Carbon black treatment system

Abstract

According to the carbon black treatment system provided by the embodiment of the invention, the cracking system is used for carrying out cracking treatment on rubber and plastic raw materials to generate primary carbon black, so that harmless and reduction pretreatment of rubber and plastic wastes is realized; the circulating fluidized bed incineration system is connected with the cracking system through a pipeline and is used for carrying out high-temperature incineration on primary carbon black to generate high-temperature flue gas, so that continuous treatment capacity and combustion efficiency which are far higher than that of blending combustion of a traditional coal-fired boiler are realized in a treatment link by using a circulating fluidized bed technology; the treatment scale and the heat energy output of the primary carbon black are obviously improved; the waste heat recovery system is connected with the circulating fluidized bed incineration system and the cracking system through pipelines and used for conducting waste heat recovery and heat exchange treatment on high-temperature flue gas to generate purified flue gas and water vapor, the water vapor is used for generating electricity to generate electric power, and therefore efficient recovery of flue gas heat energy is achieved, dependence on external energy is reduced, and the energy utilization rate is increased. The efficient utilization of the rubber and plastic waste is realized.

Description

Technical Field

[0001] This invention relates to the field of crude carbon black treatment technology generated by pyrolysis reaction, and in particular to a carbon black treatment system. Background Technology

[0002] In the integrated pyrolysis process for rubber and plastics, the high-value utilization of pyrolysis oil and the effective disposal of by-products are key to realizing its economic and environmental benefits. Currently, the pyrolysis oil produced by this technology can be refined into high-quality, low-sulfur marine fuel, becoming the mainstream resource utilization path in the industry; the combustible gas produced as a process by-product is also usually reused within the system as a heat source. However, the end-use of another major by-product, pyrolysis crude carbon black, still faces significant challenges: as a low-quality filler, although recycled rubber products can partially replace virgin carbon black, its low purity, poor added value, dust and volatile matter pollution during processing, and limited low-end market capacity result in unsatisfactory overall economic and environmental benefits; as a co-fuel for coal-fired boilers, although heat energy can be recovered, its fine particles and low combustion rate not only waste heat energy but also increase the carbon content of boiler ash, affecting subsequent resource utilization. Summary of the Invention

[0003] In view of the above problems, embodiments of the present invention are proposed to provide a carbon black processing system that overcomes or at least partially solves the above problems.

[0004] To address the above problems, embodiments of the present invention disclose a carbon black processing system, comprising: The pyrolysis system is used to receive and pyrolyze rubber and plastic raw materials to produce primary carbon black; A circulating fluidized bed incineration system, connected to the pyrolysis system, is used to receive and incinerate the primary carbon black to generate high-temperature flue gas; The waste heat recovery system is connected to the circulating fluidized bed incineration system and the pyrolysis system respectively. It is used to receive the high-temperature flue gas and exchange heat with the high-temperature flue gas to generate purified flue gas and water vapor, and use the water vapor to generate electricity.

[0005] Optionally, the pyrolysis system includes: A pretreatment device is used to receive and pretreatment the rubber and plastic raw materials and output raw material granules; A thermal pyrolysis reactor, connected to the pretreatment unit, is used to receive and pyrolyze the raw material particles to generate primary carbon black and pyrolysis oil; An oil tank, connected to the pyrolysis reactor, is used to receive and store the pyrolysis oil; A buffer chamber, connected to the pyrolysis reactor, is used to receive and store the primary carbon black.

[0006] Optionally, the circulating fluidized bed incineration system includes: The return feeder is connected to the pyrolysis system, cyclone separator and incinerator via pipelines. It is used to receive the primary carbon black output from the pyrolysis system and the secondary carbon black output from the cyclone separator, and to transport the primary carbon black and the secondary carbon black to the incinerator. The incinerator, connected to the return feeder via a pipeline, is used to receive and incinerate the primary carbon black, producing high-temperature flue gas and secondary carbon black. A cyclone separator, connected to the incinerator, is used to separate the high-temperature flue gas and the secondary carbon black generated by the incinerator.

