# US 11,306,916 B2 · Plastic-powered power generator > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,306,916 B2 - Document ID: US11306916B2 - Status: Granted - Kind: B2 - Application number: 16/859,580 - Filed: 2020-04-27 - Published: 2021-09-23 - Granted: 2022-04-19 - Earliest claimed: 2020-03-18 - Applicants: Daniel Caris - Inventors: Daniel Caris - Web page: https://patentgrep.com/patent/US11306916B2 ## CPC - F23G 5/46: Recuperation of heat - F01K 11/02: the engines being turbines - F01K 21/00: Steam engine plants not otherwise provided for - F23G 7/12: of plastics, e.g. rubber - F23L 7/00: Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam - F23G 2206/203: with a power/heat generating installation - F23G 2209/28: Plastics or rubber like materials - Y02E 20/12: Heat utilisation in combustion or incineration of waste - F23G: CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION - F01K: STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES (gas-turbine or jet-propulsion plants F02; nuclear power plants, engine arrangements therein G21D) - F23L: SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ({air-supply arrangements for fluent fuels F23C;} firebridges with means for feeding air or steam F23M3/04; baffles or shields with air supply passages F23M9/04); VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS {(dampers and throat restrictors for open fire-places F24; air inlet valves for open fire fronts F24)}; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Plastic-powered power generator. In an embodiment, the plastic-powered power generator comprises a primary reactor with an air-fuel distribution assembly configured to supply fluidized polymer, air, and oxidizer to a primary reactor chamber, and an ignition system configured to ignite a mixture of the fluidized polymer, air, and oxidizer. The primary reactor chamber extends into a secondary reactor, to, when ignited, heat air flowing through the secondary reactor from a blower to a heat exchanger. The heated air flow converts fluid, in a coil within the heat exchanger, into steam, which can drive a turbine to generate electrical power. ## Claims ### Claim 1 A plastic-powered power generator comprising: a primary reactor comprising an air-fuel distribution assembly, an ignition system, and a primary reactor chamber, wherein the primary reactor chamber comprises a first opening on one end of the primary reactor chamber and a second opening on a second end of the primary reactor chamber, wherein the air-fuel distribution assembly is configured to supply fluidized polymer, air, and an oxidizing agent through the first opening in the primary reactor chamber, and wherein the ignition system is configured to ignite a mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber; a secondary reactor comprising a secondary reactor body with a first opening on one end of the secondary reactor body, a second opening on a second end of the secondary reactor body, and a third opening on a side of the secondary reactor body, wherein the second end of the primary reactor chamber extends perpendicularly through the third opening in the side of the secondary reactor body, such that the second opening of the primary reactor chamber is within the secondary reactor body; a heat exchanger comprising a first opening on one end of the heat exchanger, a second opening on a second end of the heat exchanger, and a coil, configured to contain fluid, between the first opening and the second opening, wherein the first opening of the heat exchanger is connected to the second opening of the secondary reactor; and a blower configured to create air flow through the secondary reactor into the heat exchanger, such that the air flow is heated in the secondary reactor through the second opening of the primary reactor, and the heated air flow from the secondary reactor heats the coil in the heat exchanger, and wherein the plastic-powered generator is configured to create thermal energy to generate power. ### Claim 2 (depends on 1) The plastic-powered power generator of claim 1, further comprising a reducer positioned between the blower and the secondary reactor, wherein the reducer is configured to speed up the air flow into the secondary reactor. ### Claim 3 (depends on 1) The plastic-powered power generator of claim 1, wherein the second opening of the primary reactor chamber is angled with respect to a longitudinal axis of the primary reactor chamber, such that the second end of the primary reactor chamber extends farther into the secondary reactor at a side nearer the blower than at a side farther from the blower. ### Claim 4 (depends on 3) The plastic-powered power generator of claim 3, wherein the second end of the primary reactor chamber comprises a lip which extends over a portion of the second opening of the primary reactor chamber. ### Claim 5 (depends on 1) The plastic-powered power generator of claim 1, wherein the air-fuel distribution assembly comprises an air-oxidizer manifold that comprises: a dispersal port comprising a channel from a rear surface of the air-oxidizer manifold to a front surface of the air-oxidizer manifold, wherein the front surface of the air-oxidizer manifold faces the first opening in the primary reactor chamber; at least one concentric channel, surrounding the dispersal port, recessed into the rear surface of the air-oxidizer manifold; at least one inlet port through a side surface of the air-oxidizer manifold and connected to the at least one concentric channel; and one or more jet holes extending through the air-oxidizer manifold from a recessed surface of the at least one concentric channel to the front surface of the air-oxidizer manifold. ### Claim 6 (depends on 5) The plastic-powered power generator of claim 5, wherein the one or more jet holes are angled with respect to a longitudinal axis of the air-oxidizer manifold. ### Claim 7 (depends on 5) The plastic-powered power generator of claim 5, wherein the at least one concentric channel comprises two or more concentric channels, wherein the at least one inlet port comprises two or more inlet ports that are each connected to one of the two or more concentric channels, and wherein the one or more jet holes comprise a plurality of jet holes. ### Claim 8 (depends on 7) The plastic-powered power generator of claim 7, wherein one of the two or more concentric channels is recessed deeper into the rear surface of the air-oxidizer