Apparatus and process for separation of organic materials from attached insoluble solids, and conversion into useful products

A process for converting a feedstock containing organic matter attached to insoluble solids into at least one useful material, comprising:

• preparing a slurry from the feedstock;
• heating the slurry to produce a liquid mixture and solid material that includes the insoluble solids;
• removing the solid material from the liquid mixture;
• reacting the liquid mixture in a first reaction to produce a reacted feed comprising at least one reacted solid product, at least one reacted liquid product, and water;
• separating said at least one reacted solid product, said water, and said at least one reacted liquid product from said reacted feed;
• and
• converting said at least one reacted liquid product into at least one useful material in a second reaction, wherein said reacting drives off steam and wherein said steam is redirected to heat said slurry during said preparing.

A process for converting a feedstock containing organic matter attached to insoluble solids into at least one useful material, comprising:

• preparing a slurry from the feedstock;
• heating the slurry to produce a liquid mixture and solid material that includes the insoluble solids;
• removing the solid material from the liquid mixture;
• reacting the liquid mixture in a first reaction to produce a reacted feed comprising at least one reacted solid product, at least one reacted liquid product, and water;
• separating said at least one reacted solid product, said water, and said at least one reacted liquid product from said reacted feed;
• and
• converting said at least one reacted liquid product into at least one useful material in a second reaction wherein said at least one liquid product comprises at least one fat derivative or fatty acid.

A process for converting a feedstock into at least one useful material, comprising:

• preparing a slurry from the feedstock having organic matter attached to insoluble solids contained therein;
• passing the slurry through a heat exchanger, wherein one or more gases is vented, to produce a conditioned slurry that comprises a liquid mixture and a solid material that includes the insoluble solids;
• removing the solid material from the liquid mixture;
• reacting the conditioned slurry in a first reaction, wherein steam and gas is liberated, to produce a reacted feed comprising at least one reacted solid product, at least one reacted liquid product, and water, wherein the reacted solid product comprises at least one mineral;
• lowering a temperature, and lowering a pressure, of the reacted feed, to produce an intermediate feed;
• separating the at least one mineral from the intermediate feed, thereby producing a mixture comprising at least one reacted liquid product, and water;
• diverting said water to storage;
• subjecting said at least one reacted liquid product to a second reaction wherein carbon solids and a mixture of hydrocarbon vapor and gases are produced.

A process for converting municipal sewage sludge into at least one useful material, comprising:

• preparing a slurry from the municipal sewage sludge;
• heating the slurry at a pressure above the saturation pressure of water in the sewage sludge slurry to produce a liquid mixture and insoluble solids;
• removing the insoluble solids;
• reacting the liquid mixture in a first reaction at a pressure of at least the saturation pressure of water in the liquid mixture to produce a reacted feed comprising at least one reacted solid product, and at least one reacted liquid product, and water;
• separating said at least one reacted solid product, said water, and said at least one reacted liquid product from said reacted feed;
• and
• converting said at least one liquid product into a at least one of hydrocarbon oils, fuel gas and a mixture of minerals and carbon, said converting comprising a liquid—liquid separation.

A process for converting animal processing wastes into at least one useful material, comprising:

• preparing a slurry from the animal processing waste;
• heating the slurry at a pressure above the saturation pressure of water in the animal processing waste slurry to produce a liquid mixture and bone material;
• removing the bone material;
• reacting the liquid mixture in a first reaction at a pressure at least at the saturation pressure of water in the liquid mixture to produce a reacted feed comprising at least one reacted solid product, and at least one reacted liquid product, and water;
• separating the at least one reacted solid product, the water, and the at least one reacted liquid product from the reacted feed;
• and
• converting the at least one reacted liquid product into at least one of hydrocarbon oils, fuel gas, and carbon, said converting comprising a liquid—liquid separation.

A process for converting a feedstock containing organic matter attached to insoluble solids into at least one useful material, including at least one of an oil, a fuel gas or purified solid, the process comprising:

• preparing a slurry from the feedstock;
• heating the slurry to a first temperature sufficient to lower the viscosity of slurry and separate insoluble solids to produce a liquid mixture with solid material that includes the insoluble solids
• removing the solid material from the liquid mixture
• reacting the liquid mixture in a first reaction at a second temperature to hydrolyze polymeric organic materials in the liquid mixture at a pressure at least at the saturation pressure of water in the liquid mixture to produce a reacted feed comprising water, at least one reacted solid product, and at least one reacted liquid product including an oil phase;
• separating said at least one reacted solid product, said water, and said at least one reacted liquid product from said reacted feed;
• and
• converting said at least one reacted liquid product into at least an oil by subjecting said at least one reacted liquid product to a liquid—liquid separation.

A process for producing fuel from a feedstock containing organic and inorganic material, comprising:

• preparing a slurry including water from the feedstock to form a process stream;
• heating the process stream to a temperature sufficient to separate inorganic materials from organic materials,
• removing at least one inorganic material from the process stream after said heating;
• reacting the process stream at a pressure above the water saturation pressure of water in the process stream to at least hydrolyze polymeric organic materials in the process stream;
• rapidly reducing the pressure on the process stream after said reacting to recover vapors and heat, including steam;
• separating and removing solids and water from the process stream after reducing the pressure;
• diverting at least a part of the process stream for use as a fuel.