[0007] Optionally, the waste heat recovery system includes: The waste heat recovery device is connected to the circulating fluidized bed incineration system through a pipeline. It is used to receive the high-temperature flue gas and boiler feedwater, and to exchange heat between the high-temperature flue gas and boiler feedwater to generate steam and low-temperature flue gas. A flue gas purification device, connected to the waste heat recovery device, is used to receive and purify the low-temperature flue gas discharged from the waste heat recovery device. A steam turbine generator set is connected to the waste heat recovery device to receive and utilize the steam to generate electricity and produce boiler feedwater and low-pressure steam.

[0008] Optionally, the steam turbine generator set is used to output boiler feedwater to the waste heat recovery device; The steam turbine generator set is also connected to the pyrolysis system to output the low-pressure steam to the pyrolysis system to dry the rubber and plastic raw materials and keep the products in the pyrolysis system warm.

[0009] Optionally, the pretreatment device includes an inlet and an outlet, wherein the inlet of the pretreatment device is used to receive rubber and plastic raw materials; and the outlet of the pretreatment device is used to output raw material granules. The pyrolysis reactor includes a first outlet and a second outlet. The first outlet of the pyrolysis reactor is connected to the oil tank via a pipeline for outputting pyrolysis oil to the oil tank. The second outlet of the pyrolysis reactor is connected to the buffer tank via a pipeline for outputting primary carbon black to the buffer tank. The oil tank includes an inlet, which is connected to the first outlet of the pyrolysis reactor via a pipeline, for receiving and storing the pyrolysis oil output by the pyrolysis reactor; The buffer chamber includes a discharge port, which is connected to the second discharge port of the pyrolysis reactor via a pipe, for receiving the primary carbon black output from the buffer chamber.

[0010] Optionally, the return feeder includes a first inlet, a second inlet, and an outlet; the first inlet of the return feeder is used to receive primary carbon black output from the pyrolysis system; the second inlet of the return feeder is used to receive secondary carbon black output from the cyclone separator; the outlet of the return feeder is connected to the incinerator via a pipeline for outputting the primary carbon black and / or the secondary carbon black to the incinerator; The incinerator includes a feed inlet and a gas outlet. The feed inlet of the incinerator is connected to the discharge outlet of the return feeder through a pipeline for receiving the primary carbon black. The gas outlet of the incinerator is connected to the cyclone separator through a pipeline for outputting high-temperature flue gas. The cyclone separator includes an air inlet, an air outlet, and a discharge outlet. The air inlet of the cyclone separator is connected to the air outlet of the incinerator via a pipe to receive the high-temperature flue gas and secondary carbon black output from the incinerator. The air outlet of the cyclone separator is connected to the waste heat recovery system to output the high-temperature flue gas after cyclone separation. The discharge outlet of the cyclone separator is connected to the feed inlet of the return feeder to output the secondary carbon black separated from the high-temperature flue gas.

[0011] Optionally, the waste heat recovery device includes an air inlet, a water inlet, a first air outlet, and a second air outlet. The air inlet of the waste heat recovery device is connected to the circulating fluidized bed incineration system via a pipeline for receiving the high-temperature flue gas; the water inlet of the waste heat recovery device is used to receive the boiler feedwater; the first air outlet of the waste heat recovery device is connected to the steam turbine generator set via a pipeline for outputting the steam to the steam turbine generator set; and the second air outlet of the waste heat recovery device is connected to the flue gas purification device via a pipeline for outputting the heat-exchanged low-temperature flue gas. The flue gas purification device includes an air inlet and an air outlet. The air inlet of the flue gas purification device is connected to the second air outlet of the waste heat recovery device through a pipeline for receiving the low-temperature flue gas. The air outlet of the flue gas purification device is used to output purified flue gas. The steam turbine generator set includes an air inlet, a water outlet, and an air outlet. The air inlet of the steam turbine generator set is connected to the first air outlet of the waste heat recovery device for receiving steam. The water outlet of the steam turbine generator set is used to output boiler feedwater. The air outlet of the steam turbine generator set is used to output low-pressure steam.

[0012] Optionally, the steam turbine generator set further includes: the outlet of the steam turbine generator set is connected to the inlet of the waste heat recovery device via a pipeline for outputting boiler feedwater to the waste heat recovery device; the outlet of the steam turbine generator set is connected to the pyrolysis system via a pipeline for outputting low-pressure steam to the pyrolysis system.