manifold than a second one of the two or more concentric channels. ### Claim 9 (depends on 7) The plastic-powered power generator of claim 7, further comprising a pneumatic system that is configured to supply air through a first one of the two or more inlet ports, and supply an oxidizing agent through a second one of the two or more inlet ports. ### Claim 10 (depends on 9) The plastic-powered power generator of claim 9, wherein the pneumatic system is further configured to supply the air through the second inlet port. ### Claim 11 (depends on 10) The plastic-powered power generator of claim 10, wherein the pneumatic system is configured to: monitor a temperature in the primary reactor chamber; while the temperature remains below a predetermined threshold, supply the air through the first inlet port, and supply the oxidizing agent through the second inlet port; and, when the temperature exceeds the predetermined threshold, supply the air through both the first inlet port and the second inlet port, and reduce or stop the supply of the oxidizing agent through the second inlet port. ### Claim 12 (depends on 5) The plastic-powered power generator of claim 5, wherein the air-fuel distribution assembly further comprises an air-fuel mixer that is attached to the rear surface of the air-oxidizer manifold, wherein the air-fuel mixer comprises: an internal chamber; a fluidized polymer outlet port connecting the internal chamber to the dispersal port in the air-oxidizer manifold; an air inlet port configured to supply air flow through the internal chamber; and a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber. ### Claim 13 (depends on 12) The plastic-powered power generator of claim 12, further comprising a fluidizer that comprises: a body comprising a first opening in a first end and a second opening in a second end, wherein the body is configured to house one or more layers of polymer; a base that covers the first opening in the body, wherein the base comprises an internal cavity, an air inlet port configured to receive air, and a porous membrane between the internal cavity and the first opening in the body; and a lid that covers the second opening in the body, wherein the lid comprises a fluidized polymer outlet port that is connected to the fluidized polymer inlet port of the air-fuel mixer, so as to provide fluidized polymer to the air-fuel mixer through the connected fluidized polymer outlet and inlet ports. ### Claim 14 (depends on 1) The plastic-powered power generator of claim 1, wherein the ignition system comprises one or more electrode pairs, wherein each of the one or more electrode pairs comprises a positive electrode aligned, through the primary reactor chamber, with a ground electrode. ### Claim 15 (depends on 14) The plastic-powered power generator of claim 14, wherein the one or more electrode pairs comprise a plurality of electrode pairs, and wherein the plurality of electrode pairs alternate in orientation, such that no positive electrode is adjacent to another positive electrode and no ground electrode is adjacent to another ground electrode. ### Claim 16 (depends on 15) The plastic-powered power generator of claim 15, wherein the plurality of electrode pairs comprise two or more electrode pairs that are oriented in a plane that is orthogonal to a plane in which two or more other electrode pairs are oriented. ### Claim 17 (depends on 15) The plastic-powered power generator of claim 15, further comprising a distributor system that comprises: a high-spark energy generator and a ground distributor, wherein each of the high-spark energy generator and the ground distributor comprises a distributor cap comprising a plurality of towers arranged around a circumference of the distributor cap, wherein each of the plurality of towers on the distributor cap of the high-spark energy generator is electrically connected to a positive electrode in one of the plurality of electrode pairs, and wherein each of the plurality of towers on the distributor cap of the ground distributor is electrically connected to a ground electrode in one of the plurality of electrode pairs, and a pulley connected to a rotor by a shaft, such that, when the pulley rotates, the rotor passes underneath each of the plurality of towers in a sequence; and a motor that drives a timing belt to rotate the pulleys of the high-spark energy generator and the ground distributor, such that, as the rotor of the high-spark energy generator passes underneath a tower on the distributor cap of the high-spark energy generator, the rotor of the ground distributor simultaneously passes underneath a corresponding tower on the distributor cap of the ground distributor, so as to create a spark from the positive electrode that is electrically connected to the tower on the distributor cap of the high-spark energy generator to the ground electrode that is electrically connected to the corresponding tower on the distributor cap of the ground distributor. ### Claim 18 (depends on 1) The plastic-powered power generator of claim 1, wherein the heat exchanger is configured to receive an aqueous fluid into the coil and output steam, resulting from heating the coil, through a steam line connected to the coil, and wherein the plastic-powered power generator further comprises: an electrical generator; and a turbine configured to spin the electrical generator as the steam passes through the turbine, so as to produce electrical power from the electrical generator. ### Claim 19 (depends on 18) A method comprising: pulverizing plastic waste to create sub-micron-scale polymer; fluidizing the polymer; and using the plastic-powered power generator of claim 18 by supplying the fluidized polymer, air, and an oxidizing agent to the primary reactor, supplying the aqueous fluid to the coil within the heat exchanger, igniting the mixture of the fluidized polymer, air, and oxidizing agent within the primary reactor chamber using the ignition system, and operating the blower to create air flow through the secondary reactor into the heat exchanger, to convert the aqueous fluid into steam that spins the turbine which spins the electrical generator to produce electrical power. ### Claim 20 (depends on 19) The method of claim 19, wherein pulverizing the plastic waste comprises: shredding the plastic waste into micron-scale plastic waste; and pelletizing the shredded micron-scale plastic waste into the sub-micron-scale polymer.