Processing system and processing method

Abstract

A processing system (1) is provided with a supply device (10), a switching mechanism (20), a thermal decomposition device (30), and a first recovery device (50). A supply device (10) continuously or intermittently supplies a material to be processed to a supply pipe (11) having a branch section. A switching mechanism (20) selectively switches the flow path of the material to be processed in the branch portion. Each of the thermal decomposition devices (30) receives the material to be processed on the downstream side of each of the branched plurality of supply pipes, and thermally decomposes the received material to be processed by irradiating the received material to be processed with microwaves. The first recovery device (50) sequentially recovers a first product including a fluid generated by thermal decomposition from each of the plurality of thermal decomposition devices.

Description

Technical Field

[0001] This invention relates to a processing system and a processing method. Background Technology

[0002] As a technology for breaking down waste plastics and extracting reusable materials, there exists a method known as chemical recycling.

[0003] For example, the processing apparatus disclosed in Patent Document 1 heats waste plastics, causing the chlorine-based polymers to thermally decompose and thus produce chlorine compounds. In doing so, the processing apparatus separates the waste plastics into molten waste plastics and chlorine compounds.

[0004] Reference List

[0005] Patent documents

[0006] Patent Document 1: Japanese Unexamined Patent Application Publication JP 2002-317072. Summary of the Invention

[0007] To achieve a circular society, we look forward to further improvements in recycling technology.

[0008] This disclosure was made to address this problem and aims to provide a processing system that can efficiently recycle and reuse materials.

[0009] The processing system according to this disclosure includes a supply device, a switching mechanism, a pyrolysis device, and a first recovery device. The supply device continuously or intermittently supplies the material to be processed into a supply pipe having branches. The switching mechanism selectively switches the flow path of the material to be processed in the branches. Each of the pyrolysis devices receives the material to be processed downstream of each of the multiple supply pipes in the branches, and thermally decomposes the received material to be processed by irradiating it with microwaves. The first recovery device sequentially recovers a first product containing the fluid generated by the pyrolysis from each of the multiple pyrolysis devices.

[0010] In the processing method according to this disclosure, the processing system performs the following processing: The processing system continuously or intermittently supplies the material to be processed to a supply pipe having branches. The processing system sequentially selects the flow path of the material to be processed in each branch. In a pyrolysis device installed on a plurality of corresponding branches of the supply pipe, the processing system supplies the material to be processed to the pyrolysis device associated with the selection. The processing system causes the pyrolysis device receiving the material to be processed to pyrolyze the material. The processing system sequentially recovers the fluid generated after pyrolysis from each of the plurality of pyrolysis devices.

[0011] According to this disclosure, a processing system and method for efficiently recycling and reusing materials can be provided. Attached Figure Description

[0012] Figure 1 This is an overall structural diagram of the processing system according to the first embodiment;

[0013] Figure 2 This is a block diagram of the processing system according to the first embodiment;

[0014] Figure 3 This is a flowchart of the processing method according to the first embodiment;

[0015] Figure 4 This is a diagram showing the state changes of the switching mechanism and the pyrolysis device;

[0016] Figure 5 This is a structural diagram of a pyrolysis apparatus;

[0017] Figure 6 This is a diagram showing the first state of the pyrolysis apparatus;

[0018] Figure 7 This is a diagram showing the second state of the pyrolysis apparatus;

[0019] Figure 8 This is a flowchart illustrating the processing method implemented by the pyrolysis apparatus; and

[0020] Figure 9 This is an overall structural diagram of the processing system according to the second embodiment. Detailed Implementation

[0021] The present invention will now be described through embodiments thereof, but the invention according to the claims is not limited to the following embodiments. Furthermore, not all components / structures described in the embodiments are necessary means to solve the problem. For clarity, appropriate omissions and simplifications have been made in the following description and drawings. Note that in the drawings, the same elements are labeled with the same reference numerals, and repeated descriptions are omitted where necessary.

[0022] <Implementation Method 1>

[0023] The embodiments of the present invention will now be described with reference to the accompanying drawings. Figure 1 This is an overall structural diagram of the processing system according to the first embodiment. Figure 1 The components / structure of the processing system 1 shown are schematically illustrated for ease of understanding. The processing system 1 thermally decomposes the material M10 to be processed and recovers the first product M21 and the second product M22. The processing system 1 includes, as a main component, a supply device 10, a switching mechanism 20, a thermal decomposition device 30, a pressure control valve 40, a first recovery device 50, a second recovery device 70, and a control device 80.

[0024] Note that in this disclosure, components labeled with the same reference numerals have the same function or structure. Furthermore, regarding the reference numerals for multiple components shown in this disclosure, one letter from each of the different letters may be added after the same numeral. In this case, although the components with different letters differ from each other, they have the same function or structure.

[0025] The supply device 10 continuously or intermittently supplies the material to be processed M10 to the supply pipe 11, which has branches. The supply device 10 is an extrusion device that continuously extrudes the heated and mixed material to be processed M10 into the supply pipe. The supply device 10 may also be an injection device that intermittently injects the heated and mixed material to be processed M10 into the supply pipe.

