Catalytic Fuel Technology

Catalytic Fuel Technology

The Catalytec CFC 700 System™ waste to energy process is carbon neutral, highly efficient, pollution-less, modular in design, and economically viable. Using waste products as feedstock, the produced fuel is a Straight Fuel Oil, not an additive, with equal or better  power produced in terms of BTU content, as compared to the US highway diesel fuel standard (ASTM D975). CFC derived fuels can also be mixed or blended with similar weight conventional or existing fuel oil stock.

“A single Catalytec CFC 700 System can produce up to 185 gallons per hour of Catalytic Fuel”

The Catalytec CFC 700 System™ uses a proprietary catalyst to provide low-temperature thermal hydrocracking of a wide range of organic waste products (used oils, fats, greases, plastics, MSW, medical waste, agricultural waste, commercial or industrial organic waste, biomass, etc.) with an extremely high rate of efficiency and low cost. The uniform pore size in the proprietary catalyst provides consistent and efficient cracking to specifically C10 to C22 carbon chains, the same weight range as middle distillate fuel oils derived from crude. Depending on the molecular composition of the feedstock and other factors, the input to output conversion efficiency will range from 20% to as high as 90%.

CFC Technology:


  • Eliminates the need to use food products (corn, rice, etc.) to produce renewable fuel.
  • Creates renewable, sustainable sources of stable liquid fuel from waste streams.
  • Provides a safe, pollution-free, low temperature, continuous-flow process; no metal steam, coking, dioxins, furans, or other toxins are formed.
  • Significantly reduces carbon footprint.
  • Closes the loop in re-using all man-made waste with an elegant, profitable solution.
  • Does not require government subsidies to provide attractive financial returns.
  • Creates new jobs and secondary markets in the clean and renewable energy industries.

 



CATALYTEC's first CFC concept demonstration and feedstock verification device which was located at Alcoa Aluminum's Micromill facility near Reno, NV, from 2010-2012.

Our patents pending CFC 700 System uses a low temperature, catalytically driven refining process. The proprietary zeolite catalyst provides chemical reaction and thermal hydrocracking of long-chain carbon molecules at temperatures and pressures much lower than those of traditional crude refineries. This is a tremendous savings in terms of required energy, cost to produce, safety and environmental impact. Our catalyst is an inert, non-toxic  zeolite, which when heated to its trigger temperature becomes very active, effectively “cutting” all presented organic molecules to a size or length smaller than the pore size of the catalyst. The system utilizes viscous friction, pressure and specific cavitation to mix, circulate and heat the feedstock mixture in the combustion-less, closed-loop, fluid-dynamic circuit. The chemical reaction occurs in seconds, within a very narrow set of operational parameters, including but certainly not limited to temperature, physical size of reaction, flow rate, pressure. Control of these and several other parameters are critical to control and efficiency of the reaction. Newly fractionated hydrocarbons, up to C22 in size, rise on the heat-energy of the reaction into a distillation column and are condensed into liquid. The reaction is always maintained below 340°C. Thus no coke, metal steam or dangerous halogens and other toxins are formed, allowing a large measure of safety when located near people.

All engineering, construction, and manufacturing of Catalytec CFC 700 Systems™ will comply with U.S. technical regulations. Safety features and installed equipment are state of the art. A single Catalytec CFC 700 System™ (30’H x 30’W x 30’D) can produce up to 185 gallons of catalytic fuel per hour.

 

 

 

 

CFC Process Overview:


  • Carrier oil (approximately 25-30% of total input) is introduced to the circuit, after being preheated to remove water molecules. Catalyst, buffer, and solid materials (ground to particle sizes of 1mm to 10mm), are introduced to the fluid dynamic circuit.
  • The material is mixed and heated via circulation in the reaction circuit.

  • Vacuum pumps reduce the internal system pressure to about 1/2 atmosphere. Upon reaching catalytic trigger temperature, the normally inert catalyst becomes extremely active and generates its own heat.

  • The catalyst allows passage of up to C-22 carbon chains, which rise as diesel steam in the dehydration column. It is then condensed to a liquid and flows to a cooling tank, before dehydration and finishing processes.

  • The reaction is moderately aggressive, occurring in seconds and supporting a continuos process.

  • Any inert or other materials not processed, including spent catalyst and salts, are discharged as tar-like slurry, which typically accounts for 5% of total throughput. It can be use as a paving or roofing product extender, or baked dry and used as road base or filler.

 

CFC Eliminates Food vs Fuel Debate

The Catalytec CFC 700 System™ does not depend on food crops to create fuel. The Catalytec CFC 700 System™ converts waste materials into high power, catalytic fuels. Arable land, used to grow food crops, can continue to be used for food production.

Closed-Loop, Continuous Production Design

Our Catalytec CFC 700 Systems™ use a closed-loop, emission-less design. The System is maintained at 0.5 bar (½ atmosphere). This “pressure-less” feature eliminates the potential for system leaks, enabling the location of CFC Plants near population centers without risk to public safety.

Low Energy Production Requirement

The Catalytec CFC 700 System™ can powered by a combined heat and power unit (“CHP”), which provides  heat and electrical energy to run the plant. Approximately 10% of the produced distillate fractions is undesirable as a finished product, but can be used as fuel for the CHP to power the plant, protecting investors from any price volatility in plant power expense.

Patent Pending Technology

Catalytec has several German and International patent applications on file and more pending worldwide.