Frank Pringle -- Microwave recovery of fossil fuels --
High-Frequency Attenuating Wave Kinetics (HAWK) -- articles,
patent

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**[rexresearch.com](../index.htm)**

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**Frank PRINGLE**

**High-Frequency Attenuating Wave Kinetics
(HAWK)**

***Microwave Recovery of Fossil Fuels***

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[**http://www.globalresourcecorp.com**](http://www.globalresourcecorp.com)

GLOBAL RESOURCE CORPORATION   
BLOOMFIELD BUSINESS PARK   
408 BLOOMFIELD DR. UNIT 3   
WEST BERLIN , NJ 08091

Phone: 856-767-5661; Fax: 856-767-5664

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Featured as a 2007 Innovation of the Year ("Best of What's
New") in *Popular Science* : [**http://www.popsci.com/popsci/flat/bown/2007/innovator\_2.html**](http://www.popsci.com/popsci/flat/bown/2007/innovator_2.html)

"The machine is a microwave emitter that extracts the petroleum
and gas hidden inside everyday objectsor at least anything made
with hydrocarbons, which, it turns out, is most of whats around
you."

*Time* ("Best Inventions of the year")
:  [**http://www.time.com/time/specials/2007/article/0,28804,1677329\_1678027\_1677993,00.html**](http://www.time.com/time/specials/2007/article/0,28804,1677329_1678027_1677993,00.html)

Frank Pringle, CEO of Global Resource Corp., has developed an
emissions-free process that uses microwaves to pull fuel out of
shale rock, tires and even plastic bottles. The extraction
technology might also help recover oil that is stuck in muck
inside hundreds of capped wells across the country.

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![](green_hawk.jpg)

Frank Pringle [right] and Hawk Hogan [left] feed the Hawk
recycler, which extracts oil and gas from waste like tires.

In the microwave, under vacuum, the ground up tire is gasified,
removing all the hydrocarbons, leaving carbon black behind,
which is a salable product, used for making dyes and tires. The
input tire loses ~ 60% of its weight, turning into gases and oil
(mostly in the dieself fuel range). The products are sulfur
free.

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[**http://www.globalresourcecorp.com**](http://www.globalresourcecorp.com)  
**PowerPoint Presentation: <http://www.globalresourcecorp.com/Downloads/GRC_Presentation_2007.pps>**
  
**Engineering Data:  <http://www.globalresourcecorp.com/Engineering%20Data.html>**
  
**Press Releases:  <http://www.globalresourcecorp.com/Recent%20Press.html>**

**Videos:**

[**http://www.youtube.com/profile?user=globalresource**](http://www.youtube.com/profile?user=globalresource)  
[**http://youtube.com/watch?v=nCcV0DhkDtk**](http://youtube.com/watch?v=nCcV0DhkDtk)

Converting rubber and plastic to oil and gas - Global Resource
Corporation (GRC) is reducing plastics back to oil and
combustible gas using 1200 different frequencies within the
microwave range, which act on specific hydrocarbon materials.
This video demonstrates taking 100 grams of ground up tires and
turning it into oil and gas (mostly diesel range).

[**http://www.youtube.com/watch?v=GRfAZdbri78**](http://www.youtube.com/watch?v=GRfAZdbri78)

Demonstrates converting low value Coal into environmentally
friendly high-value products such as methane and hydrogen, as
well as environmentally friendly Slag discharge, with further
technologies being developed to turn it into petrolium coke.

[**http://youtube.com/watch?v=PdqO0OOnelE**](http://youtube.com/watch?v=PdqO0OOnelE)

Global Resource Corp announced today that performance tests to
convert bituminous coal into kerosene without using any
additives. The process was invented in 1923 but has never been
completed without additives and a required heat source, which is
now replaced by GBRC's patent-pending microwave technology.

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Global Resource Corp's HAWK recycler extracts oil and gas in
seconds from most everyday objects like tires, plastic cups, as
well as from shale, coal, and tar sands. Microwaves tuned to an
optimum frequency separate the component parts which can be
burned or condensed into liquid fuel, using only a small portion
of the energy produced.

GRCs Patent Pending discoveries encompass many years of
research and development working in high frequencies of
microwave (RF) identifying specific frequencies most suitable
for the target substance. The microwave frequences are applied
in linear acceleration with molecular excitation of polar
molecules intrinsic to hydrocarbons and other carbon materials.
The process can also be used for extracting heavy oil from
capped-off oil wells.

The first commercial plant is under construction. Available
Production unit expected in early 2008.

---

**Description:**

"To everything there is a frequency that excites its molecules
best. Just like the 2450MHz frequency magnetron in your kitchen
microwave oven which is specific to water (H2O) molecules, GRCs
hydrocarbon specific frequencies are generated by much higher RF
klystrons that actually crack the hydrocarbon chain into its
characteristic fuels.

"By definition it is not pyrolysis because cracking the
hydrocarbon chain is inherent to specific frequencies and has
little to do with the amount of heat generated. The process
however is done without water and performed in an oxygen starved
environment. We call this technology: **High-Frequency
Attenuating Wave Kinetics** or HAWK for short.

"There is also no CO2 or CO produced in the process because
there is no oxidation other than possibly a miniscule amount
that may be pre-existing in the material or minerals processed.
GRCs vacuum environment creates an accelerated pressure thereby
assimilating what Mother Nature has done through countless years
to make fuels.

"The two basic elements offered for all GRCs applications are
in situ and off situ. We have designed klystron machinery for
gasifying hydrocarbons where they exist or in fabricated
systems. In-situ meaning processed deep in the ground, rock
formations or anywhere naturally occurring and off-situ meaning
processed above ground that is mined or material removed from
site.

"A klystron is a microwave electron tube with velocity
modulation that is different from magnetrons. Its uses were
privy to military applications for radar jamming before stealth
technologies became more dominant in later years. GRC is the
first to commercialize this technology and by modifying
amplifiers and power supplies to suit our applications, we now
possess the technology that will free America from foreign oil
imports."

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[**http://www.globalresourcecorp.com/Downloads/GRC\_Presentation\_2007.pps**](http://www.globalresourcecorp.com/Downloads/GRC_Presentation_2007.pps)

Mr. Frank Pringle began work identifying Specific Microwave
Frequencies in 1996 while working to separate ceramics from bulk
glass cullet systems. Since the, and mainly over the past seven
years, Mr. Pringle has identified over 1200 specific RF
microwave frequencies intrinsic to hydrocarbon
elements/materials.

---

[**http://biz.yahoo.com/prnews/071113/cltu081.html?.v=97**](http://biz.yahoo.com/prnews/071113/cltu081.html?.v=97)

"Global Resource Corporation is a Worldwide Petroleum Research,
Engineering, Development, and Manufacturing Company that thinks
outside the box and is responsible for bringing innovation and
new technologies to the petrochemical industries where we offer
many proprietary solutions in Enhanced Oil & Energy Recovery
Processes."

"Global Resource Corp. has a patent pending process that allows
for removal of oil and alternative petroleum products at very
low cost from various resources, including shale deposits, tar
sands, waste oil streams and bituminous coal with significantly
greater yields and lower costs than are available utilizing
existing known technologies. The process uses specific
frequencies of microwave radiation to extract oils and
alternative petroleum products from secondary raw materials, and
is expected to dramatically reduce the cost for oil and gas
recovery from a variety of unconventional hydrocarbon resources.
GBRC's technology will not only be developed to extract oil from
shale, but from depleted oil fields in the US and elsewhere,
many of which still contain more than half of the hydrocarbons
originally in these fields, because the residual hydrocarbons
are too viscous to extract with conventional technology."

---



**US Patent Application #  20070131591**

**Pringle; Frank G.**   
**June 14, 2007**

**MICROWAVE-BASED RECOVERY OF HYDROCARBONS
AND FOSSIL FUELS**

![](pringlepat.jpg)

**Abstract ---** The present invention provides
methods for decomposing and extracting compositions for the
recovery of petroleum-based materials from composites comprising
those petroleum-based materials, comprising subjecting the
compositions and/or composites to microwave radiation, wherein
the microwave radiation is in the range of from about 4 GHz to
about 18 GHz. The present invention also provides for products
produced by the methods of the present invention and for
apparatuses used to perform the methods of the present
invention.

**Correspondence Name and Address:**

WOODCOCK WASHBURN LLP   
CIRA CENTRE, 12TH FLOOR   
2929 ARCH STREET   
PHILADELPHIA  PA 19104-2891  US

Assignee Name and Adress:  Mobilestream Oil, Inc., West
Berlin NJ

U.S. Current Class:  208/402; 204/157.15; 422/186; 585/241
  
U.S. Class at Publication:  208/402; 585/241; 204/157.15;
422/186   
Intern'l Class:  C10G 1/10 20060101 C10G001/10; C10G 1/00
20060101 C10G001/00; C07C 1/00 20060101 C07C001/00; B01J 19/08
20060101 B01J019/08

**Description**

**CROSS-REFERENCE TO RELATED APPLICATIONS**

[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 60/750,098, "Method for Using Microwave
Radiation", filed Dec. 14, 2005, the entirety of which is
incorporated by reference herein.

**FIELD OF THE INVENTION**

[0002] The present invention relates to methods and apparatuses
for using microwave radiation and more particularly, to methods
and apparatuses for decomposing compositions comprising
petroleum-based materials.

**BACKGROUND OF THE INVENTION**

[0003] Petroleum-based materials are integral to the world's
economy and demand for such fuels and consumer products is
increasing. As the demand rises, there is a need to efficiently
and economically extract petroleum-based materials to fulfill
that demand. As such, it would be advantageous to not only be
able to extract petroleum-based materials from the earth, but to
also recycle consumer products to recapture those
petroleum-based materials.

[0004] Worldwide oil consumption is estimated at seventy-three
million barrels per day and growing. Thus, there is a need for
sufficient oil supplies. Tar sands, oil sands, oil shales, oil
cuttings, and slurry oil contain large quantities of oil,
however, extraction of oil from these materials is costly and
time-consuming and generally does not yield sufficient
quantities of usable oil.

[0005] Soil contaminated with petroleum products is an
environmental hazard, yet decontamination of petroleum-tainted
soil is time-consuming and expensive.

[0006] Furthermore, it has been estimated that 280 million
gallons of oil-based products such as plastics go into landfills
each day in the United States. It would be desirable to
recapture and recycle the raw materials of these products.

[0007] Scrap vehicle tires are a significant problem worldwide
and their disposal presents significant environmental and safety
hazards, including fires, overflowing landfills, and atmospheric
pollution. While there are a number of existing applications for
these tires, including tire-derived fuels, road construction,
and rubber products, these applications are insufficient to
dispose of all the available scrap tires. The major components
of tires are steel, carbon black, and hydrocarbon gases and
oils, which are commercially desirable. As such, it is
advantageous to develop processes for the recovery of these
products from scrap vehicles tires. Prior art methods of
decomposing scrap vehicle tires do not produce commercial-grade
carbon black and require high temperatures and extended exposure
times for recovery of the hydrocarbon components.

[0008] Efforts to recycle tires using microwave technology has
been described in **U.S. Pat. Nos. 5,507,927** and **5,877,395**
to Emery. Efforts to recover petroleum from
petroleum-impregnated media has been described in **U.S. Pat.
Nos. 4,817,711** and **4,912,971** to Jeambey. Efforts
to decompose plastics using microwave radiation has been
described in **U.S. Pat. No. 5,084,140** to Holland. The
prior work has involved the use of single-frequency microwave
radiation. Single-frequency microwave radiation is a slow
process that does not provide uniform heating. Moreover,
single-frequency microwave radiation typically results in arcing
on metal components.

[0009] Thus, there is a need for methods and apparatuses for
the recycling of petroleum-based compositions and for the
recovery of petroleum-based materials from composites containing
petroleum-based materials. The invention is directed to these
and other important needs.

**SUMMARY OF THE INVENTION**

[0010] The present invention provides methods for decomposing
compositions comprising carbon-based materials comprising
subjecting the compositions to microwave radiation for a time
sufficient to at least partially decompose the composition,
wherein the microwave radiation comprises at least one frequency
component in the range of from about 4 GHz to about 18 GHz.

[0011] The present invention provides methods for decomposing
compositions comprising petroleum-based materials comprising
subjecting the compositions to microwave radiation for a time
sufficient to at least partially decompose the composition,
wherein the microwave radiation comprises at least one frequency
component in the range of from about 4 GHz to about 18 GHz.

[0012] The present invention further provides methods for
recovery of petroleum-based materials from composites comprising
those petroleum-based materials. The methods of the present
invention include subjecting the composite to microwave
radiation for a time sufficient to extract the petroleum-based
material, wherein the microwave radiation comprises at least one
frequency component in the range of from about **4 GHz to
about 18 GHz**.

[0013] The present invention also provides for products
produced by the methods of the present invention.

[0014] The present invention additionally provides apparatuses
for decomposing compositions comprising petroleum-based
materials. The apparatuses of the present invention comprise a
microwave radiation generator, wherein the generator is capable
of applying microwave radiation characterized as having at least
one frequency component in the range of from 4 GHz to about 18
GHz, and at least one container to collect decomposed components
from the compositions. The present invention further provides
apparatuses for extracting petroleum-based materials from
composites comprising the petroleum-based material. These
apparatuses comprise a microwave radiation generator, wherein
the generator is capable of applying microwave radiation
characterized as having at least one frequency component in the
range of from 4 GHz to about 18 GHz, and at least one container
to collect decomposed components from the composite.