[0026] The supply device 10 is communicatively connected to the control device 80 and operates according to the instructions of the control device 80. Furthermore, the supply device 10 has one or more sensors, such as thermometers and pressure gauges. The supply device 10 can provide data from its one or more sensors to the control device 80.

[0027] The material to be treated, M10, contains at least a resin and a catalyst used for the thermal decomposition of the resin. The resin may be, for example, any thermoplastic resin, such as polyethylene (PE), polypropylene (PP), polycarbonate (PC), acrylonitrile-butadiene-styrene copolymer (ABS), or polyamide (PA), or any thermosetting resin, such as epoxy resin, unsaturated polyester, polyimide, or polyurethane. Furthermore, the resin may also be a composite material containing carbon fibers, glass fibers, cellulose fibers, etc., in either thermoplastic or thermosetting resin. The catalyst contains a substance that heats up when irradiated with predetermined microwaves and thus promotes the thermal decomposition of the resin. More specifically, the catalyst is an electromagnetic wave absorber, such as iron oxide or carbon fiber. Additionally, the catalyst may also contain substances that promote heating and thermal decomposition, such as citric acid.

[0028] The supply pipe 11 is a conduit that guides the material to be processed M10, which is continuously or intermittently supplied by the supply device 10, to multiple pyrolysis units 30 through its branches. A switching mechanism 20 is provided on the branches of the supply pipe 11. Figure 1 The supply pipe 11 shown has three branches, each of which has a switching mechanism 20.

[0029] Each of the switching mechanisms 20 can selectively switch the flow path of the material M10 to be processed in the branch of the supply pipe 11. Each of the switching mechanisms 20 guides the material M10 to be processed from the upstream supply pipe 11 to one of the two supply pipes 11 in the branch. The switching mechanism 20 is communicatively connected to the control device 80 and switches the selected supply pipe 11 according to the instructions of the control device 80.

[0030] The processing system 1 includes switching mechanisms 20A, 20B, and 20C, which serve as switching mechanisms 20. Switching mechanism 20A guides the material to be processed M10 from the supply device 10 to either the pyrolysis device 30A or the switching mechanism 20B. Switching mechanism 20B guides the material to be processed M10 from the switching mechanism 20A to either the pyrolysis device 30B or the switching mechanism 20C.

[0031] The switching mechanism 20C is connected to and does not branch off from the switching mechanism 20B and the pyrolysis device 30C. The switching mechanism 20C can guide the material M10 to be processed from the switching mechanism 20B to the pyrolysis device 30C, or stop guiding it to the pyrolysis device 30C. However, when a pyrolysis device 30 (e.g., a pyrolysis device 30D) is additionally provided in the processing system 1, the configuration of the switching mechanism 20C can be expanded so that the material M10 to be processed can be guided to the additionally provided pyrolysis device 30D. With the above configuration, each of the switching mechanisms 20 selects one or more pyrolysis devices 30 to supply the material M10 to be processed.

[0032] The pyrolysis apparatus 30 receives the material to be processed M10 downstream of the supply pipes 11 with multiple corresponding branches, and thermally decomposes the received material to be processed M10 by irradiating it with microwaves. Each component of the pyrolysis apparatus 30 generates a first product M21 and a second product M22 from the material to be processed M10 through pyrolysis. Each component of the pyrolysis apparatus 30 supplies the first product M21 to the first recovery device 50. Each component of the pyrolysis apparatus 30 supplies the second product M22 to the second recovery device 70.

[0033] Each component in the pyrolysis apparatus 30 is communicatively connected to the control device 80 and operates according to the instructions of the control device 80. Furthermore, each component in the pyrolysis apparatus 30 has one or more sensors, such as thermometers and pressure gauges. Each component in the pyrolysis apparatus 30 can provide data from its onboard sensors to the control device 80.

[0034] The first product M21 is a fluid and contains hydrogen. The second product M22 is one or more substances other than the first product M21 and contains carbon. The carbon is, for example, carbon nanotubes (CNTs).

[0035] Microwaves are, for example, electromagnetic waves with a frequency of 300 MHz to 30 GHz, preferably electromagnetic waves with a frequency of 2.45 GHz. Each of the thermal decomposition apparatuses 30 has at least a magnetron for generating microwaves. The output of the magnetron is, for example, about 1000 watts. Each of the thermal decomposition apparatuses 30 irradiates the received material to be processed M10 with microwaves for, for example, about 5 to 10 minutes. Note that the magnetron output and microwave irradiation time shown above are merely examples, and the operation of each of the thermal decomposition apparatuses 30 in this embodiment is not limited to the examples shown here.

[0036] The processing system 1 includes thermal decomposition devices 30A, 30B, and 30C, which are thermal decomposition devices 30. Thermal decomposition device 30A is connected to a switching mechanism 20A, a first recovery device 50, and a second recovery device 70. Therefore, thermal decomposition device 30A thermally decomposes the material M10 received from the switching mechanism 20A, sending the first product M21 generated by thermal decomposition to the first recovery device 50, and sending the second product M22 generated by thermal decomposition to the second recovery device 70. Note that a pressure control valve 40A is inserted between the thermal decomposition device 30 and the first recovery device 50. Each of the pressure control valves 40 maintains the pressure of the delivered gas within a constant range.

