EQUIPMENT AND METHODS FOR AUTOMATIC CONTROL OF WASTE PYROLYSIS

Abstract

A project to transform plastic waste into sustainable fuels and valuable chemicals. Pyrolysis systems and methods are presented. In an example, a pyrolysis a reactor started with electricity and then self-generating non-condensable It uses a double heating cycle sustained by the combustion of synthesis gas. [Further details omitted] In one example, a first and a second pyrolysis reactor are operating in series. system operations simultaneously generate electricity or recycled pyrolytic material. It is driven by thermal energy. The system also dynamically manages thermal heating transitions and continuous processing. actively reduce material bridging and feeder clogging during the process for the purpose of varying the pitch of the compression screw against the feeder motor torque. running a continuous feedback control loop to automatically modulate It includes a Programmable Logic Controller (PLC).

Description

1 TARIFF DEVICE FOR AUTOMATIC CONTROL OF WASTE PYROLYSIS. METHOD Technical Area This invention enables the conversion of plastic waste into sustainable fuels through thermochemical decomposition. and falls into the field of pyrolysis systems where they are converted into valuable chemicals. Furthermore Specifically, the invention relates to feed material bridging during waste pyrolysis and to prevent inlet throat blockages, and to dynamically implement hybrid dual-fuel heating architecture. real-time sensor feedback loops for balancing purposes an automated Programmable Logic System 10 configured to execute This relates to the PLC (Processor Control Center) system and the methods associated with this system. State of the art Pyrolysis designed for thermochemical recycling of plastic polymeric waste. Due to the physical properties of the feed material, the systems face serious operational challenges. It encounters disruptions. Shredded plastic waste is subjected to preheating and then... As the material is advanced through the feeding mechanism, it is non-uniform. softening, high melt viscosity, and material in the reactor inlet throat. It tends to form bridging or "cold plugs". These blockages mechanical jamming, increased torsional resistance in drive motors, and continuous production 20 This leads to disruptions in the communication lines. Furthermore, optimizing energy efficiency requires a complex hybrid heating framework. This requires operation. The systems require an external power source at the initial system startup. using a power source (such as electrical resistance elements); stable 25 in the reactor chamber non-condensable synthesis that is self-generated when state pyrolysis is achieved. It switches to burning gas. Separate electrical dimmers and gas fuel Manually managing the overlapping thermal balance between the lines is extremely important. It is inefficient and poses a risk of thermal instability. 2 Current technology addresses localized physical material blockages and requires dynamic, automated solutions. an integrated control architecture capable of simultaneously handling fuel-to-electricity thermal tracking It cannot provide this. Continuous, self-operating without manual operator intervention. real-time sensor data to ensure the operation is effective A critical need for a dynamically responsive automated control system 5 It is located. A brief description of the invention. Our invention provides a central hub for automating a pyrolysis architecture. A hardware-10 managed by a Programmable Logic Controller (PLC). It offers a software control platform. The system uses internal temperature sensors, line a special system consisting of internal torque sensors and fluid pressure transducers It continuously samples real-time data from the network. To eliminate power supply failures, the PLC uses motor torque variances of 15. a blockage prevention system that identifies localized structural bottlenecks through The feed cycle is running. When a torque resistance increase is recorded, the PLC Temporary, high-speed operation on variable-pitch compression screw for cleaning the plug. Simultaneously localized current while performing a torque-driven reverse rotation cycle. It modulates the inputs. 20 To optimize system efficiency, PLCs automatically control the synthesis gas lines. internal transient pressure and in order to restrict the proportional valve smoothly. It continuously analyzes temperature trends. This affects the gas burner output. By dynamically reducing primary electrical inputs while increasing them, the system automatically, 25 It locks into a self-sufficient thermal equilibrium. 3 Detailed description of the invention Figures and Descriptions FIGURE 1: Physical hardware components managed by the automation layer, Schematic of a pyrolysis reactor showing its sensors and control interfaces. It is the appearance. 5 FIGURE 2: Feeder motor torque, anti-clogging operations and hybrid dual Programmable Logic for dynamically managing fuel-based heating transitions. Automatic control logic loops executed by the controller (PLC) It is a flowchart that illustrates this. Referring to the figures, the automatic control integration is shown in System 10, Figure 1. an integrated Programmable Logic System structurally linked to its components It is managed by the PLC (Processor Controller). The physical architecture is variable. with screw conveyor (102) configured as a step compression screw It includes a equipped feeder (96). The screw winding of the screw conveyor (102) flows downstream from the upstream hopper area. towards its output (104) a constant compression ratio between 1.5:1 and 3:1 It has a decreasing variable step. This structural decrease occurs under preheating. by mechanically compressing softened, shredded plastic polymeric solid waste Increasing bulk density and highly viscous melt flow in material 20 To eliminate bridging, the reactor via the rotary valve (106) It forces it into its reservoir (108). The control network is directly connected to the motor reducer unit (126) of the feeder assembly. It includes a series of temperature sensors (128) and inline torque sensors, each 25 Both of them continuously transmit operational data to the PLC. As indicated in the control logic in FIGURE 2, the PLC provides continuous, real-time monitoring. A safety feedback loop is implemented. The in-line torque sensor is located at the waste inlet. 30 beforehand indicates that a plastic cold plug or material blockage has begun. When the PLC detects an increase in structural resistance exceeding a defined safety threshold, 4 It immediately interrupts the forward drive of the motor reducer unit (126). PLC then to break and clean the internal bottleneck in the motor reducer unit (126) Short-term, high-torque reverse rotation cycle of screw conveyor (102) He orders him to carry it out. Simultaneously, the PLC adjusts localized temperatures to reduce melt viscosity. To change the heated shaft (116) or external elements, the electric current is switched off quickly. a control signal to the electronic thyristor dimmer (130) to modulate. It transmits. Also, between the PLC's initial operation phase and subsequent processing operations. It automatically coordinates the complex thermal transition. PLC, reactor internal temporary liquid from inside the reservoir (108) and from the synthesis gas outlet pipe (146) It continuously samples pressure and temperature data. In the initial phase, the system, It is based on the first heat source (94). 15 As the pyrolysis reaction matures between 400°C and 800°C, it is collected in a collection vessel. (166) an increasing amount of non-condensable synthesis gas accumulates. The PLC detects this volume increase via pressure transducers and the fuel Dynamic automatic proportional valve positioned along the supply pipe (168) 20 It modulates as follows: The PLC modulates proportionally to increase the gas flow to the fuel burner (170). While opening the valve smoothly, electricity is simultaneously drawn from the power source (92). paired to reduce or cut off the power to the connections and brushes (124) It transmits a command. By dynamically balancing these inputs, the PLC manually... 25 that benefit from fuel produced spontaneously without operator intervention It achieves optimized, automatic steady-state thermal balance.