[0015] The general description and the following detailed
description are exemplary and explanatory only and are not
restrictive of the invention, as defined in the appended claims.
Other aspects of the present invention will be apparent to those
skilled in the art in view of the detailed description of the
invention as provided herein.

**BRIEF DESCRIPTION OF THE DRAWINGS**

[0016] The summary, as well as the following detailed
description, is further understood when read in conjunction with
the appended drawings. For the purpose of illustrating the
invention, there are shown in the drawings exemplary embodiments
of the invention; however, the invention is not limited to the
specific methods, compositions, and devices disclosed. In
addition, the drawings are not necessarily drawn to scale. In
the drawings:

[0017] **FIGS. 1A-1G** illustrate an embodiment of the
present invention directed to processing tire cuttings using
microwaves to recover fuel oil;

[0018] **FIG. 2A** is an elevation view, axial direction,
of a microwave reactor suitable for processing oil cuttings
according to an aspect of the present invention;

[0019] **FIG. 2B** illustrates an elevation view of the
microwave reactor of FIG. 2A, longitudinal direction;

[0020] **FIG. 2C** illustrates an elevation view of the
microwave device and control room suitable for generating
microwaves and propagating the same through waveguides;

[0021] **FIGS. 3A-3B** illustrate several embodiments of
the present invention for extracting petroleum-based materials
from oil slurry;

[0022] **FIG. 4A** illustrates an elevation view of a
microwave reactor system suitable for processing shale rock, tar
sands, drill cuttings, and the like;

[0023] **FIG. 4B** provides a plan view of FIG. 4A;

[0024] **FIG. 5A** is an illustration of one embodiment of
the present invention for extracting petroleum-based materials
from heavy oil contained in oil wells;

[0025] **FIG. 5B** is an illustration of one embodiment of
the present invention for extracting petroleum-based materials
from oil shale, in situ;

[0026] **FIG. 6** is an illustration of one embodiment of
the present invention for extracting petroleum-based materials
from tar sands, oil sands and shale rock;

[0027] **FIG. 7** is an schematic of one embodiment of the
present invention for decomposing vehicle tires;

[0028] **FIG. 8A** is a plan view of an oil platform
incorporating a drill cuttings microwave processing unit;

[0029] **FIG. 8B** illustrates an elevation view of the oil
platform in FIG. 8A;

[0030] **FIG. 8C** illustrates a vertical and horizontal
configurations of the drill cuttings microwave processing unit
suitable for use in the oil platform illustrated in FIG. 8A;

[0031] **FIG. 9A** is a depiction of an electron microscope
photograph of carbon black produced by the method of the present
invention;

[0032] **FIG. 9B** is a depiction of an electron
microscope photograph of carbon black produced by the method of
the present invention;

[0033] **FIG. 9C** is a depiction of an electron microscope
photograph of carbon black produced by the method of the present
invention; and

[0034] **FIGS. 10A-10E** illustrate an additional
embodiment of a drum reactor system for processing materials
containing hydrocarbons.

**DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS**

[0035] The present invention may be understood more readily by
reference to the following detailed description taken in
connection with the accompanying figures and examples, which
form a part of this disclosure. It is to be understood that this
invention is not limited to the specific devices, methods,
applications, conditions or parameters described and/or shown
herein, and that the terminology used herein is for the purpose
of describing particular embodiments by way of example only and
is not intended to be limiting of the claimed invention. Also,
as used in the specification including the appended claims, the
singular forms "a," "an," and "the" include the plural, and
reference to a particular numerical value includes at least that
particular value, unless the context clearly dictates otherwise.
The term "plurality", as used herein, means more than one. When
a range of values is expressed, another embodiment includes from
the one particular value and/or to the other particular value.
Similarly, when values are expressed as approximations, by use
of the antecedent "about," it will be understood that the
particular value forms another embodiment. All ranges are
inclusive and combinable.

[0036] It is to be appreciated that certain features of the
invention which are, for clarity, described herein in the
context of separate embodiments, may also be provided in
combination in a single embodiment. Conversely, various features
of the invention that are, for brevity, described in the context
of a single embodiment, may also be provided separately or in
any subcombination. Further, reference to values stated in
ranges include each and every value within that range.

[0037] "Sweeping," as the term is used herein, is defined as
the application of a plurality of radiation frequencies over a
period of time.

[0038] "Pulsing," as used herein, means subjecting the
composition to microwave radiation for a period of time,
followed by periods of time wherein the composition is not
subjected to microwave radiation.

[0039] "Oil," as used herein, means any hydrocarbon or
petroleum-based oil.

[0040] "Gas," as used herein, includes any hydrocarbon-based
material that is in the gaseous state at atmospheric temperature
and pressure and includes, but is not limited to, methane,
ethane, propane, butane, isobutene, or mixtures thereof.

[0041] "Carbon black," as used herein, includes any grade of
commercially-acceptable carbon black, including, but not limited
to, rubber black.

[0042] "Oil sands," also known as "tar sands," are deposits of
bitumen, a heavy black viscous oil.

[0043] "Oil shale" is sedimentary rock containing a high
proportion of Kerogen, which, when heated, can be converted into
oil.

[0044] "Slurry oil" is refinery waste oil.

[0045] "Oil cuttings" are the waste product generated during
the drilling of oil wells. Examples of oil cuttings include, but
are not limited to, bits and pieces of oil-soaked soil and rock.

[0046] "Hydrocarbons" are compositions that comprise carbon and
hydrogen.

[0047] "Carbon-based" refers to matter that comprises carbon.

[0048] "Decompose" and "decomposing" refers to a process
whereby matter is broken down to smaller constituents. For
example, solids can be broken down into particles, liquids,
vapors, gases, or any combination thereof, rubbery materials can
be broken down into liquids, vapors, gases, or any combination
thereof, viscous liquids can be broken down to lower viscosity
liquids, vapors, gases, or any combination thereof, liquids can
be broken down to vapors, gases, or any combination thereof;
composite materials comprising inorganic solids and trapped
organic matter can be broken down to inorganic solids and
released organic vapors and gases, and the like.

[0049] 1 Torr=1 mm Hg=1 millimeter mercury.

[0050] Methods for decomposing compositions comprising
petroleum-based materials are set forth herein. The compositions
used in the present invention contemplate any composition
comprised of petroleum-based, carbon-based and various
hydrocarbon materials. The petroleum-based materials may be
present in the composition in amounts ranging from about 1% to
100%, by weight, based on the weight of the composition.
Preferably, the composition is a vehicle tire. In other
embodiments, the composition comprises plastic, which includes,
but is not limited to ethylene (co)polymer, propylene
(co)polymer, styrene (co)polymer, butadiene (co)polymer,
polyvinyl chloride, polyvinyl acetate, polycarbonate,
polyethylene terephthalate, (meth)acrylic (co)polymer, or a
mixture thereof. A variety of natural and synthetic resins and
rubbers can also be decomposed according to the methods
described herein. Various carbon-based materials that can also
be processed according to the inventions described herein
include coal, such as anthracite coal and bituminous coal.

[0051] In one embodiment, the composition is subjected to
microwave radiation for a time sufficient to at least partially
decompose the composition. The microwave radiation can be in the
range of from about 4.0 and about 12.0 GHz. Other ranges can
also be used, for example, in the range of from about 4 GHz to
about 18 GHz, and more preferably in the range of from about 12
GHz to about 18 GHz. For example, coal can be processed at
frequencies in the range of from about 4 GHz to about 18 GHz,
and more preferably in the range of from about 12 GHz to about
18 GHz.

[0052] In one embodiment, the composition is subjected to one
or more pre-selected microwave radiation frequencies.
Preferably, the pre-selected microwave radiation frequency will
be the resonating microwave frequency, i.e, the microwave
radiation frequency at which the composition absorbs a maximum
amount of microwave radiation. It has been determined that
different compositions of the present invention will absorb more
or less microwave radiation, depending on the frequency of the
microwave radiation applied. It has also been determined that
the frequency at which maximum microwave radiation is absorbed
differs by composition. By using methods known in the art, a
composition of the present invention can be subjected to
different frequencies of microwave radiation and the relative
amounts of microwave radiation absorbed can be determined.
Preferably, the microwave radiation selected is the frequency
that comparatively results in the greatest amount of microwave
radiation absorption. In one embodiment, microwave radiation
frequency resulting in a comparative maximum absorption of
microwave radiation by the compositions of the present invention
is in the range of from about 4.0 and about 12.0 GHz. In others,
particularly with respect to vehicle tires, the microwave
radiation frequency resulting in a comparative maximum
absorption of microwave radiation by the compositions of the
present invention is in the range of from about 4.0 and about
7.2 GHz. In yet others, the microwave radiation frequency
resulting in a comparative maximum absorption of microwave
radiation by the compositions of the present invention is in the
range of from about 4.0 and about 6.0 GHz.

[0053] The present invention also provides methods for
subjecting a composition to a sweeping range of microwave
radiation frequencies for a time sufficient to at least
partially decompose the composition. Preferably, variable
frequency microwave ("VFM") is used to sweep the compositions.
VFM is described in U.S. Pat. No. 5,321,222 to Bible, et al. and
U.S. Pat. No. 5,521,360 to Johnson, et al., incorporated herein
by reference in their entireties. Unlike single frequency
microwave radiation, VFM produces a bandwidth of microwave
radiation frequencies that are applied sequentially to the
composition. Consequentially, the field distribution with VFM is
substantially more uniform than the field distribution of single
microwave frequency radiation. The more uniform field
distribution of VFM produces fewer hot spots, resulting in more
uniform heating of the composition. Moreover, generally, no
single frequency is applied for longer than about 25 .mu.s. The
short duration of each applied frequency produces no build-up of
charge, thus eliminating discharge, or arcing, typically
observed during single frequency microwave irradiation.

[0054] In some embodiments, particularly with respect to
vehicle tires, the range of microwave radiation frequencies
swept is in the range of from about 4.0 GHz to about 12.0 GHz.
In certain embodiments, the range of microwave radiation
frequencies swept is in the range of from about **5.8 GHz to
about 7.0 GHz**. In still others, the range of microwave
radiation frequencies swept is in the range of from about **7.9
GHz and 8.7 GHz**. In some embodiments, range of microwave
radiation frequencies is in the C-Band frequency range, the
C-Band frequency range encompassing microwave frequencies in the
range of from about 4.0 GHz to about 8.0 GHz. In other
embodiments, the range of microwave radiation frequencies is in
the X-Band frequency range, the X-band frequency range
encompassing microwave frequencies in the range of from about
8.0 GHz to about 12.0 GHz.

[0055] Preferably, the sweeping of the range of microwave
radiation frequencies encompasses a pre-selected, resonating
microwave radiation frequency characterized as having at least
one frequency component in the range of from about 4.0 GHz to
about 12.0 GHz. This frequency can be selected by using the
methods described herein and techniques known in the art.
Preferably, the bandwidth of the sweeping range of microwave
radiation is about 4.0 GHz. More preferably, the range of
microwave frequencies with which the composition is swept, is
about .+-.2 GHz of the pre-selected microwave radiation
frequency. For example, if the pre-selected microwave radiation
frequency is 7.2 GHz, the composition would be swept with the
range of microwave radiation frequencies encompassing from about
5.2 to about 9.2 GHz. The microwave frequencies can also be
swept at about .+-.1.5 GHz, or even .+-.1.0 GHz, or even .+-.0.5
GHz of the preselected microwave frequency.

[0056] Upon decomposition of the compositions subjected to the
methods and apparatuses of the invention, flammable
hydrocarbon-based gases are released. To reduce the risk of
ignition, it is preferred that the method be performed in an
oxygen-deprived atmosphere. Preferably, the composition is
exposed to less than about 12% oxygen. More preferably, the
composition is exposed to less than about 8% oxygen. Even more
preferably, the composition is exposed to less than about 5%
oxygen.

[0057] In one embodiment, the composition is exposed an inert
gas atmosphere. Preferably, the inert gas is nitrogen, argon, or
mixtures thereof.

[0058] In some embodiments, the composition is exposed to less
than atmospheric pressure. Preferably, the composition is
exposed to less than about 40 Torr. More preferably, the
composition is exposed to less than about 20 Torr. Even more
preferably, the composition is exposed to less than about 5
Torr. Without being bound by any particular theory or operation,
it is believed that operating at sub-atmospheric pressures helps
to recover hydrocarbon-based gases and prevents over-heating.

[0059] In one embodiment, the composition of the present
invention forms a vehicle tire. Using the methods of the present
invention, the tire can be decomposed to produce at least one of
oil, gas, steel, sulfur, and carbon black.

[0060] Over-exposure to microwave radiation and over-heating of
the composition of the present invention may result in the
recovery of non-commercially-acceptable carbon black.
Controlling the temperature of the composition during microwave
irradiation prevents such over-exposure and over-heating to
produce commercially-acceptable carbon black. Preferably, the
temperature of the composition does not exceed about 700.degree.
F. More preferably, the temperature of the composition does not
exceed about 500.degree. F. Even more preferably, the
temperature of the composition does not exceed about 465.degree.
F.

[0061] In one embodiment, the temperature of the composition
can be controlled while performing the method of the present
invention by pulsing the microwave radiation subjection. For
example, microwave radiation can be applied until the
composition temperature reaches about 465.degree. F., at which
time, the application of microwave radiation can be stopped for
a time sufficient for the composition to cool between about 5 to
25 degrees. Once the composition has cooled, the application of
microwave radiation can be resumed. This process can be
repeated, as necessary, until the composition is sufficiently
decomposed.