[0037] Similarly, the pyrolysis device 30B is connected to the switching mechanism 20B and pyrolyzes the material M10 to be processed received from the switching mechanism 20B to generate a first product M21 and a second product M22. The pyrolysis device 30B sends the first product M21 to the first recycling device 50 and sends the second product M22 to the second recycling device 70 through the pressure control valve 40B.

[0038] The pyrolysis device 30C is connected to the switching mechanism 20C and pyrolyzes the material M10 to be processed received from the switching mechanism 20C to generate a first product M21 and a second product M22. The pyrolysis device 30C sends the first product M21 to the first recycling device 50 and sends the second product M22 to the second recycling device 70 through the pressure control valve 40B.

[0039] The first recovery unit 50 sequentially recovers a first product M21, containing fluids generated by thermal decomposition, from multiple pyrolysis units 30 (i.e., pyrolysis unit 30A, pyrolysis unit 30B, and pyrolysis unit 30C). The first recovery unit 50 extracts hydrogen from the recovered first product M21. The first recovery unit 50 includes a pressure control valve 51, a hydrogen extraction unit 52, an accumulator 53, and a gas recovery unit 54 as its main components.

[0040] Pressure control valve 51 supplies the gas received from the upstream side to the downstream side at a constant pressure. Pressure control valve 51 receives the first product M21 from each of the pressure control valves 40 and supplies the received first product M21 to the hydrogen extraction unit 52.

[0041] Hydrogen extraction device 52 selectively separates and extracts hydrogen from the first product M21 and supplies the extracted hydrogen to accumulator 53. Accumulator 53 stores the hydrogen received from hydrogen extraction device 52. Furthermore, hydrogen extraction device 52 supplies the gas from the first product M21 after hydrogen extraction to gas recovery unit 54. Hydrogen extraction device 52 may have, for example, a hydrogen permeation membrane. The hydrogen permeation membrane selectively permeates hydrogen and does not permeate any substance other than hydrogen. Hydrogen extraction device 52 may employ means other than a hydrogen permeation membrane. For example, hydrogen extraction device 52 may separate hydrogen by cooling the first product M21 or by using a predetermined adsorbent.

[0042] The second recovery device 70 receives the second product M22 from the pyrolysis device 30 and stores the received second product M22. More specifically, the second recovery device 70 sequentially recovers the second product M22 from the pyrolysis device 30 and separates and extracts carbon from the recovered second product M22. The second recovery device 70 includes a separation device 71, a carbon recovery unit 72, and a residue recovery unit 73 as main components. The separation device 71 separates the second product M22 into carbon and residue other than carbon. The carbon separated from the second product M22 by the separation device 71 is supplied to the carbon recovery unit 72, and the residue is supplied to the residue recovery unit 73.

[0043] The control device 80 is a computing device that has at least a central processing unit (CPU) with computing capabilities. The control device 80 may be, for example, a computer, tablet terminal, or smartphone. The control device 80 may be a dedicated device with computing capabilities. The control device 80 controls the composition of the processing system 1. More specifically, for example, the control device 80 controls the timing of the switching mechanism 20 performing switching.

[0044] Next, refer to Figure 2 The functions of processing system 1 will be further explained. Figure 2 This is a block diagram of the processing system 1 according to the first embodiment. Figure 2 The processing system 1 is shown as being divided into functional blocks. In the processing system 1, the control device 80 is communicatively connected to the supply device 10, the switching mechanism 20, the pyrolysis device 30, and the first recovery device 50.

[0045] Furthermore, the control device 80 includes a processor 81, a memory 82, and an interface 83 as its main components. The processor 81 is an arithmetic unit containing a CPU, and controls the components based on data acquired from the components. The memory 82 includes at least non-volatile memory storing programs for implementing the functions of this disclosure, and random access memory (RAM) used by the control device 80 during operation. The interface 83 includes communication circuitry following a communication protocol used by the control device 80 to communicate with the components. The interface 83 also includes an operation input mechanism for receiving operations performed by a user of the management processing system 1.

[0046] With the above configuration, the control device 80 controls the operation of the supply device 10, the switching mechanism 20, and the pyrolysis device 30. For example, the control device 80 controls the switching mechanism 20 to switch the flow path of the supply pipe 11 based on predetermined switching conditions. The switching conditions are, for example, time. In this case, the control device 80 controls the switching mechanism 20 to switch the flow path at each preset switching time. Furthermore, in this case, the control device 80 operates the pyrolysis device 30 in response to the control of the switching mechanism 20.

[0047] Furthermore, the control device 80 can control the switching mechanism 20 based on other switching conditions. Examples of other switching conditions include the operating status of the pyrolysis device 30. For instance, when the control device 80 detects that one of the multiple pyrolysis devices 30 has discharged the first product M21 and the second product M22, the control device 80 can control the corresponding switching mechanism 20 to supply new material M10 to be processed to that pyrolysis device 30.

[0048] The control device 80 can obtain the pressure status of the accumulator 53 from the first recovery device 50, and control the operation of the supply device 10 and the pyrolysis device 30 based on the internal pressure of the accumulator 53. That is, when the pressure of the accumulator 53 reaches or exceeds a threshold, the control device 80 can control the pyrolysis device 30 to stop the supply of the first product M21. In addition, in response to this, the control device 80 can control the supply device 10 to stop the supply of the material to be processed.