Claims

REQUESTS 1. A reactor with a feeder and a reactor chamber containing a helical shaft. A pyrolysis system comprising a reservoir, a condenser, and a fuel burner, 5 to prevent material clogging and manage power transitions through a central Programmable Logic Controller (PLC) This is an automation method that includes the following: To preheat the shredded solid waste before loading it into the reactor chamber. Operating the feeder using a primary heat source; To produce synthesis gas and solid residue, shredded solid waste is processed in reactor 10. pyrolysis in the reservoir; pyrolytic oil and non-condensable synthesis gas To produce it, condense the synthesis gas in the condenser; then transfer it to the reactor chamber. to provide a secondary heat source, non-condensable synthesis gas is used as fuel Directing to the burner; pyrolysis using numerous real-time sensors. Monitoring at least one dynamic operating parameter of the process; and system 15 in response to the dynamic operating parameter monitored to maintain its balance Automatically modulating system inputs via a central PLC. The method being characterized.

2. The method is according to claim 1 and has at least one dynamic operating parameter for reactor 20. It includes the internal temperature of the reservoir and the PLC, the second heat source. As the thermal energy output provided by the primary heat source increases, the energy flowing to the primary heat source... It reduces power proportionally and dynamically.

3. The method according to claim 1 is synthesized with at least one dynamic operating parameter 25 It involves measuring fluid pressure within a gas flow, and PLC, pressure solid waste inside the reactor chamber in response to fluctuations to change the volumetric holding time the helix rotation speed It changes dynamically. 6 4. The method must be in accordance with claim 1 and have at least one dynamic operating parameter. It involves measuring a pressure inside a capacitor, and the PLC uses this pressure as a unit. If the safety threshold is exceeded, the non-condensable synthesis gas is removed from the fuel burner. to automatically remove a safety bypass valve It activates. 5 5. The method must be in accordance with claim 1 and have at least one dynamic operating parameter. It includes the mechanical torque load measured on the shaft of the helix and the PLC. To prevent material jamming, the mechanical torque load is predetermined. When a safety limit is exceeded, the feeder's processing feed rate is dynamically increased to 10. It reduces it accordingly.

6. A device for pyrolyzing shredded solid waste, including the following: It includes: A feeder equipped with a primary heat source; 15 The reactor chamber, which is structurally connected to the feeder, and the wastewater from the reactor chamber. entrance, It has a synthesis gas outlet, a solid residue outlet, and a heated conveyor shaft. internal It contains a spiral; 20 A capacitor in liquid contact with the synthesis gas outlet; It is positioned to provide a secondary heat source to the reactor chamber. The fuel burner is in liquid contact with the gas outlet of the condenser; To redirect hot process gas from the reactor chamber back to the feeder. a structured exhaust transmission line and a sensor network communicatively connected to 25 A device containing a connected Programmable Logic Controller (PLC).

7. According to claim 6, the device is a PLC, and it monitors the temperature associated with the fuel burner. the first heat in response to the increasing temperature reading from the sensor Automatic thermal 30 by dynamically weakening the power going to the source. 7 to perform a balancing feedback loop It is structured.

8. According to claim 6, the device is a PLC, measuring the actual output of the synthesis gas. 5 that will change the rotation speed of the internal screw according to the time steam pressure. It is structured in this way.

9. According to claim 6, the device is a PLC, and the torque is measured on a heated conveyor shaft. The feeder automatically adjusts its feed speed in response to the load. It is structured in a way that will restrict it.

10. According to claim 6, the device is a PLC, and the pressure inside the capacitor... if the sensor detects a pressure exceeding its safety limit Emergency measures to remove non-condensable synthesis gas from the fuel burner. It is configured to activate the automatic bypass valve. 20 30

Images