[0062] Decomposition products obtained from the compositions
using the methods of the present invention may be refined and/or
purified using techniques known in the art.

[0063] The present invention also provides methods for
extracting petroleum-based materials from composites comprising
the petroleum-based materials by subjecting the composites to
microwave radiation for a time sufficient to extract the
petroleum-based material. Preferably, the microwave radiation is
in the range of from about 4.0 and about 12.0 GHz.

[0064] The composites are any material comprising
petroleum-based materials, including, but not limited to, at
least one of oil sands, oil shale, slurry oil, oil cuttings, and
soil or sand contaminated with petroleum-based materials. As
used herein, "composites" also includes, but is not limited to,
oil wells.

[0065] In one embodiment, the composite is subjected to one or
more pre-selected microwave radiation frequencies. Preferably,
the pre-selected microwave radiation frequency will be the
resonating microwave frequency, i.e, the microwave radiation
frequency at which the composite absorbs a maximum amount of
microwave radiation. It has been determined that different
composites of the present invention will absorb more or less
microwave radiation, depending on the frequency of the microwave
radiation applied. It has also been determined that the
frequency at which maximum microwave radiation is absorbed
differs by composite. By using methods known in the art, a
composite of the present invention can be subjected to different
frequencies of microwave radiation and the relative amounts of
microwave radiation absorbed can be determined. Preferably, the
microwave radiation selected is the frequency that comparatively
results in the greatest amount of microwave radiation
absorption. In one embodiment, microwave radiation frequency
resulting in a comparative maximum absorption of microwave
radiation by the composite of the present invention is in the
range of from about 4.0 and about 12.0 GHz. In others, the
microwave radiation frequency resulting in a comparative maximum
absorption of microwave radiation by the composite of the
present invention is in the range of from about 7.9 and about
12.0 GHz. In yet others, the microwave radiation frequency
resulting in a comparative maximum absorption of microwave
radiation by the composite of the present invention is in the
range of from about 7.9 and about 8.7 GHz.

[0066] The present invention also provides methods for recovery
of petroleum-based materials from composites comprising those
petroleum-based materials, by subjecting the composite to a
sweeping range of microwave radiation frequencies for a time
sufficient to extract the petroleum-based material, and wherein
the range of frequencies of the microwave radiation is in the
range of from about 4.0 GHz to about 12.0 GHz. The composites
are any material comprising petroleum-based materials,
including, but not limited to, at least one of oil sands, oil
shale, slurry oil, oil cuttings and soil or sand contaminated
with petroleum-based materials.

[0067] Preferably, variable frequency microwave ("VFM") is used
to sweep the composites. VFM is described in **U.S. Pat. No.
5,321,222** to Bible, et al. and **U.S. Pat. No. 5,521,360**
to Johnson, et al., incorporated herein by reference in their
entireties. Unlike single frequency microwave radiation, VFM
produces a bandwidth of microwave radiation frequencies that are
applied sequentially to the composite. Consequentially, the
field distribution with VFM is substantially more uniform than
the field distribution of single microwave frequency radiation.
The more uniform field distribution of VFM produces fewer hot
spots, resulting in more uniform heating of the composite.
Moreover, generally, no single frequency is applied for longer
than about 25 .mu.sr, or no longer than about 20 .mu.s, or no
longer than about 15.mu.s, or even no longer than about 10.mu.s.
The short duration of each applied frequency produces no
build-up of charge, thus eliminating discharge, or arcing,
typically observed during single frequency microwave
irradiation.

[0068] In certain embodiments, the range of microwave radiation
frequencies is in the range of from about 7.9 GHz to about 12.0
GHz. In still others, the range of microwave radiation
frequencies is in the range of from about 7.9 GHz and 8.7 GHz.
In some embodiments, range of microwave radiation frequencies is
in the C-Band frequency range, the C-Band frequency range
encompassing microwave frequencies in the range of from about
4.0 GHz to about 8.0 GHz. In other embodiments, the range of
microwave radiation frequencies is in the X-Band frequency
range, the X-band frequency range encompassing microwave
frequencies in the range of from about 8.0 GHz to about 12.0
GHz.

[0069] Preferably, the sweeping of the range of microwave
radiation frequencies encompasses one or more pre-selected
microwave radiation frequencies in the range of from about 4.0
GHz to about 12.0 GHz. This frequency can be selected by using
the methods described herein and techniques known in the art. In
one embodiment, the pre-selected microwave radiation frequency
is in the range of from about 7.9 and about 8.7 GHz. In other
embodiments, the bandwidth of the sweeping range of microwave
radiation is about 4.0 GHz. More preferably, the range of
microwave frequencies with which the composition is swept, is
about .+-.2 GHz of the pre-selected microwave radiation
frequency. For example, if the pre-selected microwave radiation
frequency is 7.2 GHz, the composition would be swept with the
range of microwave radiation frequencies encompassing from about
5.2 to about 9.2 GHz.

[0070] Upon extraction, flammable hydrocarbon-based gases are
released. To reduce the risk of ignition, it is preferred that
the method be performed in an oxygen-deprived atmosphere.
Preferably, the composite is exposed to less than about 12%
oxygen. More preferably, the composite is exposed to less than
about 8% oxygen. Even more preferably, the composite is exposed
to less than about 5% oxygen.

[0071] In one embodiment, the composite is exposed to an inert
gas atmosphere. Preferably, the inert gas is nitrogen, argon, or
mixtures thereof.

[0072] In some embodiments, the composite is exposed to less
than atmospheric pressure. Preferably, the composite is exposed
to less than about 40 Torr. More preferably, the composite is
exposed to less than about 20 Torr. Even more preferably, the
composite is exposed to less than about 5 Torr.

[0073] In one embodiment, the composite is subjected to
microwave radiation sufficient to heat the petroleum-based
material to its boiling point temperature. Boiling point
temperatures of petroleum-based materials are known in the art.
Reducing the pressure at which the composite is exposed will
result in a decrease in the boiling point temperature of the
petroleum-based material. Those of skill in the art will be able
to determine the boiling point temperatures of petroleum-based
materials at different pressures.

[0074] In some embodiments, the methods of the present
invention may be used in situ to extract petroleum-based
materials from composites located in the field. In other
embodiments, inert gases may be flowed, in situ, onto the
composites. In one embodiment, the pressure surrounding the
composite may be reduced to below atmospheric pressure.

[0075] Using the methods of the present invention, oil and/or
gases can be recovered from the composite.

[0076] The petroleum-based material extracted using the methods
of the present invention may be refined and/or purified using
techniques known in the art.

[0077] The present invention also provides for apparatuses for
decomposing a composition comprising a petroleum-based material.
In one embodiment, the apparatuses of the present invention
comprise a microwave radiation generator, wherein the generator
is capable of applying microwave radiation characterized as
having at least one frequency component in the range of from
about 4.0 and about 12.0 GHz, and at least one container to
collect decomposed components from the composition. In one
embodiment, the microwave radiation generator is capable of
applying a microwave radiation frequency between about 4.0 and
about 12.0 GHz.

[0078] In other embodiments, the apparatuses of the present
invention comprise a microwave radiation generator, wherein the
generator is capable of applying a sweeping range of frequencies
of microwave radiation characterized as having at least one
frequency component in the range of from about 4.0 GHz to about
12.0 GHz, and at least one container to collect decomposed
components from the composition. In other embodiments, microwave
radiation generator is capable of applying sweeping microwave
radiation in the C-Band frequency range. In yet other
embodiments, microwave radiation generator is capable of
applying sweeping microwave radiation in the X-Band frequency
range. In yet other embodiments, microwave radiation generator
is capable of applying sweeping microwave radiation in the
Ku-Band frequency range (about 12 GHz to about 18 GHz). In
further embodiments, the microwave radiation generator is
capable of applying sweeping microwave radiation in the range of
about 5.8 GHz to about 7.0 GHz. In yet other embodiments, the
microwave radiation generator is capable of applying sweeping
microwave radiation in the range of about 7.9 GHz to about 8.7
GHz.

[0079] In another embodiment, the chamber is open to the
outside atmospheric conditions. In other embodiments, the
chamber is closed to the outside atmosphere. In yet other
embodiments, the chamber has an internal pressure of less than
atmospheric pressure. Preferably, the chamber is capable of
operating at a pressure of less than about 40 Torr. More
preferably, the chamber is capable of operating at a pressure of
less than about 20 Torr. Even more preferably, the chamber is
capable of operating a pressure of less than about 5 Torr.

[0080] The present invention also provides for apparatuses for
extracting a petroleum-based material from a composite
comprising the petroleum-based material. In one embodiment, the
apparatuses of the present invention comprise a microwave
radiation generator, wherein the generator is capable of
applying microwave radiation characterized as having at least
one frequency component in the range of from about 4.0 GHz to
about 12.0 GHz, and at least one container to collect the
extracted petroleum-based material. In some embodiments, the
microwave radiation generator is capable of applying a microwave
radiation frequency of characterized as having at least one
frequency component in the range of from about 4.0 and about
12.0 GHz.

[0081] In other embodiments, the apparatuses of the present
invention comprise a microwave radiation generator, wherein the
generator is capable of applying a sweeping range of frequencies
of microwave radiation characterized as having at least one
frequency component in the range of from about 4.0 GHz to about
12.0 GHz, and at least one container to collect the extracted
petroleum-based material. In some embodiments, the microwave
radiation generator is capable of applying sweeping microwave
radiation in the C-Band frequency range. In yet other
embodiments, microwave radiation generator is capable of
applying sweeping microwave radiation in the X-Band frequency
range. In further embodiments, the microwave radiation generator
is capable of applying sweeping microwave radiation in the range
of about 5.8 GHz to about 7.0 GHz. In yet other embodiments, the
microwave radiation generator is capable of applying sweeping
microwave radiation in the range of about 7.9 GHz to about 8.7
GHz.

[0082] In some embodiments, the apparatuses of the present
invention may be used in situ to extracted petroleum-based
materials from composites located in the field.

[0083] In other embodiments, the apparatuses further comprise
at least one chamber for holding the composite. In another
embodiment, the chamber is open to the outside atmospheric
conditions. In other embodiments, the chamber is closed to the
outside atmosphere. In yet other embodiments, the chamber has an
internal pressure of less than atmospheric pressure. Preferably,
the chamber is capable of operating at a pressure of less than
about 40 Torr. More preferably, the chamber is capable of
operating at a pressure of less than about 20 Torr. Even more
preferably, the chamber is capable of operating at a pressure of
less than about 5 Torr.

[0084] In other embodiments, the apparatuses further comprise
at least one chamber for holding the composition. The volume of
the compositions of the present invention may reduce during
decomposition. In some embodiments, the chamber may have a
conveyor having a perforated bottom such that decomposed
materials may fall out of the chamber once reaching a particular
size, so as not to over-expose the materials to microwave
radiation. The conveyor may be adapted to be oscillated.

[0085] An exemplary embodiment of the present invention is
depicted in FIGS. 1A-1G. FIGS. 1A-1G demonstrates one apparatus
wherein tire fragments are placed on a first conveyor belt that
carries the tire pieces through three, differently-sized
chambers of the apparatus. In a first chamber, the tire pieces
are exposed to microwave radiation using the methods described
herein. As the tire fragments decompose, the smaller pieces will
fall through perforations in the first conveyor and drop to a
second conveyor. The second conveyor is not exposed to microwave
radiation in the first chamber. The second conveyor carries the
pieces to a second chamber, wherein they are exposed to
microwave radiation using the methods described herein. As the
pieces decompose, the smaller pieces fall through the
perforations in the second conveyor to a third conveyor. The
perforations in the second conveyor are smaller than the
perforations in the first conveyor. The third conveyor is not
exposed to microwave radiation in the second chamber. The third
conveyor carries the pieces to a third chamber, wherein they are
exposed to microwave radiation using the methods described
herein. As the pieces decompose, the smaller pieces fall through
the perforations in the third conveyor to a fourth conveyor. The
perforations in the third conveyor are smaller than the
perforations in the second conveyor. Decomposition will be
essentially complete after exposure in the third chamber and the
material remaining on the fourth conveyor will be mainly steel,
carbon black, and ash, which can be further processed using
techniques known in the art.

[0086] FIG. 1 comprises FIGS. 1A-1F, along with inset FIG. 1G.
The orientation of FIGS. 1A through FIG. 1F are set forth in the
inset in FIG. 1. Referring to FIGS. 1A-1G, there is provided an
embodiment of the present invention directed to processing tire
cuttings using microwaves to recover fuel oil. The processing
equipment described herein is commercially available from one or
more process equipment manufacturing companies.

[0087] FIG. 1A illustrates an elevation view of the beginning
section of a tire cuttings plant layout according to an aspect
of the present invention. This illustration shows two tire
processing lines side-by-side in a parallel configuration. Tires
from automobiles and trucks are first cut into suitable chips,
e.g., 4.times.4 or 5.times.5 chips (not shown). The tire chips
are transported using incline belt conveyor 120 to accumulation
silos 102. The tire chips are then conveyed from the
accumulation silos 102 to a pre-washer screw wash section 122.
Tire chips are then conveyed to a pressure washer hot water
sonic washer 105. Dirt, stones, gravel and other debris is
cleaned off of the tire chips to minimize contamination of the
process further downstream. The tire chips are then dried using
forced air dryer system 106. FIG. 1B is a plan view of the
beginning section of a tire cuttings plant layout corresponding
to FIG. 1A. Cleaned and dried tire chips are then conveyed up
another conveyor 120, as set forth in FIGS. 1C and 1D, below.