[0049] Next, refer to Figure 3 The processing performed by processing system 1 is described. Figure 3 This is a flowchart of the processing method according to the first embodiment. Figure 3 The flowchart illustrates the processing performed by the control device 80 of the processing system 1.

[0050] First, the control device 80 continuously or intermittently supplies the material to be processed M10 to the supply pipe 11 with branches (step S11). More specifically, the supply device 10, receiving instructions from the control device 80, begins to supply the material to be processed M10.

[0051] Next, the switching mechanism 20 selects the flow path of the material M10 to be processed in the branch (step S12). The material M10 to be processed is transported to the supply pipe 11 associated with the selection through the flow path selected by the switching mechanism 20.

[0052] Next, the switching mechanism 20 supplies the material to be processed M10 to the thermal decomposition device 30 installed on the supply pipe 11 of the corresponding branch and the thermal decomposition device 30 related to the selection (step S13).

[0053] Next, the control device 80 causes the thermal decomposition device 30, which has received the material to be processed M10, to thermally decompose the material to be processed M10 (step S14). That is, the thermal decomposition device 30 irradiates the material to be processed M10 with microwaves.

[0054] Next, the first recycling device 50 and the second recycling device 70 respectively recover the material to be processed M10 (i.e., the first product M21 and the second product M22) that has been thermally decomposed by the thermal decomposition device 30 (step S15).

[0055] Next, the control device 80 determines whether the predetermined switching conditions are met (step S16). If the control device 80 does not determine that the predetermined switching conditions are met (step S16: No), then step S16 is repeated. On the other hand, if the control device 80 determines that the predetermined switching conditions are met (step S16: Yes), then step S17 is executed.

[0056] Note that the predetermined switching condition is, for example, a preset time. In this case, for example, when the timer and thermal decomposition start simultaneously, and then after a preset time period has elapsed, the control device 80 determines that the switching condition is met.

[0057] In step S17, the control device 80 determines whether the system has terminated (step S17). System termination occurs, for example, when the user performs an operation instructing the system to terminate. Alternatively, system termination occurs, for example, when there is no more material M10 available to be processed from the supply device 10. If the control device 80 determines the system has terminated (step S17: Yes), the processing system 1 proceeds to step S18, stops the supply device 10 (step S18), and ends a series of processes. On the other hand, if the control device 80 does not determine the system has terminated (step S17: No), the processing system 1 proceeds to step S19.

[0058] In step S19, the switching mechanism 20 switches the flow path (step S19). That is, the processing system 1 switches the pyrolysis device 30 used for the thermal decomposition of the material M10 to be processed. If the switching mechanism 20 switches the flow path, the processing system 1 returns to step S13.

[0059] Next, refer to Figure 4The flow path switching performed by the switching mechanism 20 and the processing performed by the pyrolysis device 30 associated with the flow path switching are explained. Figure 4 This is a diagram showing the state changes of the switching mechanism and the pyrolysis device. Figure 4 The processing system 1 shown is illustrated in the following order, starting from the top of the figure: processing system 1 in state T1, processing system 1 in state T2 following state T1, and processing system 1 in state T3 following state T2.

[0060] In state T1, the supply device 10 supplies the material to be processed M10 to the switching mechanism 20A. The switching mechanism 20A is in a state in which it supplies the material to be processed M10 received from the supply device 10 to the pyrolysis device 30A.

[0061] In this state, the pyrolysis device 30A is in the state of receiving the material to be processed M10 from the supply device 10 via the switching mechanism 20A. The pyrolysis device 30B is in the state of pyrolyzing the received material to be processed M10. The pyrolysis device 30C is in the state of sending the first product M21 generated by the pyrolysis of the material to be processed M10 to the first recycling device 50 and the second product M22 to the second recycling device 70.

[0062] In state T2 following state T1, the supply device 10 supplies the material to be processed M10 to the switching mechanism 20A. The switching mechanism 20A is in a state where it supplies the material to be processed M10 received from the supply device 10 to the switching mechanism 20B. The switching mechanism 20B is in a state where it supplies the material to be processed M10 received from the switching mechanism 20A to the switching mechanism 20C. The switching mechanism 20C is in a state where it supplies the material to be processed M10 received from the switching mechanism 20B to the pyrolysis device 30C.

[0063] In this configuration, the pyrolysis apparatus 30C receives the material to be processed M10 from the supply device 10 via the switching mechanisms 20A, 20B, and 20C. The pyrolysis apparatus 30A is in a state where it pyrolyzes the received material to be processed M10. The pyrolysis apparatus 30B is in a state where it sends the first product M21 generated from the pyrolysis of the material to be processed M10 to the first recycling device 50, and the second product M22 to the second recycling device 70.

[0064] In state T3 following state T2, the supply device 10 supplies the material to be processed M10 to the switching mechanism 20A. The switching mechanism 20A is in a state where it supplies the material to be processed M10 received from the supply device 10 to the switching mechanism 20B. The switching mechanism 20B is in a state where it supplies the material to be processed M10 received from the switching mechanism 20A to the pyrolysis device 30B.

