directing vapors emitted from the raw material into a vapor compartment surrounding the heating compartment. The heating compartment may include a plurality of louver units with embedded heating components. Each louver unit includes heating fins (a heat transfer medium) that delivers heat to the coal. Each louver unit also includes an insulation layer adjacent a vapor opening where vapors emitted from the coal pass into the vapor compartment. The vapors are directed to a distillation column where carbon based vapors, volatiles, fuel vapors and the like may be liquefied for transport to a refinery or directly refined into fuels. Further, a clean coal char (toxins and carbon vaporized) is delivered to a power generation plant to provide cleaner emissions relative to unprocessed coal.
1. A retort unit comprising:
a heating compartment surrounded by a vapor compartment, the heating compartment defining a plurality of passages where vapors emitted from a material within the heating compartment flow into the vapor compartment, the heating compartment further including:
at least a first louver unit including a first plate with a first lower section angularly positioned relative to a first upper section, the first lower section having a first side and a second side opposite the first side, the first side of the first lower section including a plurality of heat sink fins substantially aligned with a flow of the material over the first louver unit and a first heating element adjacent the second side of the first lower section, the first heating element configured to heat the material within the heating compartment and being interposed between the heat sink fins and a first insulation layer disposed on the second side of the first lower section; and
at least a second louver unit including a second plate with a second lower section angularly positioned relative to a second upper section, the second lower section having a first side and a second side opposite the first side, the first side of the second lower section including a plurality of heat sink fins substantially aligned with a flow of the material over the second louver unit and a second heating element adjacent the second side of the second lower section, the second heating element also configured to heat the material within the heating compartment, and being interposed between the heat sink fins and a second insulation layer disposed on a second side of the second lower section, wherein the second lower section is spaced below at least a portion of the first lower section such that the plurality of heat sink fins coupled to the first side of the first lower section extends inwardly toward the plurality of the heat sink fins coupled to the first side of the second lower section so that material flowing over the first lower section of the first louver unit is deposited on the second lower section of the second louver unit so that the plurality of heat sink fins coupled to the first side of the first lower section are staggered relative to the plurality of heat sink fins coupled to the first side of the second lower section.
2. A retort unit of claim 1 wherein each of the plurality of heat sink fins extends upwardly from each of the lower sections.
3. A retort unit of claim 1 wherein the heating fins are rectangularly shaped plates extending along the vertical height of the lower section.
4. A retort unit of claim 1 wherein the first heating element comprises a first heating chamber coupled to the first lower section of the first plate and the second heating elements comprise a second heating chamber coupled to the second lower section of the second plate.
5. A retort unit of claim 4 wherein the heating chambers further include a cal rod type heating element disposed within the chambers cast within aluminum.