[0088] FIG. 1C is an elevation view of the midsection of the
tire cuttings plant layout described here. Cleaned and dried
chips are transported to accumulation silo 112, which are then
transported along transport conveyor 120 to microwave room 124.
The details of the microwave room 124 or further described in
FIG. 1G below. In this elevation view, a dual wall tank with
enclosed high high-capacity heat exchanger 118 is shown in
dotted lines. This high-capacity heat exchanger receives
hydrocarbon vapor produced by the microwave reactors residing
within the microwave room 124. The position of the dual wall
tank with enclosed high-capacity heat exchanger 118 is
illustrated further in FIG. 1D.

[0089] FIG. 1D is a plan view of the midsection of the tire
cuttings plant layout described here. Accumulation silos 112
feed tire chips via incline belt conveyor 120 and screw feed
in-feed section 117 to a series of microwave reactors within
hermetically sealed reactor room 116 with filtration system and
vacuum pumps. Tire chips in the screw feed in-feed section 117
are fed into a first microwave reactor 150 (see FIG. 1G)
residing within the microwave room 116. The microwave room is
depicted in FIG. 1D containing two sets of microwave reactors
side-by-side. Additional microwave reactors and additional lines
can also be added. Hydrocarbon vapors generated in the microwave
reactors from the irradiated tire chips are collected out of the
top of each of the microwave reactors. The hydrocarbon vapors
are then transported, under vacuum (e.g. at a pressure less than
ambient) to heat exchanger 118. The heat exchanger is capable of
further separating hydrocarbon vapors to oil and high carbon
gases by cooling to a liquid or a vapor, depending on the
vaporization temperature of the hydrocarbon vapors.

[0090] The microwave reactor room 116 is also depicted having
refrigeration equipment 123 for maintaining constant room
temperature. Processed tire chips exit the microwave reactor 154
(FIG. 1G) by a screw feed discharge section 115. Processed tire
chips exit the final microwave room hot and are subsequently
cooled using cooler 114. The cooled processed tire chips (below
about 110.degree. F.) then enter a pregrader grinder system 113,
where processed carbon containing materials are separated from
metallic materials (e.g., metal tire cords). Metal materials are
separated using a suitable magnetic conveyor take away system,
as shown in 121 in FIGS. 1E and 1F. Organic particles (e.g.
carbon black) can further be shipped to bulk feed trucks
equipped to handle fine particles, other packaging, as well as
rail cars. The resulting organic particles are composed
primarily of carbon. In some embodiments, the organic particles
can be used as electronic activators, as described herein.

[0091] FIGS. 1E and 1F illustrate the magnetic conveyor take
away system 121 for separating metal particles from nonmagnetic
organic matter. Metal is stored in a metal storage unit 140
while nonmagnetic organic matter (e.g., carbon particles) is
transported via incline belt conveyor 120 to silo and grinder
130. Carbon particles prepared according to the processes of the
present invention are suitable for use as electron activators
for the microwave processing of heavy residual refinery oil and
other materials (e.g., residual oil from the bottom of a
hydrocarbon distillation apparatus that is traditionally unable
to be further processed). In one embodiment, the tire sidewalls
can be separated from the tire treads. Tire treads typically
have a greater amount of carbon black than the sidewalls.
Accordingly, the amount of carbon black recovered from the
treads is greater than that of the sidewalls. In one aspect,
carbon black can be accumulated to form electron activator by
processing the treads. Electron activator that can be further
used in processing heavy viscous oil feedstocks. Also present is
a sifter system with grinder return 111 for preparing controlled
particle size carbon material. The matter in the silo and
grinder 130 is transported by a pneumatic tube conveyor system
119 and auxiliary pump 136 toward sifter 132, and then to sorter
134, and finally to a super sack gantry system 138. The super
sack entry system 109 is suitable for loading and unloading
using forklift delivery. Also shown is electrical enclosure 108
containing control panels, a centrifugal feeder/sorter system
110 for managing fine particles.

[0092] As shown in FIGS. 1D and 1G, the microwave reactor room
contains two series of three reactors each (one series is
illustrated in FIG. 1G). Tire pieces enter first reactor 150 via
screw feed infeed section 117. This reactor is the largest
reactor of the series. 4.times.4 or 5.times.5 inch tire chips
are first exposed to microwaves in the first reactor 150 by
operation of the microwave antennas in the first microwave
chamber 160. In this first stage, the tire pieces "pop" or
explode into smaller pieces when exposed to the microwaves. The
smaller pieces are separated through a mesh belt 170, and then
transported onto another transportation mesh belt 172. The mesh
is designed to keep the microwaves in the first reactor from
getting through and over heating the tire chips. Typically, the
temperature of the tire chips is maintained at about 465.degree.
F. or less. The mesh size in the larger reactor will have an
opening of approximately 2 inches, the mesh size in the midsized
reactor is approximately 0.5 inches, and the mesh size opening
for the smallest reactor is approximately 1/16''.

[0093] Microwaves are generally generated outside of the
microwave room and transported into the microwave room by a
suitable microwave conduit, e.g. stainless steel wire. The
design and interconnection of the three microwave reactors in
series is provided so that the location of the tire chips in the
microwave radiation zone is maintained so that the tire chips do
not exceed 465.degree. F. Initially, "popping" of the tire
begins in the first reactor 150 when the temperature of the tire
chips is in the range of from about 300.degree. F. to about
450.degree. F. It has been surprisingly found that once the
temperature exceeds about 450.degree. F., the carbon black
residing within the tires can be charred and overcooked and the
efficiency of the process for recovering hydrocarbon fuel oils
diminishes drastically. Accordingly temperature is desirably
maintained below about **465.degree. F**., or even below
about 550.degree. F. Without being bound by any particular
theory of operation, it appears that the tire chips pop because
the reactors are under vacuum and a lot of gas within the tire
chips is being released suddenly upon irradiation with
microwaves.

[0094] Suitable operating pressures are the range of up to
about 20 mm of mercury, or even up to about 40 mm of mercury, or
even up to about 100 mm of mercury. Accordingly, tire chips
processed in the first microwave reactor 150 are then
transported to the second microwave reactor 152, where the
processed chips are further irradiated under vacuum using
microwave antennas 162. The tire chips are further reduced in
size, and fall through mesh 174, and then transported to the
third microwave reactor 154. In the third microwave reactor 154,
the processed chips are further irradiated using microwave
antenna 164. Processed chips are finally transported by a screw
feed discharge section 118 and exit the microwave reactors from
screw feed discharge section 166, and through airlock (not
shown) and onto conveyor 156.

[0095] Each of the microwave reactors are fed with microwave
conduits terminating in a suitable cone or nozzle. The first
microwave reactor has more microwave nozzles 160 as it is larger
than the other two microwave reactors. The second microwave
reactor is shown with microwave nozzles 162, and the third
microwave reactor is shown with microwave nozzles 164. Each of
the microwave reactors contains vacuum lines 180 to transport
the resulting hydrocarbon gases to the high-capacity heat
exchanger 118 (shown in dotted lines). Also shown in the
microwave room 124 are refrigeration equipment 123 to maintain
the temperature of the ambient conditions in the microwave room,
and support structures 158 for supporting the microwave
reactors.

[0096] Suitable microwave ranges for the processing of tire
chips includes using X-band microwave radiation generators (not
shown) transmitted via conduit in tubes at various frequencies
to each of the reactors. Microwave frequencies for tire
processing varies from X-band down towards C-Band radiation.
X-band is 5.2 to 10.9 GHz; C-band is 3.9 to 6.2 GHz. K-band
radiation is also useful in some embodiments. K-band is 10.9 GHz
to 35 GHz, which includes the sub-bands Ku (15.35 GHz to 17.25
GHz) and Ka (33.0 GHz to 36.0 GHz). Typically separate microwave
antenna tubes are separated in frequency by approximately 0.2
gigahertz. In the embodiment shown in FIG. 1G, a total of
approximately 36 microwave antenna tubes are transported from a
microwave source (not shown) to the microwave reactors. The
largest microwave reactor 150 has the greatest number of tubes,
for example about 18. The second microwave reactor 152 has fewer
tubes, approximately 12. The third microwave reactor 154 has the
fewest number of tubes, approximately 60. Each of the tubes are
capable of operating at different frequencies, which frequencies
in certain preferred embodiments varies between about 7.0 and
6.4 GHz. The ends of the microwave antenna from which the
microwave radiation exits into the reactor chambers are fitted
with a suitable cone antenna. Each of the cone antennae emits
microwave radiation at a separate frequency, which is typically
about 0.2 GHz different than the others that irradiate into each
of the microwave reactors. Microwaves are typically fixed in
frequency but they may also be capable of being swept in a
varying frequency manner, for example, by using a variable
frequency microwave generator. A number of different frequency
combinations are envisioned, for example each of the cone
antennas may be fixed in frequency, vary in frequency, or any
combination thereof. As the tire chips are irradiated, volatile
hydrocarbon vapors are emitted from the tire chips and collected
by vacuum tubing. Hydrocarbon vapors are then transported to a
heat exchanger condenser. Highly volatile gases and vapors that
are not conveniently liquefied can be separately recovered as a
high BTU gas product.

[0097] The plant layout described in FIGS. 1A-1G is operated at
a product speed (per line) of approximately 30 tires per minute
on average. Hourly production rate is approximately 36000 pounds
per hour or approximately 1300 ft..sup.3 per hour. This is based
upon a used automobile tire weight of approximately 20 pounds
(9.1 kg). Or alternatively a used truck tire about 40 pounds
(18.2 kg). The shredded tire chip sizes can be in the range of
from about 3 to about 5 inches. Average loose density of the
chips is approximately 24 pounds per cubic foot to about 33
pounds per cubic foot. Heat values generated at atmospheric
pressure range from approximately 12,000 BTUs per pound to about
15,000 BTUs per pound.

[0098] FIG. 2A is an elevation view, axial direction, of a
microwave reactor suitable for processing oil cuttings according
to an aspect of the present invention. Oil cuttings comprise
dirt, rock, water, carbon deposits, and the like, which oil
cuttings are obtained during drilling operations. Drilling
operations include drilling from an oil rig, drilling from a
deep-sea oil platform, as well as mining of shale rock and coal
deposits. During drilling, rock that is rich in hydrocarbons is
typically reached prior to hitting a pocket of oil. This
hydrocarbon rich rock is transported up to the surface and can
comprise up to 15% oil, and even up to 25% oil. The consistency
can also be similar to oil shale. Hydrocarbon rich rock can be
considered hazardous waste and would need to be disposed of
properly. It cannot be sent to a landfill, and accordingly it
has traditionally been handled by combustion. This is
particularly a problem on an oil rig in the middle of the ocean,
where it may be forbidden to dump oil drillings comprising
greater than 1% hydrocarbon content. Accordingly, the process of
the present invention can also be used to recover hydrocarbons
from drill cuttings, thereby permitting the drill cuttings to be
placed back in the environment after the hydrocarbons have been
substantially removed. As used herein the term "substantially
removed" refers to a composition comprising less than 1% by
weight hydrocarbon content. Oil drill cuttings having less than
0.01% by weight hydrocarbon has been produced using the
processes described herein. Accordingly, the methods suitably
provide drill cuttings that comprise less than 1 percent, or
even less than 0.5 percent, or even less than 0.2 percent, or
even less than 0.1 percent, or even less than 0.05 percent, or
even less than 0.02 percent, or even less than 0.01 percent by
weight hydrocarbons based on weight oil cuttings. Suitable oil
cuttings enter into the system through in-feed grinder system
201. Oil cuttings are ground to a suitable size, then fed into
the microwave reactor chamber (vacuum sealed reactor tank 216)
via in feed screw 202. The vacuum sealed reactor tank 216
contains a helical mixer element 203 for mixing and stirring the
ground oil cuttings. The reactor tank is typically filled to
about 40% of its total volume. The microwaves irradiate the
contents of the reactor via antennas that are oriented in an
orbital arrangement emanating from the top of the reactor. The
microwave antennas are desirably flexible and irradiate from
several slides from the top the reactor towards the mixing
material below. A helical mixer element is turned using a motor
210. Microwaves emanating from a cone antenna or a plurality of
cone antennas (not shown) irradiate the oil cuttings with
suitable microwave radiation. Hydrocarbon gases and oil vapor
exit towards the top vacuum tubing towards vacuum pump and
collected in a suitable heat exchanger vapor condensing unit.
Hydrocarbon vapor gases produced by the process of irradiating
the oil cuttings with microwaves exit via a vacuum discharge
tube (not shown). Residual geologic material and unreacted
carbon deposits settled towards the bottom of the reactor. The
unvaporized matter is discharged from the microwave reactor 216
via screw feed discharge section 204, and exits the system via
discharge system 206. Material exiting the system is suitably
clean of hydrocarbons so as to be considered nonhazardous waste.
For example, material exiting the reactor can be returned to the
ocean after drilling, or can be returned to the land after
drilling. Also shown is reactor support structure 205 for
holding the components as set forth in the system.

[0099] FIG. 2B illustrates an elevation view of the microwave
reactor of FIG. 2A, longitudinal direction. Oil cuttings are
added to the system as in-feed via an airlock at 201, which oil
cuttings are then transported to the reactor 216 via in-feed
screw 202. Depicted in this diagram is conduit 214 for pulling
vacuum on the airlock, and on the vacuum sealed reactor tank
216, using vacuum pumps 207. Microwave waveguides 212 are shown
entering the vacuum sealed reactor tank 216. Microwaves
emanating from a suitable microwave cone antenna radiates the
oil cuttings within the reactor tank. A helical mixer element
203 rotates to mix the oil cuttings, convey the oil cuttings,
and reflects microwaves throughout the volume of the chamber.
After suitable microwave processing at a particular residence
time, the reacted oil cuttings exits the reactor through screw
feed discharge section 204 and exits via a suitable airlock 206
of the discharge system. Also shown is reactor support structure
205.