[0065] In this state, the pyrolysis device 30B receives the material to be processed M10 from the supply device 10 via the switching mechanism 20A and the switching mechanism 20B. The pyrolysis device 30C performs pyrolysis on the received material to be processed M10. The pyrolysis device 30A sends the first product M21 generated by the pyrolysis of the material to be processed M10 to the first recycling device 50 and the second product M22 to the second recycling device 70.

[0066] After state T3, processing system 1 returns to state T1 and repeats the processing. Thus, in processing system 1, switching mechanism 20 sequentially selects the flow path of the material M10 to be processed in the branch. If the selected pyrolysis device 30 receives the material M10, it performs pyrolysis on the received material M10. First recovery device 50 sequentially recovers the first product M21, which is the fluid produced after pyrolysis, from multiple pyrolysis devices 30. Similarly, second recovery device 70 sequentially recovers the second product M22, which is the fluid produced after pyrolysis, from multiple pyrolysis devices 30.

[0067] The structure of processing system 1 and the processing performed by processing system 1 have been described above. With the above structure, processing system 1 sequentially supplies the material to be processed M10, continuously or intermittently supplied by supply device 10, to multiple pyrolysis devices 30. Furthermore, processing system 1 sequentially recovers the first product M21 and the second product M22 generated by the pyrolysis performed by the multiple pyrolysis devices 30. Therefore, supply device 10 can continuously and efficiently supply the material to be processed M10 to the pyrolysis devices 30 without being limited by the processing rate of the pyrolysis devices 30. Furthermore, the first recovery device 50 can continuously recover the first product M21 without being limited by the processing rate of the pyrolysis devices 30. Similarly, the second recovery device 70 can continuously recover the second product M22 without being limited by the processing rate of the pyrolysis devices 30.

[0068] Next, refer to Figure 5 The structure of the thermal decomposition device 30 will be described. Figure 5 This is a structural diagram of a pyrolysis apparatus. The pyrolysis apparatus 30 includes a container 300, an irradiation device 301, a receiving port 310, a gas inlet 320, a tray 330, a tray drive unit 331, a second outlet 340, a first outlet 350, an exhaust valve 360, and a sensor 370 as its main components.

[0069] The container 300 is a hollow shell made of, for example, heat-resistant metal or ceramic, and can hold a predetermined amount of material M10 to be treated. The upper part of the container 300 is provided with a receiving port 310, a gas inlet 320, and a first outlet 350. Furthermore, the lower part of the container 300 is shaped like a mortar, and a second outlet 340 is provided at the lowest point of the container 300. The container 300 houses a tray 330 and a tray drive unit 331. In addition, an irradiation device 301 is mounted on the top or side of the container 300.

[0070] To thermally decompose the material M10 to be treated within container 300, irradiation device 301 irradiates the material M10 with microwaves. Irradiation device 301 has one or more magnetrons for generating microwaves, and one or more antennas for irradiating container 300 with microwaves generated by the one or more magnetrons. Note that container 300 has an electromagnetic wave transmission region for transmitting the microwaves generated by irradiation device 301 into the interior of container 300. The electromagnetic wave transmission region is formed by openings for electromagnetic wave transmission or by a material that allows electromagnetic waves to pass through.

[0071] Note that the pyrolysis apparatus 30 may have multiple irradiation devices 301. The antenna of each irradiation device 301 may have a movable part for changing the microwave irradiation area. Through the movable design of the antenna, the pyrolysis apparatus 30 can suppress the deviation of the microwaves applied to the material M10 to be treated.

[0072] The receiving port 310 is connected to the supply pipe 11 located downstream of the switching mechanism 20. Thus, the pyrolysis device 30 receives the material M10 to be processed from the supply pipe 11 through the receiving port 310.

[0073] Gas inlet 320 is an inlet for supplying inert gas from the outside into the container 300. The pyrolysis apparatus 30 receives the material to be processed M10 and also receives inert gas. The inert gas may be, for example, helium, argon, nitrogen, or carbon dioxide. With the container 300 filled with inert gas, the pyrolysis apparatus 30 activates the irradiation device 301 to apply microwaves. Gas inlet 320 has a switching valve 321, thereby controlling the supply of inert gas to the container 300. Note that to fill the container 300 with inert gas, the pyrolysis apparatus 30 may have a structure that evacuates its interior, for example, by using a vacuum pump. In this case, the container 300 may, for example, have a vacuum pump suction port. The vacuum pump suction port is connected to the vacuum pump via a switching valve.

[0074] Note that container 300 may have multiple gas inlets 320. In addition, gas inlets 320 may, for example, be capable of supplying inert gas with a pressure sufficient to agitate the material M10 to be treated or the second product M22 on tray 330.

[0075] Tray 330 is a plate-shaped component with a horizontally extending surface on which the material to be treated, M10, is placed during thermal decomposition. Tray 330 can be formed from a flat or curved surface. (About...) Figure 5 The tray 330 shown has a central portion that gradually bulges out in a spindle shape, while the outer periphery is lower than the central portion. This structure allows the surface area of ​​the tray 330 to be larger than the surface area of ​​a surface parallel to the horizontal plane. Therefore, the tray 330 can relatively increase the surface area of ​​the material M10 to be processed placed on it. Consequently, the tray 330 can relatively increase the area of ​​the material M10 to be processed that receives microwaves. Note that the shape of the uneven portion of the tray 330 is not limited to the above-described form.

