# US 11,774,094 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 11,774,094 B2 - Document ID: US11774094B2 - Status: Granted - Kind: B2 - Application number: 17/751,475 - Filed: 2022-05-23 - Published: 2022-11-10 - Granted: 2023-10-03 - Earliest claimed: 2020-03-18 - Applicants: Daniel Caris - Inventors: Daniel Caris - Web page: https://patentgrep.com/patent/US11774094B2 ## 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 5/027: pyrolising or gasifying stage (pyrolisation of sludge C02F11/00; destructive distillation of carbonaceous materials C10B53/00) - F23G 5/30: having a fluidised bed - F23G 5/442: {Waste feed arrangements} - F23G 7/12: of plastics, e.g. rubber - F23G 2201/303: Burning pyrogases - F23G 2202/103: in separate chambers - F23G 2205/20: using airblast or pneumatic feeding - F23G 2206/203: with a power/heat generating installation - F23G 2207/101: for temperature - F23G 2209/28: Plastics or rubber like materials - 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) ## 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 may convert 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, wherein the primary reactor chamber comprises a plurality of flat sides; 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 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, 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 flows into the heat exchanger. ### Claim 2 (depends on 1) The plastic-powered power generator of claim 1, wherein the secondary reactor body is cuboid. ### Claim 3 (depends on 1) The plastic-powered power generator of claim 1, wherein the secondary reactor body comprises a temperature-sensor port, configured to receive a temperature sensor. ### Claim 4 (depends on 3) The plastic-powered power generator of claim 3, further comprising the temperature sensor, seated within the temperature-sensor port, such that a sensing portion of the temperature sensor extends into an interior of the secondary reactor body. ### Claim 5 (depends on 1) The plastic-powered power generator of claim 1, wherein the secondary reactor comprises a first set of mounting holes encircling the first opening, a second set of mounting holes encircling the second opening, and a third set of mounting holes encircling the third opening. ### Claim 6 (depends on 1) The plastic-powered power generator of claim 1, wherein the primary reactor chamber comprises an octagonal body with eight flat sides. ### Claim 7 (depends on 1) The plastic-powered power generator of claim 1, wherein the air-fuel distribution assembly comprises an air-fuel mixer, and wherein the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connected to the internal chamber. ### Claim 8 (depends on 7) The plastic-powered power generator of claim 7, further comprising a fluidizer, wherein the fluidizer comprises: a body comprising an internal cavity configured to house micro-fine polymer between a first end and a second end of the body, and an opening at the first end of the body; a base that covers the opening at the first end of the body, wherein the base comprises an internal cavity, and an air inlet port configured to receive air; a porous membrane between the internal cavity of the base and the internal cavity of the body; and a pump that pumps fluidized polymer from the internal cavity of the body to the fluidized polymer inlet port of the air-fuel mixer. ### Claim 9 (depends on 8) The plastic-powered power generator of claim 8, wherein the pump comprises: an outlet that is connected to the fluidized polymer inlet port of the air-fuel mixer; a fuel pick-up tube that provides a pathway from the internal cavity of the body of the fluidizer to the outlet; and an inlet configured to supply air over an end of the fuel pick-up tube to create a vacuum of low pressure within the fuel pick-up tube. ### Claim 10 (depends on 8) The plastic-powered power generator of claim 8, wherein the fluidizer further comprises a vent tube that provides a pathway from the internal cavity of the body of the fluidizer to an exterior of the fluidizer. ### Claim 11 (depends on 8) The plastic-powered power generator of claim 8, wherein the fluidizer further comprises a fill tube that provides a pathway from an exterior of the fluidizer to the internal cavity of the body of the fluidizer. ### Claim 12 (depends on 1) The plastic-powered power generator of claim 1, wherein the air-fuel distribution assembly comprises an air-oxidizer manifold, and wherein the air-oxidizer manifold comprises: a first dispersal port comprising a channel from a rear surface of the air-oxidizer manifold to a front surface of the air-oxidizer manifold; at least one concentric channel, surrounding the dispersal port and recessed into the front 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 a jet plate covering the front surface of the air-oxidizer manifold and facing the first opening in the primary reactor chamber, wherein the jet plate comprises a second dispersal port in fluid communication with the first dispersal port, and one or more jet holes in fluid communication with the at least one concentric channel. ### Claim 13 (depends on 12) The plastic-powered power generator of claim 12, wherein the at least one concentric channel comprises two or more concentric channels, and 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. ### Claim 14 (depends on 13) The plastic-powered power generator of claim 13, wherein one of the two or more concentric channels is recessed deeper into the front surface of the air-oxidizer manifold than a second one of the two or more concentric channels. ### Claim 15 (depends on 13) The plastic-powered power generator of claim 13, 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 16 (depends on 15) The plastic-powered power generator of claim 15, wherein the pneumatic system is further configured to supply the air through the second inlet port. ### Claim 17 (depends on 16) The plastic-powered power generator of claim 16, 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 18 (depends on 12) The plastic-powered power generator of claim 12, wherein the air-fuel distribution assembly further comprises an air-fuel mixer, and wherein the air-fuel mixer comprises: an internal chamber; an air inlet port configured to supply air flow through the internal chamber, wherein the air inlet port narrows to a throat that connects to the internal chamber; a fluidized polymer inlet port configured to supply fluidized polymer to the internal chamber; and a fluidized polymer outlet port connecting the internal chamber to the first dispersal port in the air-oxidizer manifold. ### Claim 19 (depends on 12) The plastic-powered power generator of claim 12, further comprising a one-piece dispenser nozzle that connects to the first dispersal port through the second dispersal port. ### Claim 20 (depends on 1) A method comprising: fluidizing sub-micron-scale polymer; and using the plastic-powered power generator of claim 1 by supplying the fluidized polymer, air, and an oxidizing agent to the primary reactor; 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.