[0100] FIG. 2C illustrates an elevation view of the microwave
device and control room suitable for generating microwaves and
propagating the same through waveguides. The microwave device
and control room 208 is depicted as comprising an electrical
panel and a series of six individual microwave generators (222,
226, 230, 234, 238, and 242) each connected to a series of
microwave antennas (220, 224, 228, 232, 236, and 240). The
antennas are combined into a combined antenna conduit 212 which
exits the microwave device control room 208 and leads towards
the vacuum sealed reactor tank 216 as shown in FIG. 2B. Suitable
microwaves for processing oil drill cuttings have frequencies in
the range of about 11.2 to about 11.8 GHz, typically about 11.5
GHz. Oil shale can also be processed using the equipment and
processes described herein at a microwave frequency in the range
of from about 10.6 to about 11.2 GHz, and typically about 10.9
GHz. Tar sands can be appropriately processed using microwaves 4
to about 12 GHz. Tar sands can also be processed in the K-band,
preferably in the Ku band. Anthracite coal deposits can also be
processed in the KU band as well. A vacuum is maintained within
the microwave reactor chamber using suitable vacuum and
hydrocarbon vapor condensation equipment, for example at
pressures less than about 100 mm of mercury, and even at
pressures of less than about 40 mm of mercury, or even at
pressures of less than about 20 mm of mercury. Maintaining such
low operating pressures helps to keep the overall process
temperatures below about 465.degree. F. or even a temperatures
less than about 450.degree. F. so as to prevent overheating and
efficient recovery of hydrocarbon vapors. A large proportion of
the hydrocarbon vapors can be condensed into liquid fuel oil at
ambient temperatures.

[0101] The system described in FIGS. 2A-2C can be suitably
adapted and scaled to process oil cuttings at a throughput of up
to about 2 tons per hour to even up to about 10 tons per hour.
It should be readily apparent to the skilled person how to
increase the size and power of the microwave reactor chamber to
yield higher throughputs.

[0102] The system described in FIGS. 2A-2C can also be suitably
adapted in scale to process oil shale rock. The processing of
oil shale rock includes irradiating it with suitable microwaves
at power sufficient to increase the temperature of the oil shale
rock to within a range of from about 500.degree. C. to about
600.degree. C. Without being bound by any theory of operation,
it is believed that these processing temperatures are
considerably hotter than compared to tire cuttings for the
reason that more energy needs to be applied to the rocks to
volatile lies the hydrocarbons. This is in contrast to softer,
substantially higher concentration hydrocarbon, tires that
readily absorb the microwave energy. Suitable shale rocks are
broken down into small pieces after being mined. For example,
shale rock pieces are suitably smaller than an inch cube, even
smaller than a half inch cube, or even smaller than about 3/8''
cube, even smaller than about a half inch cube, or even smaller
than about 1/4'' cube. The hydrocarbon content of the oil shale
rock typically comprises hydrocarbons comprising from about C10
to about C25, or even from about C14 to about C22. Oil shale
rock can contain up to about 5% by weight hydrocarbons, or even
up to about 15% by weight hydrocarbons, or even up to about 25%
by weight hydrocarbons. In some cases, shale rock can contain up
to about 70% by weight hydrocarbons.

[0103] FIGS. 3A and 3B depicts several embodiments of the
present invention for recovering petroleum-based materials and
hydrocarbons from oil slurry. FIGS. 3A and 3B are schematic
illustrations of two embodiments of a microwave assisted system
for the distillation and recovery of heavy oil bottoms, e.g.,
oil slurry, from a distillation plant. FIG. 3A shows the
following elements of a traditional hydrocarbon distillation
plant: 302 distillation tower 360 unrefined inlet into
distillation tower; 304 vapor line; 306 natural gas line; 308
gas separator; 310 pump; 312 LPG line; 314 gasoline lines; 316
jet fuel (kerosene) line; and 318 inset: close-up view of the
liquid vapor contact caps with an a distillation tower. This
distillation system can be modified using the microwave process
of the present invention as follows. An electron activator 320
is added using an electron activator pump 322 into residual oil
362. Hot residual oil line (e.g., heavy oil) 362 is pumped into
the microwave reactor 330 and atomized using an atomizer 334.
Microwave waveguide antenna 336 is powered from the microwave
room and control system 340, which control system includes
microwave generators 342 and microwave waveguides 344. The
microwaves exit the waveguide antenna 336 at cone nozzles within
the microwave reactor so as to radiate the atomized residual oil
above the atomizer 334. Vacuum pumps 350 connected to the vacuum
line 332 maintains pressure of less than about 20 mmHg, or even
less than about 40 mmHg, or even less than about 100 mmHg. The
irradiation of the atomized residual oil gives rise to cracking
of the residual heavy oil, which in turn produces hydrocarbon
vapors such as natural gas 352 and heavier hydrocarbon vapors
such as diesel and heating oil 354. In the microwave reactor
330, residual oil 362 is removed from the bottom of a
distillation tower 302, combined with electron activator 320 and
processed by microwave after atomization. We have discovered
that addition of the electron activator to the residual oil, for
example about 2% by weight based on residual oil of carbon small
particles, gives rise to a much faster, more efficient
absorption of the microwaves to yield more efficient cracking of
the residual oil. Accordingly, electron activator made using
microwave processing of tire chips as described supra is useful
for making electron activator. Suitable electron activator is
provided as a fine powder, for example of about a hundred mesh,
or finer. The electron activator may be coarser than 100 mesh,
depending on the precise application and handling requirements.
Without being limited by any particular theory of operation, the
electron activator enhances the absorption of microwaves by the
residual oil, which gives rise to faster processing and more
efficient processing of the heavy oil. As a result, the electron
activator, which comprises carbon powder particulates, are
capable of absorbing microwave radiation. Solid particles
containing residual hydrocarbons, such as electron activator,
result in popping (as in popcorn) when irradiated. Without being
bound by any particular theory of operation, it is believed that
the popping action of the small electron activator particles
within the residual oil enhances the microwave processing of the
residual oil. In certain embodiments, the electron activator
functions as a catalyst for effectuating the microwave cracking
process.

[0104] Suitable microwave radiation frequency ranges from about
8.0 to about 8.8 GHz, or in the range of from about 8.1 GHz to
about 8.7 GHz, or even in the range of from about 8.2 GHz to
about 8.6 GHz, or even in the range of from about 8.3 GHz to
about 8.5 GHz, or even about 8.4 GHz. The microwave reactor
contains a series of microwave cone antennas that radiate the
atomized residual oil with microwaves. These microwave cone
antennas can each receive the same or different microwave
frequencies. When the frequencies differ, they typically are
separated by increments of about 0.2 GHz. Ranges of microwave
frequencies are typically useful for processing the atomized
residual oil in this manner. Accordingly multiple microwave
antennas 344 receive microwaves generated by a plurality of
microwave generators 342 provided in the microwave control
system 340. Microwaves are transmitted through microwave
antennas 344 to the microwave antenna conduit 336. Microwaves
then enters the microwave reactor. Typically the residual oil
362 is pre-heated to a temperature of about 350.degree. C. so
that it is capable of flowing under pressure and atomized. The
use of microwaves has been demonstrated to effectively crack the
hydrocarbon chains in the heavy residual oil. Atomization helps
to increase the surface area of the residual oil and decrease
particle size, thereby effectuating absorption of the microwaves
and cracking of the hydrocarbon chains. The residual oil is
suitably heated to temperatures sufficient that can flow under
pressure and atomized. Suitable temperatures are at least about
250.degree. C., or even at least about 300.degree. C., or even
at least about 350.degree. C., or even at least about
400.degree. C., or even at least about 450.degree. C., or even
at least about 500.degree. C. The residual oil may be preheated
using any of a variety of heating methods, for example
convection, conduction, or irradiation, e.g. microwaves. The
heavy residual oil chains crack at least several times.

[0105] Processes according to the present invention are capable
of producing combustible gases. The processes according to the
present invention are also capable of producing at least several
different weights of oils. These oil products range from carbon
content of hydrocarbon chains comprising from 14 carbons up to
about 25 carbons. The starting residual oils comprise
hydrocarbon chains having at least 25 carbons or even at least
28 carbons. The hydrocarbons in the residual oil do not
necessarily need to be linear hydrocarbon chains, for example
cyclic and branched hydrocarbons are also envisioned. Instead of
atomization, hot flowing residual oil can be formed into a thin
film and irradiated with microwaves, or can be ejected into a
shooting stream and irradiated with microwaves, or can be broken
into droplets under force of pressure and irradiated with
microwaves. Similar related processes give rise to narrow
dimension residual oil droplets. In certain embodiments the
products of microwave radiation within the microwave reactor 330
illustrated in FIG. 3A can be recycled back to the distillation
tower 302 for further processing.

[0106] FIG. 3B is a schematic of another embodiment of a
microwave assisted distillation and recovery unit for heavy oil
bottoms from a distillation plant. This embodiment is similar to
that described in FIG. 3B, with the exception that this
embodiment further includes a reboiler 348 for heating the
bottoms coming from distillation tower 302 by a transfer line
370. The reboiler heats the bottoms which are distilled in
vacuum tower 340. Residual oil 346 from the vacuum tower is
combined with electron activator 320 using electron activator
pump 322 to provide a mixture of residual oil in electron
activator 362. This mixture is then atomized in microwave
reactor in 330. The operation of the microwave reactor is
similar to that discussed supra in FIG. 3A.

[0107] FIG. 4A illustrates an elevation view of a microwave
reactor system suitable for processing shale rock, tar sands,
drill cuttings, and the like. Inlet feed screw 402 is suitable
for transporting shale rock and other hydrocarbon containing
cuttings and the like into microwave reaction chamber 412.
Helical screw mixing flights 408 are mounted to an axle 406
which is rotated using a motor. Helical screw mixing flights mix
and transport the material, such as shale rock pieces, in the
microwave reaction chamber interior 404. Microwave antennas 410
enter the interior of the microwave reaction chamber 404. The
material within the microwave reaction chamber interior is
stirred and irradiated. Vapors are removed using a vacuum
recovery system and condensing unit (not shown). Material
depleted of hydrocarbon vapor is discharged through the exit
discharged from feed system 416. Also shown is a support
structure 414.

[0108] FIG. 4B provides a plan view of FIG. 4A, wherein the
direction of the material is shown entering the microwave
reaction chamber via onlet feed screw 402 mixing within the
microwave reaction chamber by a helical screw mixing flights
408, and finally exiting via exit discharge screw feed system
416. FIG. 4C is an elevation view of the microwave reactor
system along the axis 406, the near end being the exit discharge
screw feed system section 416. FIG. 4D illustrates a suitable
microwave device control room, waveguides, and vacuum pumps
suitable for use with the system illustrated in FIG. 4A. FIG. 4E
illustrates an optional hopper elevator for transporting
material into the inlet feed section 402. FIGS. 4F and 4G
illustrate three horizontal microwave reactor systems operating
in parallel. FIG. 4H illustrates additional microwave
generators, waveguides and vacuum pumps for operating the three
horizontal microwave reactors illustrated in FIGS. 4F and 4G.
The processing of hydrocarbon containing materials, such as
shale rock, tar sands, drill cuttings and the like, is conducted
in a vacuum environment, less than about 20 mm of mercury, or
less than about 40 mm of mercury, or even about less than 100 mm
of mercury. The hydrocarbon containing materials are subject to
heating by the microwaves and other heating means, up to about
350.degree. C., or even up to about 450.degree. C., or even up
to about 550.degree. C., or even up to about 600.degree. C. The
hydrocarbon containing materials are removed from the microwave
reactor chamber via a suitable vacuum plumbing system. The
hydrocarbons are recovered using a suitable heat exchange or
condensing system (not shown).

[0109] FIG. 5A depicts an exemplary embodiment of the present
invention for extracting petroleum-based materials, carbon-based
materials and hydrocarbon-based materials in situ. A probe
capable of generating microwave radiation (e.g., cone, antennae
or nozzle) according to the methods of the present invention can
be lowered into drilled oil wells. Using the methods of the
present invention, the petroleum-based materials can be
vaporized and collected at surface-level and processed using
techniques known in the art. FIG. 5A illustrates a schematic
view of a microwave system for in situ recovery of oil from
geologic deposits. A suitable geologic deposit 526 includes an
oil well, a capped oil well, a shale rock deposit, a tar sand
deposit, a coal deposit, and the like. This illustration depicts
a vacuum recovery unit 502 (e.g., a Venturi type system) for
recovering geologic hydrocarbons such as fossil fuels from a
capped oil well. This system comprises casing 504 extending from
the surface of the ground to the geologic carbon deposits at
526. A microwave waveguide is delivered through the casing to
the geologic carbon deposit 526. A microwave antenna nozzle 510
resides at the end of the microwave waveguide 506 proximate to
the geologic carbon deposit, into which microwaves radiate. On
the ground surface is illustrated portable electric generator
522, portable pumping system 524, and portable microwave
generation station control unit 520. Hydrocarbon vapors
generated by the microwaves in the geologic carbon deposit 526
are transported under vacuum as vaporized geologic carbon
deposit (e.g., oil vapor) 508 to the vacuum recovery unit on the
surface ground. Capped oil wells contain hydrocarbons that can
be cracked to oil, suitable for use as diesel fuel. This
involves opening up capped oil wells, optionally adding electron
activator into the wells (which aid in absorbing the microwaves
and converting the heavy oil in the wells to hydrocarbon vapor),
and irradiating the heavy hydrocarbons with microwaves. Once
vaporized, the hydrocarbons are readily transported to the
surface using suitable vacuum piping, or other plumbing means
528. The vacuum recovery unit 502 is also capable of
fractionating the hydrocarbons into other hydrocarbon products.
Oils that are difficult to recover using normal pumping means
can be recovered according to the processes.