[0076] The tray drive unit 331 supports the tray 330 from its lower side, allowing the tray 330 to move up and down. When the tray 330 is moving upwards via the tray drive unit 331, its outer periphery contacts the sidewall 302 protruding inwards from the outer periphery of the container 300. Therefore, the material M10 to be processed falling from the receiving port 310 is positioned on the upper surface of the tray 330. When the tray 330 is moving downwards via the tray drive unit 331, a gap is formed between the outer periphery of the tray 330 and the sidewall 302. Therefore, the second product M22 generated after thermal decomposition falls downwards through the gap between the outer periphery of the tray 330 and the sidewall 302. The second product M22 falling from the tray 330 continues to fall onto the mortar-shaped surface formed at the lower part of the container 300 and moves to the lower part of the container 300 through the second discharge port 340.

[0077] Note that the tray drive unit 331 can drive the tray 330 to rotate about a vertical axis. In addition, the tray drive unit 331 may have a stirring member that passes through the central part of the tray 330 and is rotatably arranged to stir the material M10 to be processed in the through part.

[0078] The second outlet 340 is an opening located at the bottom of the container 300, and discharges the second product M22. The second outlet 340 has a gate 341, which makes it openable and closable.

[0079] The first outlet 350 is a fluid outlet located on the upper part of the container 300, and it discharges the first product M21 generated by thermal decomposition. A switching valve 351 and an exhaust fan 352 are provided at the first outlet 350. The switching valve 351 is a valve configured to open and close freely, and it is in the open state when the thermal decomposition device 30 discharges the second product M22. When the switching valve 351 is in the open state, the exhaust fan 352, located downstream of the switching valve 351, pressurizes and delivers the second product M22 discharged from the first outlet 350 to the pressure control valve 40.

[0080] When inert gas is filled into container 300 through gas inlet 320, exhaust valve 360 ​​discharges any remaining gases inside. Furthermore, exhaust valve 360 ​​may function as a safety valve for discharging gases from container 300, preventing excessive pressure increases during the pyrolysis process performed by pyrolysis apparatus 30 when internal pressure exceeds a threshold. Note that when inert gas is filled into container 300 through gas inlet 320, pyrolysis apparatus 30 may have a structure that allows connection to the aforementioned vacuum pump instead of exhaust valve 360 ​​to discharge any remaining gases. By using a vacuum pump to discharge these gases, pyrolysis apparatus 30 can efficiently alter the environment inside container 300.

[0081] Sensor 370 measures at least one of temperature and pressure inside container 300. Sensor 370 can supply the measured data to control device 80.

[0082] The pyrolysis apparatus 30 is connected to the secondary battery 200 and receives power from the secondary battery 200. The secondary battery 200 supplies power to the pyrolysis apparatus 30. More specifically, for example, the secondary battery 200 may supply power to the irradiation device 301 of the pyrolysis apparatus 30. The secondary battery 200 is, for example, a lithium-ion battery.

[0083] In addition, the secondary battery 200 can store electricity generated from renewable energy sources. Figure 5 The secondary battery 200 shown receives power supplied from the wind power generation system 90. The wind power generation system 90 is one embodiment of a power generation system using renewable energy. Note that, regarding the power used for the supply devices 10, etc., other than the pyrolysis device 30, the processing system 1 can receive power supplied from the power generation system using renewable energy.

[0084] With the above-described structure, the processing system 1, equipped with the secondary battery 200, can thermally decompose the material M10 to be processed while reducing environmental impact. Note that the power generation system utilizing renewable energy can be a system that utilizes sunlight or geothermal energy. Furthermore, the power generation system using renewable energy can, for example, be a system that generates electricity using hydrogen produced through a hydrogen boiler.

[0085] Note that the secondary battery 200 may be a reusable product (reusable product). Reusable products include, for example, products that have been used in electric vehicles or the like and then removed from electric vehicles or the like because they no longer meet the specifications for use in electric vehicles or the like. By using a reusable product for the secondary battery 200, the processing system 1 can reduce its environmental impact.

[0086] Next, refer to Figure 6 and Figure 7 The operation of the pyrolysis device 30 is explained. Figure 6This is a diagram showing the first state of the thermal decomposition apparatus 30. Figure 6 In the process, the thermal decomposition device 30 receives the material to be processed M10 through the receiving port 310, and the irradiation device 301 irradiates the received material to be processed M10 with microwaves.

[0087] When the thermal decomposition apparatus 30 irradiates the material to be treated M10 with microwaves, the material to be treated M10 is irradiated with microwaves. Substances in the irradiated material to be treated M10 that absorb microwaves, such as electromagnetic wave absorbers, are heated, thereby increasing their temperature. As a result, the resin mixed in the material to be treated M10 is also heated and undergoes thermal decomposition. At this time, the temperature in the decomposition treatment zone 130 is, for example, 400°C to 900°C.

[0088] One or more polymers of the heated resin decompose and are converted into hydrogen, one or more lower hydrocarbons, one or more organic gases, and other intermediate products. Thermal decomposition continues as microwaves are continuously applied by the thermal decomposition apparatus 30, and a first product M21 and a second product M22 are generated from the material to be treated M10. After the material to be treated M10 has decomposed into the first product M21 and the second product M22, the thermal decomposition apparatus 30 stops applying microwaves.