[0013] Optionally, the oil tank also includes an air inlet connected to the waste heat recovery system via a pipeline, for receiving low-pressure steam output by the waste heat recovery system to keep the pyrolysis oil in the oil tank warm; The pretreatment device also includes an air inlet connected to the waste heat recovery system via a pipeline, for receiving low-pressure steam output from the waste heat recovery system to dry the raw material particles in the pretreatment device.

[0014] The embodiments of this invention include the following advantages: A pyrolysis system is used to pyrolyze rubber and plastic raw materials to generate primary carbon black, thereby achieving harmless and reduced-volume pretreatment of rubber and plastic waste; a circulating fluidized bed incineration system is connected to the pyrolysis system via pipelines to incinerate the primary carbon black at high temperatures, generating high-temperature flue gas. This utilizes circulating fluidized bed technology to achieve a continuous processing capacity and combustion efficiency far exceeding that of traditional coal-fired boilers, significantly improving the processing scale and heat output of primary carbon black; a waste heat recovery system is connected to both the circulating fluidized bed incineration system and the pyrolysis system via pipelines to recover and exchange the waste heat from the high-temperature flue gas, generating purified flue gas and steam. The steam is then used to generate electricity, achieving efficient recovery of flue gas heat energy, reducing dependence on external energy sources, and realizing efficient utilization of rubber and plastic waste. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a structural block diagram of a carbon black processing system provided in an embodiment of the present invention; Figure 2 This is a structural block diagram of another carbon black processing system provided in an embodiment of the present invention.

[0017] Explanation of reference numerals in the attached figures: 10-Pyrolysis system, 20-Circulating fluidized bed incineration system, 30-Waste heat recovery system, 101-Pretreatment device, 102-Thermal pyrolysis reaction device, 103-Oil tank, 104-Buffer bin, 201-Return feeder, 202-Incinerator, 203-Cyclone separator, 301-Waste heat recovery device, 302-Flue gas purification device, 303-Steam turbine generator set. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] The terms "first," "second," etc., used in the specification and claims of this invention are used to distinguish similar objects and are not used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention can be implemented in orders other than those illustrated or described herein. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0020] In the integrated pyrolysis process of rubber and plastics, the resource utilization of pyrolysis crude carbon black, a byproduct, is crucial to the system's economic efficiency and environmental benefits. Currently, conventional low-value utilization methods are limited by the properties of the product, making it difficult to realize its potential value: as a filler for reclaimed rubber, it can partially replace virgin carbon black, but due to the low purity and extremely low market added value of pyrolysis crude carbon black, the processing process easily generates dust and volatile matter pollution, and the market demand for low-end products is limited, easily leading to capacity backlog; as a boiler co-fuel, it can recover some heat energy, but because the pyrolysis crude carbon black has dense particles and a low specific surface area, the random pyrolysis and agglomeration during the pyrolysis process result in a very wide particle size distribution, with particles ranging from micrometers to millimeters possibly coexisting. Cracked coarse carbon black has a high carbon content and a calorific value of 20-28 MJ, thus possessing extremely high "fuel value." However, due to these characteristics, when it is incorporated into coal-fired boilers, the combustion speed is slow, the burnout rate is low, and the heat loss is significant. This not only causes significant heat loss but also leads to excessive carbon content in boiler ash, rendering it unusable. While the preparation of activated carbon through activation is a high-value-added approach, the high impurities in the raw materials and the high energy consumption of activation result in a final product with performance far lower than commercially available activated carbon. Furthermore, the cost per ton exceeds 3,000 yuan, making it uncompetitive in the market.

[0021] Current technological approaches generally rely on physical blending or simple conversion of pyrolysis crude carbon black, failing to address its inherent characteristics for targeted quality improvement. To meet low-end filling or co-firing needs, current treatment methods often involve simple grinding or direct addition, failing to effectively control its inherent defects such as high ash content, low volatile matter, high sulfur content, and wide particle size distribution. While such utilization methods can achieve some reduction and energy recovery, they come at a significant cost: extremely low product added value, risks of secondary pollution, poor energy conversion efficiency, and overall low economic and environmental benefits. Essentially, this constitutes a primary disposal path that sacrifices resource value and environmental performance.