[0110] FIG. 5B depicts an apparatus of the present invention
for recovering petroleum-based materials from oil shale, in
situ. A probe capable of generating microwave radiation
according to the methods of the present invention, can be
lowered into oil shale deposits. Using the methods of the
present invention, the petroleum-based materials can be
vaporized and collected at surface level and processed using
techniques known in the art. FIG. 5B illustrates a schematic
view of a microwave system for recovering hydrocarbons below
ground. In this embodiment, one or more microwave antennae are
shown capable of traveling horizontally underground with respect
to the ground surface. The microwave antennae are illustrated
comprising one or more microwave nozzles for vaporizing
hydrocarbon geological deposits in a vacuum environment. FIG. 5B
illustrates two conduits (on the left portion of the figure),
each containing a plurality of waveguides that terminate it into
a suitable microwave nozzle or cone emitter. Suitable microwave
cones emitters are commercially available. This process is
adapted for recovering residual oil in capped oil wells, and can
also be adapted to other geological hydrocarbon deposits such as
tar sands and shale rock. If the oil well is "dry" with mainly
heavy viscous hydrocarbon material remaining in the well, a
microwave antenna is transported down into the oil well and the
antenna-end can reside in one or more of the openings. Microwave
radiation is directed towards the geologic material in the
vicinity of the antenna.

[0111] Various hydrocarbon geological deposits can be processed
underground using this technology at various depths. Piping for
the wells can start at a diameter of about 24 inches at the
surface, which diameter is progressively narrower and narrower
as sections of piping are added as the depth increases. At a
depth of approximately 3000 feet, a typical opening (diameter)
of the piping is about 6 inches. For example oil shale deposits
in the Western part of the United States are relatively shallow,
i.e., near the surface. Strip mines are also relatively shallow,
and other deposits may be as deep as 2000 feet or more.
Previously pumped oil wells often have chambers of oil that are
not readily accessible but require opening by an additional
explosive or drilling operation. Certain chambers can also be
opened by irradiating the sealing rock material with microwaves.
In a laboratory setting, it has been discovered that oil shale
pops and reduces in size when irradiated with microwaves. As the
oil shale releases hydrocarbons (i.e. oil), the oil shale "pops"
like popcorn. Accordingly, directionalizing microwaves within
the geological chambers can give rise to breakdown of the
geological formation (i.e. the rocks pop, break apart, and fall
down and fill the cavity). Accordingly, the antennas can be
moved around within geological formations to aid in recovering
hydrocarbon material. In some embodiments microwave antennas are
placed down about 5000 feet or more, and then are
directionalized to travel on the order of approximately 100
yards or so horizontally.

[0112] Any type of hydrocarbon material present within the
geological formation can be cracked to gas and recovered at the
surface using fractionalization condensation units. For example,
any carbon suitable for use as diesel fuel can be made by
irradiating oil shale. Resulting diesel fuel is suitably used as
Cat Diesel Engine Oil. Sometimes oil wells are drilled using
directional drilling technologies. Suitable directional drilling
technologies are capable of bending at a rate of a degree a foot
to create an angle. Accordingly, flexible microwave antennas are
suitable for use in such oils. Accordingly, the process includes
uncapping a capped oil well. This can be accomplished by
drilling out a concrete plug used to cap the well, if present.

[0113] The system can include a number of auxiliary equipment
located on the surface of the ground. Such equipment includes,
for example, well drilling equipment, vacuum pump vehicle, fuel
tank vehicles, a generator vehicle, and microwave control
vehicle that includes microwave generators, microwave
waveguides, and associated equipment. The vacuum pump vehicle
can contain a vacuum pump that is capable of applying
intermittent vacuum pulse technology to raise hydrocarbon gases
to the surface. The hydrocarbon gases are recovered and
collected in a suitable distillation tower or fractionation
tower that is fitted with heat exchanger and condensing unit.
Suitable oil wells and other hydrocarbon geological deposits
residing in the ground are accessed via a tube to provide a
sealed system with the vacuum pump vehicle for producing the
vacuum environment needed for recovering a hydrocarbon vapors.
Suitable vacuums include absolute pressures of less than about
20 mm of mercury, or even less than about 40 mm of mercury, or
even less than about 100 mm of mercury. The microwave control
vehicle contains suitable flexible microwave waveguides and
generators. Typically the end of the microwave waveguides (e.g.,
antennas) are fitted with a suitable microwave cone emitter
(e.g., nozzle). The antennas are placed into the mahogany zone
in Earth in situ and microwaves are used to radiate tar sands,
or oil shale, or other hydrocarbon deposits. The microwaves
cause vaporization and gasification of the otherwise viscous and
solid-like hydrocarbon and carbon geological sources within the
ground. One or more antenna fitted with one or more cone emitter
devices can be used.

[0114] Generated hydrocarbon gases (e.g., take off gases) are
transported to a suitable fractionation tower capable of
separating the gas, as illustrated in FIG. 5C. Geological
material such as sand and rock from which hydrocarbons have been
removed remain within the geological formation. In some
embodiments, an in situ microwave process is provided. Other
embodiments do not require in situ microwave irradiation of the
geological formation, e.g., geological material containing
hydrocarbons that are mined and provided via separate feed
mechanism into a suitable microwave reactor. Geological material
such as sand and rock can be substantially totally gasified
(i.e., depleted of hydrocarbons and carbons) according to the
processes of the present invention, which geological material is
then returned to the environment substantially free of
hydrocarbons. Finally, fuel and other hydrocarbons recovered
form the geological source can be stored in a suitable tanker
vehicle and shipped for delivery, further processing, and so on.
The recovered hydrocarbons may also be transported by pipeline,
rail car, and the like. Optionally, the hydrocarbon vapor
recovered from geological sources may be fractionalized on-site
using a suitable distillation tower, as illustrated in FIG. 5A.
The process of operating a distillation tower is suitably
described in FIG. 5C, which illustration shows the separation of
crude oil using a fractionating tower into its component
products.

[0115] FIG. 6 depicts one embodiment for extracting
petroleum-based materials from shale and tar sands and oil
sands. The tar sands can be loaded into the top of the
apparatus, which can be under reduced pressure. Using gravity
and shaking, the tar sands move through the apparatus while
being exposed to microwave radiation as described herein.
Vaporized petroleum-based materials can be captured and
collected in separate vessels and refined using methods known in
the art. After the material has passed through the apparatus, it
will be essentially free of petroleum-based materials. FIG. 6
provides an elevation view of a multiple microwave reactor
system suitable for high volume recovery of petroleum, carbon
and hydrocarbons (e.g. diesel oil) from mined material, e.g.,
oil shale, oil sands, coal slag, and tar sands. This system is
illustrated having the following equipment: microwave waveguide
602; microwave antennas 620; vacuum gas line 604; microwave
reactors 606--a total of five connected in series; connecting
pipe 608 between microwave reactors 606; top airlock 610
adjacent to in-feed of surface shale and tar sand material;
airlock 612 adjacent to discharge of depleted material; baffles
614 within vertically oriented microwave reactors 606; support
structure 630 to support multiple microwave reactors connected
in series and adjacent to source of surface shale and/or tar
sands. Mined material enters the system at airlock in-feed 610,
which minimizes the amount of air entering the system. The
system is also fitted with a suitable vacuum gas line 604 to
maintain a vacuum environment (vacuum pumping equipment not
shown) of up to about 20 mm of mercury, or even up to about 40
mm of mercury, or even up to about 100 mm of mercury. Material
enters the first microwave reactors 606 adjacent to the airlock,
which material is transported along baffles 614 while being
irradiated with microwave radiation through microwave antennas
620 (as illustrated in the second through fourth microwave
reactors 606). Microwaves irradiate, heat, and crack the
hydrocarbons, which hydrocarbons exit the system via a vacuum
gas line 604 (connections between the microwave reactors 606 in
the vacuum gas line 604 not shown). Geological material leaves
the topmost microwave reactor 606 and enters a first connecting
pipe 608, which partially reacted material is transported to a
second microwave reactor 606. The process is repeated and the
material is subsequently transported and irradiated with
microwaves as it progresses along the series of microwave
reactors and connecting tubes. The processed material eventually
arrives at the bottom discharge, where it exits the system
through an airlock 612.

[0116] Another embodiment of an apparatus of the present
invention is depicted in FIG. 7. FIG. 7 is a schematic view of a
microwave reactor chamber and system for recovering fuel oil
from a hydrocarbon-containing source, such as used tires. The
system includes the following equipment and features: nitrogen
supply 702; nitrogen regulator 704; nitrogen flow valve 706;
nitrogen inlet 708 to microwave reactor chamber 710; microwave
reactor chamber 710; infrared thermocouple 712 to measure
average temperature over irradiated area; nitrogen flow meter
714 for infrared thermocouple purge (low flow); microwave
scattering reflector 716; motor 718 for microwave scattering
reflector 716; platform 720 for holding hydrocarbon containing
materials; irradiation area 722; vacuum outlet 724; vacuum gauge
726; opening 728 to microwave antennae; microwave source 730
(TVT or magnetron); temperature gauge 732; vapor transfer tube
734; condenser tube 736; cooling coil 740; oil collector 742;
valve drain 744; vacuum bypass valve 746; vacuum pump 748; flow
meter 750 for TWT nitrogen purge (flow); nitrogen supply lines
752; exhaust 754; exhaust gas flow meter 756; reactor chamber
758; reactor chamber door 760.

[0117] FIGS. 8A, 8B and 8C illustrate an embodiment of the
present invention for incorporating a microwave processing
system to process drilling cuttings on an oil drilling platform.
FIG. 8A is a plan view of an exemplary oil platform
incorporating a drill cuttings microwave processing unit. A
suitable placement of a microwave processing unit (further
illustrated in FIG. 8C) is provided. FIG. 8B illustrates an
elevation view of the oil platform in FIG. 8A. FIG. 8C
illustrates a vertical and horizontal configurations of the
drill cuttings microwave processing unit suitable for use in the
oil platform illustrated in FIG. 8A.

[0118] FIGS. 9A-9C are electron microscope photographs at
60,000 times magnification of pyrolytic carbon black material
obtained according to Example 3 and using the system illustrated
in FIG. 7. The production of this material is further described
in Example 3, below.

[0119] FIGS. 10A-10E illustrate an additional embodiment of a
system for processing materials containing hydrocarbons.
Suitable materials include shale rock, drilling cuttings, tar
sands, plastics, polymeric materials, recycled
hydrocarbon-containing materials, refuse, residual oil, slurry
oil, hydrocarbon distillation bottoms, and the like. These
figures illustrate the following equipment and features: 1001
microwave tubes, amplifier and waveguides; reactor drum 1004;
sealed material in-feed 1002 through reactor drum 1004; in-feed
screw 1003; rotating discharge screw 1005; control panel 1006;
vacuum pumps 1007; hydraulic drive transmission system 1008 for
rotating reactor drum 1004; shipping container 1009; vacuum
release support 1010; drum bearing seal 1012; roller bearings
1014; vacuum port 1016; microwave waveguides 1018 entering
rotating reactor drum 1004; mixing flight bars 1020 for mixing
materials within the rotating reactor drum 1004; bearings 1022
by which mechanism the drum slidably rotates; rotating reactor
drum axel 1024 by which mechanism the reactor drum rotates
through actuation with the hydraulic drive transmission center
1008.

[0120] FIG. 10A is an elevation view of a rotating drum reactor
system. Material enters the in-feed 1002 via a suitable source,
for example a hopper for receiving chips or chunks of material.
The material then enters into the in-feed screw 1003, which
meters the material into reactor drum 1004. The material is
stirred and mixed using mixing flight bars 1020. The drum is
rotated using the hydraulic drive system 1008. The drum reactor
is maintained under vacuum by means of vacuum pumps 1007 and
vacuum gas line. The reactor drum is vacuum sealed by means of a
drum bearing seal 1012 as shown in the inset of FIG. 10D.
Microwaves are generated at 1001 and transmitted by a waveguides
1018 into the drum reactor 1004. Hydrocarbon vapors are removed
through the vacuum gas line and collected for further processing
as described herein above.

[0121] FIG. 10B is a plan view of the rotating drum reactor
portion depicted in FIG. 10A. The rotating drum 1004 is shown
comprising a drum bearing seal 1012, which drum slidably rotates
against end caps comprising ports for microwave antenna and
vacuum connections. The reactor drum slides via roller bearings
1014 in the top and bottom end caps. The drum reactor 1004
resides within shipping container 1009. Screw conveyor 1003
conveys material into the drum reactor 1004. FIG. 10C is a plan
view of an alternative embodiment of a rotating drum reactor
system. FIG. 10D is a cross-sectional view of a drum bearing
seal used in the rotating drum reactor system.