[0089] Figure 7 This is a diagram showing the second state of the thermal decomposition apparatus 30. Figure 7 In this process, the pyrolysis device 30 is discharging the first product M21 and the second product M22 to the outside of the container 300. At this time, the tray 330 is in a lowered position, and a gap is formed between the tray 330 and the side wall 302, allowing the second product M22 to pass through. Furthermore, at the second discharge outlet 340, the gate 341 is opened. Therefore, the second product M22 falls from the outer periphery of the tray 330 to the lower part of the container 300, and further moves through the second discharge outlet 340 to the second recycling device 70.

[0090] also, Figure 7 In this process, the switching valve 351 of the first outlet 350 is opened, and the exhaust fan 352 is driven to pressurize the fluid in the container 300 and deliver it to the pressure control valve 40. As a result, the first product M21 is drawn into the first outlet 350 and discharged to the outside of the container 300. Note that at this time, inert gas can be supplied from the gas inlet 320. By supplying inert gas from the gas inlet 320, the pyrolysis apparatus 30 can facilitate the discharge of the first product M21 to the first outlet 350.

[0091] Next, refer to Figure 8 The processing performed by the pyrolysis apparatus 30 is explained. Figure 8 This is a flowchart illustrating the processing method performed by the pyrolysis apparatus. Figure 8The flowchart shown is executed, for example, by the control device 80 that controls the thermal decomposition device 30.

[0092] First, the control device 80 opens the gate 311 of the receiving port 310 (step S31). Note that when the gate 311 is opened, the switching mechanism 20 switches the flow path to supply the material to be processed M10 to the pyrolysis device 30 that performs the actions of this flowchart.

[0093] Next, the control device 80 determines whether the supply of the material M10 to be processed is complete (step S32). If the control device 80 does not determine that the supply of the material M10 to be processed is complete (step S32: No), the control device 80 repeats step S32. If the control device 80 determines that the supply of the material M10 to be processed is complete (step S32: Yes), the control device 80 closes the gate 311 of the receiving port 310 (step S33).

[0094] Next, the control device 80 activates the irradiation device 301 to irradiate the material M10 to be treated with microwaves (step S34).

[0095] Next, the control device 80 determines whether the thermal decomposition is complete (step S35). Note that the control device 80 can determine whether the thermal decomposition is complete based on data received from the sensor 370 of the thermal decomposition device 30. Alternatively, the control device 80 can determine whether the thermal decomposition has ended by determining whether the above switching conditions are met. If the control device 80 does not determine that the thermal decomposition has ended (step S35: No), the control device 80 returns to step S34 and continues to apply microwaves. If the control device 80 determines that the thermal decomposition has ended (step S35: Yes), the control device 80 begins to deliver the first product M21 and the second product M22 (step S36).

[0096] Next, the control device 80 determines whether the delivery of the first product M21 and the second product M22 is complete (step S37). The control device 80 determines whether delivery is complete, for example, based on data from the sensor 370. Alternatively, the control device 80 can determine whether delivery is complete by measuring a preset time. If the control device 80 does not determine whether delivery is complete (step S37: No), the control device 80 returns to step S36 and continues to deliver the first product M21 and the second product M22. If the control device 80 determines that delivery is complete (step S37: Yes), the control device 80 proceeds to step S38.

[0097] In step S38, the control device 80 determines whether the system has terminated (step S38). If the control device 80 does not determine that the system has terminated (step S38: No), the control device 80 returns to step S31 and repeats a series of processes. If the control device 80 determines that the system has terminated (step S38: Yes), the control device 80 ends the series of processes.

[0098] The first embodiment has been described above. With the above configuration, in the processing system 1 according to the first embodiment, the material to be processed M10, continuously or intermittently supplied from the supply device 10, is sequentially thermally decomposed by multiple thermal decomposition devices 30 and sequentially sent to the first recovery device 50 and the second recovery device 70. Thus, the processing system 1 can efficiently recover hydrogen and carbon. Therefore, according to the first embodiment, a processing system and method capable of efficiently recovering reusable materials can be provided.

[0099] <Second Implementation Method>

[0100] Figure 9 This is an overall structural diagram of the processing system according to the second embodiment. The first recovery device 50 according to the second embodiment includes a collection device 55.

[0101] The trapping device 55 extracts a predetermined fluid, such as carbon dioxide, from the first product M21 received through the pressure control valve 40. The predetermined fluid is, for example, a gas with high water solubility. The trapping device 55 separates the highly water-soluble fluid, such as carbon dioxide, from the first product M21, for example, by water displacement. The trapping device 55 supplies the first product M21 obtained by separating the predetermined fluid to the hydrogen extraction device 52 through the pressure control valve 51. With the above configuration, the first recovery device 50 can reduce the load on the hydrogen extraction device 52.

[0102] The second embodiment has been described above. Based on the first and second embodiments, a processing system and method capable of efficiently recycling reusable materials can be provided.