[0022] Therefore, how to develop a targeted upgrading technology that can directly adapt to the characteristics of pyrolysis crude carbon black and achieve its efficient and clean conversion and high-value utilization, while avoiding the economic and environmental burden caused by simple blending or inefficient activation, has become a key issue that urgently needs to be addressed in the field of rubber and plastics resource utilization.

[0023] One of the core concepts of this invention is that it provides a carbon black treatment system. A pyrolysis system is used to pyrolyze rubber and plastic raw materials to generate primary carbon black, thereby achieving the harmless and volume-reduced pretreatment of rubber and plastic waste. A circulating fluidized bed incineration system is connected to the pyrolysis system via pipelines to incinerate the primary carbon black at high temperatures, generating high-temperature flue gas. This utilizes circulating fluidized bed technology to achieve a continuous processing capacity and combustion efficiency far exceeding that of traditional coal-fired boilers, significantly improving the processing scale and heat output of primary carbon black. A waste heat recovery system is connected to both the circulating fluidized bed incineration system and the pyrolysis system via pipelines to recover and exchange the waste heat from the high-temperature flue gas, generating purified flue gas and steam. The steam is then used to generate electricity, achieving efficient recovery of flue gas heat energy, reducing dependence on external energy sources, and realizing the efficient utilization of rubber and plastic waste.

[0024] Reference Figure 1 The diagram shows a structural block diagram of a carbon black processing system provided by an embodiment of the present invention, which may specifically include the following: The pyrolysis system 10 is used to receive and pyrolyze rubber and plastic raw materials to generate primary carbon black; In this embodiment of the invention, the pyrolysis system is the core processing unit for realizing the thermochemical conversion of rubber and plastic waste. It is mainly responsible for decomposing waste tires, waste plastics, and other rubber and plastic raw materials into gaseous, liquid, and solid three-phase products in an oxygen-free or low-oxygen environment. The pyrolysis process can be achieved by precisely controlling the reaction temperature and residence time, causing the polymer chains to break and recombine, generating solid products mainly composed of primary carbon black, as well as byproducts such as pyrolysis oil and combustible gas.

[0025] The pyrolysis system can transform rubber and plastic waste that is difficult to use directly into primary carbon black with clear resource value, laying the foundation for subsequent energy recovery and material utilization, while realizing the source reduction and harmless treatment of waste.

[0026] The circulating fluidized bed incineration system 20 is connected to the pyrolysis system and is used to receive and incinerate the primary carbon black to generate high-temperature flue gas; In this embodiment of the invention, the circulating fluidized bed combustion system is a high-efficiency energy conversion unit designed specifically for the characteristics of pyrolysis crude carbon black. It is primarily responsible for the complete oxidation of fixed carbon and residual volatiles in primary carbon black under high-temperature fluidized combustion conditions, releasing chemical energy and converting it into thermal energy for high-temperature flue gas. This system utilizes high-speed airflow to keep the carbon black particles in a fluidized state, achieving sufficient gas-solid contact and extending residence time through material circulation between the furnace and separator. Compared to co-firing in conventional coal-fired boilers, its unique fluidized combustion and material circulation mechanism significantly improves the burnout rate and combustion stability of pyrolysis crude carbon black.

[0027] The circulating fluidized bed incineration system can efficiently and cleanly convert the chemical energy of pyrolyzed crude carbon black into high-quality thermal energy, generating stable high-temperature flue gas, which provides a reliable heat source for subsequent waste heat power generation, while avoiding the economic and environmental problems caused by using carbon black as a low-value fuel or filler.

[0028] The waste heat recovery system 30 is connected to the circulating fluidized bed incineration system and the pyrolysis system respectively. It is used to receive the high-temperature flue gas and exchange heat with the high-temperature flue gas to generate purified flue gas and water vapor, and use the water vapor to generate electricity.

[0029] In this embodiment of the invention, the waste heat recovery system is a key integrated unit for energy cascade utilization and system energy efficiency improvement, mainly including a waste heat boiler, a steam turbine generator set, and auxiliary heat exchange circuits. Firstly, the waste heat boiler recovers sensible heat from the high-temperature flue gas, generating superheated steam to drive the steam turbine generator set to supply electricity, thus realizing the conversion of high-grade thermal energy into electricity. Compared with the shortcomings of existing technologies, such as dispersed thermal energy utilization and low overall energy efficiency in the pyrolysis and incineration stages, the significant advantage of the embodiments of the present invention is that, through system integration and thermal energy cascade design, the high-temperature flue gas energy generated by incineration is efficiently converted into electrical energy, and the waste heat from power generation is recycled back to the pyrolysis process itself, which greatly improves the overall energy self-sufficiency rate and energy utilization efficiency, and reduces dependence on external energy and operating costs.