[0122] FIG. 10E is an elevation view of the rotating drum
reactor portion depicted in FIG. 10A. FIG. 10E further
illustrates the in-feed screw 1003 for metering the material
into reactor drum 1004, which material is stirred and mixed
using mixing flight bars 1020 as the drum is rotated using the
hydraulic drive system 1008. The drum reactor is maintained
under vacuum by means of vacuum pumps 1007 and vacuum gas line.
The reactor drum is vacuum sealed by means of a drum bearing
seal 1012 as shown in the inset of FIG. 10D. Microwaves are
generated at 1001 and transmitted by waveguides 1018 into the
drum reactor 1004. Mixing flight bars 1020 are used for mixing
materials within the rotating reactor drum 1004. Bearings 1022
are used for slidably rotating the drum while maintaining the
vacuum and microwave antenna connections. The reactor drum
rotates by means of axel 1024 through actuation with the
hydraulic drive transmission center 1008. Hydrocarbon vapors are
removed through the vacuum gas line 1016 and collected for
further processing as described herein above. Spent materials
substantially depleted of hydrocarbons exit to discharge screw
1005.

[0123] As an example, a suitable microwave rotating reactor
drum system for extracting hydrocarbons from materials such as
drill cuttings and fluids can comprise the following equipment:

[0124] A suitable microwave control center includes a number of
hydrocarbon specific modular microwave generators, high power
amplifiers, master controller module, slave driven power
modules, thermal sensors, safety I/O devices for vacuum,
interlocks, and emergency shut down, manifold banked
configuration of flexible waveguides/windows/adapter plates,
thermal metrology gear microwave power measurement instruments
and computer control station as per schedule.

[0125] A suitable 4'-0'' diameter rotating in-feed channel drum
unit with vacuum seal provisions comprises 3/8'' stainless steel
welded frame construction and bolt on stainless steel
(replaceable) hardened steel troughs driven by a direct coupled,
5-hp NEMA-4 variable speed (VFD driven) indexing servo-motor to
transfer metered product into the feed screw.

[0126] A suitable 2'-6'' diameter.times.12'-6'' long in-feed
screw assembly comprises heavy-duty stainless steel 2'' square
tubing frame supporting 3/8'' stainless steel skins with
hardened helical screw driven by a direct coupled, 2-hp NEMA-4
variable speed (VFD) servo-motor to transfer metered product
into the reactor vessel.

[0127] A suitable 5'-0'' diameter.times.3/8'' horizontal
seamlessly welded stainless steel and jacketed sub-baric vessel
is constructed with internal angular flight bars, (length varies
depending on composition of the intended process to) with
two--24'' long.times.3/8'' stainless steel end cap sections,
hardened steel circum-centerline rack & pinion hydraulic
transmission driven by a variable speed gear-head motor.
Includes a maintenance access door, piping as required to heat
vessel jacket, microwave antenna mountings, vacuum port,
pressure/flow meters and gauges as required, power transmission
is stainless steel guarded. Reactor tank and peripheral
equipment is supported by heavy duty stainless steel formed
structural channels and heavy duty external bearing wheels.

[0128] A suitable 2'-6'' diameter.times.12'-6'' long discharge
screw assembly comprises heavy-duty stainless steel 2'' square
tubing frame supporting 3/8'' stainless steel skins with
hardened helical screw driven by a direct coupled, 2-hp NEMA-4
variable speed (VFD) servo-motor to transfer metered product
into the reactor vessel.

[0129] A suitable NEMA 4 electrical motor control panel, 480
v/3 ph/60 Hz--24 volt control circuits controls all motors and
devices, directly mounted to shipping container wall, includes
Allen-Bradley PLC, touch screen diagnostics, VFD drive
components, I/O racks, rigid conduit with all marine wire specs,
color coded, tagged and match-marked for easy identification.

[0130] A suitable vacuum system comprises Dual to Quad (which
varies according to throughput) 1.5-hp oil-lubricated, rotary
vane vacuum pumps system for -20 in.Hg. continuous duty
operation. A vacuum release port system is mounted on the
discharge screw section.

[0131] Electron activator. It has been discovered that
microwave radiation in the frequency range of from about 4 GHz
to about 12 GHz is useful for selectively recovering hydrocarbon
materials from geological petroleum and mineral sources, as well
as manufactured materials such as automobile and truck tires. It
has further been found that such materials can comprise carbon
particles that absorb energy when irradiated with microwave
radiation. The heat from the energized carbon particles is
released to the adjacent hydrocarbon materials, and when
sufficient heat is released, the hydrocarbons are reduced in
molecular weight, i.e., "cracked", and vaporized. Unlike the
prior art, the present discovery discloses a particular range of
frequencies that is efficacious for the electromagnetic
stimulation and heating of carbon particles for recovering
hycrocarbons, such as diesel fuel, from difficult to recover
hydrocarbon sources.

[0132] Disclosed are methods for microwave treatment of
difficult-to-recover hydrocarbon source materials comprising
contacting the hydrocarbon source material with particles
comprising carbon, and subjecting the hydrocarbon source
material to microwave radiation. Also disclosed are methods for
microwave treatment of hydrocarbon source material comprising
contacting the hydrocarbon source material with material having
a resonating frequency in the range of from about 4 GHz to about
12 GHz, and subjecting the hydrocarbon source material to
microwave radiation characterized as having at least one
frequency component that corresponds to the resonating frequency
of the material. As used herein, carbon particles or material
having a resonating frequency corresponding to the applied
microwave radiation frequency are collectively referred to as
"electron activator".

[0133] In preferred embodiments of the disclosed methods, the
microwave radiation is one or more pre-selected microwave
radiation frequencies. Preferably, the pre-selected microwave
radiation frequency will be the resonating microwave frequency,
i.e., the microwave radiation frequency at which the particles
comprising carbon absorb a maximum amount of microwave
radiation. It has been determined that different compositions of
the present invention will absorb more or less microwave
radiation, depending on the frequency of the microwave radiation
applied. It has also been determined that the frequency at which
maximum microwave radiation is absorbed differs by composition.
By using methods known in the art, a composition of the present
invention can be subjected to different frequencies of microwave
radiation and the relative amounts of microwave radiation
absorbed can be determined. Preferably, the microwave radiation
selected is the frequency that comparatively results in the
greatest amount of microwave radiation absorption. In one
embodiment, the pre-selected microwave radiation frequency is
characterized as having at least one frequency component in the
range of from about 4 GHz to about 12 GHz. In other embodiments,
the pre-selected microwave radiation frequency is characterized
as having at least one frequency component in the range of from
about 5 GHz to about 9 GHz, from about 6 GHz to about 8 GHz, or
from about 6.5 GHz to about 7.5 GHz.

[0134] The particles comprising carbon are preferably carbon
substances that have a resonating microwave frequency of from
about 4 GHz to about 12 GHz. Many forms of carbon are known by
those skilled in the art, and, while not intending to exclude
other carbon types, it is contemplated that any form of carbon
having a resonating microwave frequency of from about 4 GHz to
about 12 GHz will be within the scope of the present invention.
For example, the particles comprising carbon can comprise carbon
black. Carbon black may be described as a mixture of
incompletely-burned hydrocarbons, produced by the partial
combustion of natural gas or fossil fuels.

[0135] Carbon blacks have chemisorbed oxygen complexes (e.g.,
carboxylic, quinonic, lactonic, phenolic groups and others) on
their surfaces to varying degrees depending on the conditions of
manufacture. These surface oxygen groups are collectively
referred to as the volatile content. In preferred embodiments,
the present invention uses carbon black having a moderate
volatile content. The volatile content of the preferred carbon
black can be composed of hydrocarbons having up to about 20
carbon atoms, or even up to about 30 carbon atoms.

[0136] The constituent parts of the electron activator
preferably have characteristic dimensions in the micrometer
range, although other particle or fragment sizes may also be
used. Because carbon particles or particles comprising another
electron activator for use in the present invention can be
present in numerous configurations, and can be irregular in
shape, the term "characteristic dimensions" is used herein to
describe the long axis in the case of substantially cylindrical
or otherwise oblong particles, and to describe diameter in the
case of substantially spherical particles, etc. In some
embodiments wherein the carbon particles comprise carbon black,
the particles can have characteristic dimensions of about 10 nm
to about 250 .mu.m. In other embodiments, the particles can have
characteristic dimensions of about 100 nm to about 100 .mu.m, or
of about 200 nm to about 10 .mu.m.

[0137] Preferred are electron activators having characteristic
dimensions that are conducive to ready dispersion within
hydrocarbon materials that are targeted for vaporization. The
electron activators can be contacted with the hydrocarbon
materials by directly introducing the electron activators into
the hydrocarbon materials environment.

[0138] In the present systems, the electron activator particles
can comprise any material that is capable of absorbing at least
a portion of the transmitted microwave radiation generated by
the microwave generator. In preferred embodiments the material
comprises carbon. The particles comprising carbon are preferably
carbon substances that have a resonating microwave frequency of
from about 4 GHz to about 12 GHz. Many forms of carbon are known
by those skilled in the art, and, while not intending to exclude
other carbon types, it is contemplated that any form of carbon
having a resonating microwave frequency of from about 4 GHz to
about 12 GHz will be within the scope of the present invention.
For example, the particles comprising carbon can comprise carbon
black. Carbon blacks have chemisorbed oxygen complexes (e.g.,
carboxylic, quinonic, lactonic, phenolic groups and others) on
their surfaces to varying degrees depending on the conditions of
manufacture. These surface oxygen groups are collectively
referred to as the volatile content. In preferred embodiments,
the present invention uses carbon black having a moderate
volatile content prepared by processing tire chips using
microwave radiation as described herein above.

[0139] The constituent parts of the particles preferably have
characteristic dimensions in the micrometer range, although
other particle or fragment sizes may also be used. Because
carbon particles or particles comprising another electron
activator for use in the present invention can be present in
numerous configurations, and can be irregular in shape, the term
"characteristic dimensions" is used herein to describe the long
axis in the case of substantially cylindrical or otherwise
oblong particles, and to describe diameter in the case of
substantially spherical particles, etc. In some embodiments
wherein the carbon particles comprise carbon black, the
particles can have characteristic dimensions of about 100 .mu.m.

**EXAMPLES**

[0140] The following examples are provided to further describe
the present invention. They are not to be construed to limit the
scope of the invention described in the claims. Many of the
examples make use of the apparatus substantially illustrated and
described in FIG. 7.

**Example 1**

[0141] A chamber capable of being subjected to between 4.0 to
12.0 GHz of microwave radiation frequencies and rated to
withstand reduced atmospheric pressure, was equipped with a 700
W, 5.8 to 7.0 GHz VFM microwave tube (Lambda Technologies,
Morrisville, N.C.). The chamber was outfitted with a nitrogen
gas inlet tube, a vacuum inlet tube, and an outlet tube
connected to a heat exchanger and collection vessel. The chamber
was also equipped with an infrared thermocouple temperature
probe.

**Example 2**

[0142] A chamber capable of being subjected to between 4.0 to
12.0 GHz of microwave radiation frequencies and rated to
withstand reduced atmospheric pressure, was equipped with a 1800
W, 7.3 to 8.7 GHz VFM microwave tube (Lambda Technologies,
Morrisville, N.C.). The chamber was outfitted with an nitrogen
gas inlet tube, a vacuum inlet tube, and an outlet tube
connected to a heat exchanger and collection vessel. The chamber
was also equipped with an infrared thermocouple temperature
probe.

**Example 3**

[0143] A 20 lb automobile tire was cut into approximately
4''.times.4'' pieces. These pieces were washed and dried. The
pieces were placed on a tray and loaded into the chamber of
Example 1. Twenty psi of N.sub.2 was introduced into the
chamber. The VFM microwave radiation was initiated (700 W,
5.8-7.0 GHz). When the temperature of the tire pieces reached
465.degree. F., the microwave radiation was halted and the tire
pieces allowed to cool about 5-25.degree. F. Microwave radiation
was resumed. This process was repeated an additional three
times. Total experiment run time was approximately twelve
minutes. The decomposition products were then analyzed.

[0144] This experiment produced 1.2 gallons of #4 oil (see
Tables 1 and 2), 7.5 lbs of carbon black, 50 cu. ft. of
combustible gases (including methane, ethane, propane, butane,
and isobutene), and 2 lbs of steel. FIGS. 9A-9C depict electron
microscope photographs of samples of carbon black produced using
this method. FIG. 9C demonstrates that the carbon black produced
by this method is comparable to commercial-grade rubber black.
TABLE-US-00001 TABLE 1 Analysis of Oil Produced by Example 3.
TEST RESULT Gross Heat of Combustion 18308 BTU/lb Gross Heat of
Combustion 144688 BTU/gal Sulfur 0.931 wt. % Kinematic Viscosity
@ 122.degree. F. 9.773 cSt Saybolt Furol Viscosity @ 122.degree.
F. 78.9 sus Sediment by Extraction 0.02 wt. % Ash @ 775.degree.
C. 0.024 wt. % Nitrogen 0.43 wt. % Samples were tested by ITS
Caleb Brett, Deer Park, TX. Samples were filtered through a 100
mesh filter prior to testing.

[0145] TABLE-US-00002 TABLE 2 Analysis of Oil Produced by
Example 3 TEST RESULT Corrected Flash Point 92.degree. C.
Corrected Flash Point 198.degree. F. API Gravity 15.56.degree.
C., 60.degree. F. 13.7.degree. API Samples were tested by ITS
Caleb Brett, Deer Park, TX.