[0103] Through the above-described construction, the processing system 1, according to the embodiment, recovers hydrogen and carbon from the material to be processed, M10. The material to be processed, M10, includes, for example, waste plastics. The Sustainable Development Goals (SDGs) adopted by the United Nations General Assembly include ensuring sustainable consumption and production. The processing system 1 contributes to ensuring sustainable consumption and production by recovering reusable hydrogen and carbon from waste plastics. Furthermore, the processing system 1 can receive at least a portion of the electricity generated by the devices used in the processing system 1 from renewable energy sources. Thus, the processing system 1 contributes to achieving a sustainable society.

[0104] Although this application has been described with reference to embodiments, it is not limited to the above description. Various modifications to the structure and details of this invention, as will be understood by those skilled in the art, are possible within the scope of this invention.

[0105] This application is based on and claims priority to Japanese Patent Application JP 2023-150841, filed on September 19, 2023, the disclosure of which is incorporated herein by reference in its entirety.

[0106] Explanation of reference numerals in the attached figures

[0107] 1. Processing System

[0108] 10. Supply device

[0109] 11 Supply Management

[0110] 20 Switching Mechanism

[0111] 30. Thermal decomposition apparatus

[0112] 40 Pressure control valve

[0113] 50 First Recovery Unit

[0114] 51 Pressure control valve

[0115] 52 Hydrogen Extraction Unit

[0116] 53 Accumulator

[0117] 54 Gas Recovery Unit

[0118] 55. Capture device

[0119] 70 Second Recycling Unit

[0120] 71 Separation device

[0121] 72 Carbon Recycler

[0122] 73 Residue Recycler

[0123] 80 Control device

[0124] 90 Wind power generation system

[0125] 200 rechargeable batteries

[0126] 300 containers

[0127] 301 Irradiation Device

[0128] 310 Receiver Port

[0129] 311 Gate

[0130] 320 Gas Inlet

[0131] 321 Switch valve

[0132] 330 pallets

[0133] 331 Pallet Drive Unit

[0134] 340 Second Export

[0135] 341 Gate

[0136] 350 First Export

[0137] 351 Switching Valve

[0138] 352 Exhaust Fan

[0139] 360° exhaust valve

[0140] 370 sensor

[0141] M10 Material to be processed

[0142] M21 First product

[0143] M22 Second product

Claims

1. The processing system has: A supply device configured to continuously or intermittently supply material to be processed into a supply pipe having branches; A switching mechanism configured to selectively switch the flow path of the material to be processed in the branch; Multiple pyrolysis devices are configured to receive the material to be processed on the downstream side of each of the multiple branch supply pipes, and to thermally decompose the received material to be processed by irradiating it with microwaves. as well as The first recovery device is configured to sequentially recover a first product containing the fluid produced by thermal decomposition from each of the plurality of said pyrolysis devices.

2. The processing system according to claim 1, wherein, The supply device is an extrusion device configured to continuously extrude heated and mixed material to be treated into the supply tube, or an injection device configured to intermittently inject heated and mixed material to be treated into the supply tube.

3. The processing system according to claim 1, wherein, Each of the components in the pyrolysis apparatus has: A container, configured to hold a predetermined amount of material to be processed; An irradiation device configured to irradiate the material to be treated with microwaves in order to thermally decompose the material to be treated within the container; The first outlet is configured to discharge the first product generated by thermal decomposition. as well as The second outlet is configured to deliver a second product other than the first product.

4. The processing system according to claim 3, wherein, The processing system also has a second recovery unit configured to sequentially recover the second product from each of the pyrolysis devices and to separate and extract carbon from the recovered second product.

5. The processing system according to any one of claims 1 to 4, wherein, The switching mechanism switches the flow path to supply the material to be processed received from the supply device to the pyrolysis device that has already sent out the pyrolyzed material to be processed.

6. The processing system according to claim 5, wherein, The processing system also includes a control device configured to control the switching mechanism to switch the flow path based on predetermined switching conditions.

7. The processing system according to claim 6, wherein, The control device controls the switching mechanism to switch the flow path at each switching time preset to the switching conditions.

8. The processing system according to claim 1, wherein, The supply device supplies the material to be treated, which contains at least resin, to the supply pipe; and Each of the thermal decomposition apparatuses thermally decomposes the material to be treated by irradiating it with microwaves, thereby enabling the extraction of at least hydrogen from the material to be treated.

9. The processing system according to claim 8, wherein, The supply device supplies the material to be treated, comprising the resin and a catalyst for promoting thermal decomposition, into the supply pipe.

10. The processing system according to claim 9, wherein, Each of the devices in the thermal decomposition apparatus thermally decomposes the material to be treated by irradiating it with microwaves at a frequency of 2.45 GHz.

11. The processing system according to claim 1, wherein, The processing system also has a secondary battery configured to supply power to the pyrolysis device.

12. The processing system according to claim 11, wherein, The secondary battery can store electricity generated from renewable energy sources.

13. The processing method includes the following steps: The material to be processed is supplied continuously or intermittently to the supply pipe with branches; Select the flow path of the material to be processed in the branch in sequence; In a pyrolysis device installed on multiple corresponding branches of the supply pipe, the material to be processed is supplied to the pyrolysis device associated with the selection. The thermal decomposition device that received the material to be processed thermally decomposed the material to be processed. as well as The fluids produced after thermal decomposition are recovered sequentially from each of the multiple thermal decomposition devices.

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