**Example 4**

[0146] A sample of oil cuttings, oil shale, tar sands, oil
sands, slurry oil, and/or a material contaminated with
petroleum-based materials, is placed in the apparatus of Example
2. The pressure is reduced to 20 Torr. Microwave radiation is
applied to the sample for a time sufficient to vaporize all the
petroleum-based material in the sample. At 20 Torr, the
petroleum-based materials vaporize between about 400 and
520.degree. F. The vaporized petroleum-based materials are
cooled and collected in a collection vessel. The material
remaining in the chamber is substantially free of
petroleum-based material.

**Example 5**

[0147] A plastic bottle was placed in the apparatus of Example
1 and exposed to microwave radiation. The exposure to microwave
radiation resulted in complete vaporization of the bottle and
recovery of petroleum-based materials.

[0148] When ranges are used herein for physical properties,
such as molecular weight, or chemical properties, such as
chemical formulae, all combinations, and subcombinations of
ranges for specific embodiments therein are intended to be
included.

[0149] The disclosures of each patent, patent application, and
publication cited or described in this document are hereby
incorporated herein by reference, in its entirety.

[0150] Those skilled in the art will appreciate that numerous
changes and modifications can be made to the preferred
embodiments of the invention and that such changes and
modifications can be made without departing from the spirit of
the invention. It is, therefore, intended that the appended
claims cover all such equivalent variations as fall within the
true spirit and scope of the invention.

---

[**http://money.cnn.com/news/newsfeeds/articles/prnewswire/CLTU04004122007-1.htm**](http://money.cnn.com/news/newsfeeds/articles/prnewswire/CLTU04004122007-1.htm)  
December 04, 2007

**Global Resource Corp.'s Energy-Producing
Microwave Technology is Featured in Philadelphia Inquirer**

WEST BERLIN, N.J., Dec. 4 /PRNewswire-FirstCall/ -- Global
Resource Corp. , a developer of a patent-pending microwave
technology and machinery for extracting oil and gas, announced
today that the *Philadelphia Inquirer* in its Monday,
December 3 Business Section, featured the company's microwave
technology for producing fuel.

The article describes the company's technology for making fuels
from old tires. It also reports on the microwave technology's
potential for cleaning the dredge from rivers as well as
disposing of worn-out tires.

Chairman Frank Pringle of General Resource Corp. said,
"Pennsylvania needs help in cleaning up its river bottoms and
getting rid of old tires and we think our process can help. As
the article notes, Global Resource's microwave technology has
the power to clean up these environmental problem areas and
produce much needed energy to heat our homes and run our cars in
an emission- free process."

The article also said that "Last week, Dinesh Agrawal
(http://www.inform.com/Dinesh+Agrawal), director of Pennsylvania
State University's Microwave Processing and Engineering Center,
signed a contract with Pringle's company, Global Resource Corp.
of West Berlin, N.J., to help him get funding and develop
large-scale applications."

The article also quoted the professor as saying "It is very,
very significant, what he has done," said Agrawal, a professor
who has been studying microwave uses for 20 years.

The article is just a latest recognition of Global Resource
Corp.'s groundbreaking microwave technology for producing usable
fuels in an emission- free process. The company also noted that
in a report made in June that was released July 17, the U.S.
Department of Energy profiled Global Resource and its microwave
technology for oil shale recovery as a help in making the U.S.
energy independent.

In addition, *Popular Science Magazine* selected Chairman
Frank Pringle as a "Green Tech Innovator" and General Resource
Corp.'s microwave technology as one of its "Best of What's New
'07."

*Time Magazine* also selected the company's microwave
technology as one of the "Best Inventions of the Year" because
of its ability to "pull fuel out of shale rock, tires and even
plastic bottles." In its annual round up of "Best Inventions of
the Year," Time Magazine selected 46 inventions in 12
categories, from Cars & Buses to Health. Global Resource's
microwave technology is included in the environment category.

*About Global Resource Corp.*

Global Resource Corp., is a developer of a patent-pending
microwave technology and machinery that extracts oil and
petroleum products from shale deposits, tar sands, capped oil
wells, bituminous coal and processed materials such as tires and
plastics as well as dredged soil from harbors and river bottoms.
Its process produces significantly greater yields and lower
costs than are available using existing technologies. Because
the process takes place in an enclosed environment it is
emission-free and an efficient and cost-effective tool for
cleaning environmental wastes and toxic materials...

---



**INVESTMENT**

PR/Media Relations Contact:   
Richard Stern   
Stern & Co.   
richstern@sternco.com   
Tel: 212-888-0044

Jeff Andrews,  CFO   
Global Resource Corporation   
Bloomfield Business Park   
408 Bloomfield Dr. Unit 3   
West Berlin, NJ 08091   
Main: 856-767-5661   
JAndrews@GlobalResourceCorp.com

Investors:   
Arun Chakraborty, Stern & Co.   
212 888 0044   
achakrab@sternco.com

---

[**http://www.azcentral.com/business/articles/1226biz-tires1227-ON.html**](http://www.azcentral.com/business/articles/1226biz-tires1227-ON.html)  
***The Arizona Republic***   
Dec. 26, 2007 04:34 PM

**Recyclers hope to bring microwave tech to
Arizona**

by **Ryan Randazzo**

Dinner-plate sized pieces of rubber hurl from the screeching
shredder as a tractor dumps another ton of used auto tires into
its maw, which resembles a grossly oversized kitchen garbage
disposal.

What rubber doesn't haphazardly escape out the top of the
machine comes out the bottom resembling the filling for a
massive machaca burrito, and Steve Robinson watches as it
streams by on a conveyor belt.

"There's a new black gold," Robinson chuckles over the roar of
the front-end loader and shredder.

Robinson has been gathering tires for one reason or another for
about 10 years, first as a volunteer project to help his
dirt-bike-riding son clean up the desert, and later for
commercial clean-ups.

Now he sells the shredded rubber as far away as Europe to be
used for cushioned ground cover in children's playgrounds, but
he's been stockpiling for a higher cause, he said.

Robinson's company, Envirotech Industries, has formed a joint
venture with a California group, Huntington Renewable Energy,
that wants to buy a giant microwave machines from New Jersey to
"cook" the tires into heating oil, natural gas, carbon and
steel, all of which would be recycled.

The microwave machines would come from New Jersey's Global
Resources Corp. The company has won accolades for its microwave
technology breakthroughs in the laboratory, including from
Popular Science and Time magazine, but has yet to prove it works
on a large scale.

*New technology*

Global Resources CEO Frank Pringle said other potential
customers have requested plans for systems but not yet placed
orders. Global Resources offers the large-scale machines for $5
million to $6 million, and he said they are a better use for
scrap tires than playground ground cover or incinerators that
burn them for energy.

"They are taking tires on the East Coast and using it to (burn
and) make concrete," Pringle said. "It really is a waste of
these materials."

Pringle said his Hawk 10 microwave machines will recover more
than a gallon of diesel fuel, 50 cubic feet of gas, two pounds
of steel and seven pounds of carbon from a 20-pound tire.
Furthermore, he says it can be done without using any water and
without any emissions, because the process will take place in a
vacuum.

But aren't tires made of rubber?

"Damn little of it," Pringle said, noting that most
manufacturers use oil-based materials.The technology works
simply by bombarding the tires with various microwave
frequencies to break them into simpler components, much like a
kitchen microwave oven uses particular frequencies to heat food.

In a video of the Global Resources laboratory posted online, a
researcher is shown placing shredded rubber into a device that
looks much like an industrial refrigerator, turning the machine
on, and returning to recover a small vial of oil that has
drained off, a dry handful of black carbon powder, and enough of
gas piped through a hose to ignite a small flame from a
laboratory burner.

The larger machines designed to process tons of tires will
churn the ground tires in a vacuum much like a giant washing
machine while zapping them with microwaves, capturing the oil
that can be condensed and the gas as it drifts off.

The result is flammable gas they hope to sell to natural gas
wholesalers and a petroleum oil that can be mixed with heating
oil, and Eco has hopes to sell most of the products if and when
the microwaves start up.

Another end product is black carbon, which can be used in ink
and carbon-fiber athletic equipment.

Eco hopes to be in operation in Arizona by fall 2008, if
permitting goes smoothly.

Pringle "stumbled upon" the 18,000 or so frequencies of
microwaves that work well with tires among the 10 million or so
possible frequencies when he was researching how to use the
technology to recycle glass. He thought to test frequencies on
tires after seeing a massive tire fire.

"I don't know if God blessed me or burdened me with this," he
said of the research.

*Building supply*

Robinson's truck drifts along the highway south of Phoenix near
his stockpile before he jerks to the side, pointing to a pile of
about a dozen tires hidden behind the scraggly desert brush.

"Those weren't there last week," he exclaims. He sends workers
along the highway to pick up such illegal dumps, which he said
come from tire dealers. He also has been buying tires from
different collectors, hoping to stockpile enough to run the Hawk
10 microwaves for six months at his facility in the Sonoran
Desert National Monument.

"Instead of people dropping them off in the desert, I see a
line of people coming in to Envirotech," Robinson said.

Because the facility is in the national monument that was
created in 2001, it is important the technology doesn't have any
dangerous emissions, he said.

Huntington Renewable Energy of California and Robinson are in
joint venture known as Eco Renewable Energy to buy the Hawk 10
equipment from Global Resource Corp.

Huntington Renewable investors were looking for an energy
project to invest in, and Robinson was looking for a way to
market his tires for the best use.

"We settled on this system as the best available," said David
Runnion, the CEO of Huntington and president of Eco. "It's
making use of something that is a big bane to society."

Eco has an agreement with its bank to buy the facility, sell it
to the bank and lease it back, Runnion said. The company is
getting its money from Canadian investors who he declined to
identify.

The Arizona plant will cost an estimated $44 million, and the
company hopes to build others.

The Hawk machines require lots of electricity to operate, but
are expected to produce much more energy in the form of natural
gas and oil than they will require to run. Eco officials hope to
process 10 tons of shredded tire material an hour.

"If we can separate ourselves from foreign oil, every bit
helps," Robinson said.

*Will it work?*

Arizona Department of Environmental Quality officials said they
couldn't comment on the plans for the tire-recycling facility,
because they hadn't seen an application for it yet.

Other experts on the technology are hard to come by, being that
it is not in use on a large scale anywhere.

Dinesh Agrawal, a materials-science professor and director of
the Microwave Processing and Engineering Center at Penn State,
said he has seen the microwave technology turn rubber to oil. He
has a research agreement with Global Resources to explore using
microwaves to recover fuel from oil shale.

"On a smaller scale, it works very nice," Agrawal said. "In a
few minutes it can convert a tire, oil shale and even plastics
into useful products."

But that's no guarantee it will work on a large scale, he said.

"To do it on a larger scale is a totally different story,"
Agrawal said. "You need to go from a few grams (of recycled
material) to a few tons. That scaling operation is a very
challenging job. Somebody has to take the risk to fund that kind
that kind of project. It is not a trivial task."

Reach the reporter at ryan.randazzo@arizonarepublic.com or
602-444-4331.

---

[**http://www.popsci.com/popsci/flat/bown/2007/innovator\_2.html**](http://www.popsci.com/popsci/flat/bown/2007/innovator_2.html)

**THE MICROWAVE MAGICIAN**

by

**Rena M Pacella**

Frank Pringle has found a way to squeeze oil and gas from just
about anything

Im not sure if Im watching a magic trick, or an invention
that will make the cigar-chomping 64-year-old next to me the
richest man on the planet. Everything that goes into Frank
Pringles recycling machine  a piece of tire, a rock, a plastic
cup  turns to oil and natural gas seconds later. Ive been
told the oil companies might try to assassinate me, Pringle
says without sarcasm.

The machine is a microwave emitter that extracts the petroleum
and gas hidden inside everyday objects  or at least anything
made with hydrocarbons, which, it turns out, is most of whats
around you. Every hour, the first commercial version will turn
10 tons of auto waste  tires, plastic, vinyl  into enough
natural gas to produce 17 million BTUs of energy (it will use
956,000 of those BTUs to keep itself running).

Pringle created the machine about 10 years ago after he drove
by a massive tire fire and thought about the energy being
released. He went home and threw bits of a tire in a microwave
emitter hed been working with for another project. It turned to
what looked like ash, but a few hours later, he returned and
found a black puddle on the floor of the unheated workshop.
Somehow, hed struck oil.

Or rather, he had extracted it. Petroleum is composed of
strings of hydrocarbon molecules. When microwaves hit the tire,
they crack the molecular chains and break it into its component
parts: carbon black (an ash-like raw material) and hydrocarbon
gases, which can be burned or condensed into liquid fuel.
Pringle figured that some gases from his microwaved tire had
lingered, and the cold air in the shop had condensed them into
diesel. If the process worked on tires, he thought, it should
work on anything with hydrocarbons. The trick was in finding the
optimum microwave frequency for each material  out of 10
million possibilities.

Pringle has spent 10 years and $1 million homing in on
frequencies for hundreds of materials. In 2004 he teamed up with
engineer pal Hawk Hogan to take the machine commercial.

Their first order is under construction in Rockford, Illinois.
Its a $5.1-million microwave machine the size of small bus
called the Hawk, bound for an auto-recycler in Long Island, New
York. More deals loom: The U.S. military may use Hawks in Iraq
on waste such as water bottles and food containers. Oil
companies are looking to the machines to gasify petroleum
trapped in shale.

Back at the shop, Pringle is still zapping new materials. A
sample labeled bituminous coal goes in and, 15 seconds later,
Pringle ignites the resulting gas. You see, he says, why they
might want to kill me.

---