[0030] This invention provides a carbon black treatment system. A pyrolysis system is used to pyrolyze rubber and plastic raw materials to generate primary carbon black, thus achieving the harmless and volume-reduced pretreatment of rubber and plastic waste. A circulating fluidized bed incineration system is connected to the pyrolysis system via pipelines to incinerate the primary carbon black at high temperatures, generating high-temperature flue gas. This utilizes circulating fluidized bed technology to achieve a continuous processing capacity and combustion efficiency far exceeding that of traditional coal-fired boilers, significantly improving the processing scale and heat output of primary carbon black. A waste heat recovery system is connected to both the circulating fluidized bed incineration system and the pyrolysis system via pipelines to recover and exchange the waste heat from the high-temperature flue gas, generating purified flue gas and steam. The steam is then used to generate electricity, achieving efficient recovery of flue gas heat energy, reducing dependence on external energy sources, and realizing the efficient utilization of rubber and plastic waste. Reference Figure 2 The diagram illustrates a structural block diagram of another carbon black processing system provided by an embodiment of the present invention, which may specifically include the following: The pyrolysis system 10 is used to receive and pyrolyze rubber and plastic raw materials to generate primary carbon black; In this embodiment of the invention, the pyrolysis system is the core front-end unit of the integrated rubber and plastic pyrolysis process, mainly used for the thermochemical conversion of mixed rubber and plastic raw materials such as waste tires and waste plastics. Primary carbon black refers to pyrolysis crude carbon black generated through the pyrolysis reaction.

[0031] In some embodiments, the pyrolysis system 10 may further include the following devices: The pretreatment device 101 is used to receive and pretreatment the rubber and plastic raw materials and output raw material granules; In this embodiment of the invention, the pretreatment device is a key pre-processing unit to ensure the uniformity and stability of the pyrolysis reaction. It performs physical treatments such as crushing, screening, and magnetic separation on rubber and plastic raw materials of different sources and forms to form raw material particles of uniform size.

[0032] In some examples, the pretreatment device includes an inlet and an outlet, the inlet of which is used to receive rubber and plastic raw materials; the outlet of which is used to output raw material particles. In this embodiment of the invention, the pretreatment device may include an inlet and an outlet. The inlet of the pretreatment device is used to receive raw materials; then the rubber and plastic raw materials are crushed and processed into raw material particles, and the outlet of the pretreatment device is used to output the raw material particles.

[0033] In some examples, the pretreatment device further includes an air inlet connected to the waste heat recovery system via a pipeline for receiving low-pressure steam output from the waste heat recovery system to dry the raw material particles in the pretreatment device.

[0034] In this embodiment of the invention, the waste heat recovery system can introduce low-pressure steam generated from waste heat recovery into the drying section of the pretreatment unit, reducing the moisture content of the raw materials through indirect heat exchange. Compared with traditional drying methods such as electric heating or natural gas heating, this embodiment of the invention makes full use of process waste heat, significantly reducing pretreatment energy consumption. Simultaneously, the steam drying temperature is well controllable, preventing premature pyrolysis of the raw materials due to localized overheating.

[0035] The thermal pyrolysis reactor 102 is connected to the pretreatment device and is used to receive and pyrolyze the raw material particles to generate primary carbon black and pyrolysis oil. In this embodiment of the invention, the pyrolysis reactor can receive raw material particles for pyrolysis reaction, producing combustible non-condensable gas, pyrolysis oil, and pyrolysis crude carbon black. The combustible non-condensable gas generates hot flue gas through combustion, providing a heat source for the pyrolysis reaction. The pyrolysis oil is sent to an oil tank for storage, and the pyrolysis crude carbon black can be sent to a buffer silo for buffering.

[0036] In some examples, the pyrolysis reactor includes a first outlet and a second outlet. The first outlet of the pyrolysis reactor is connected to the oil tank via a pipeline for discharging pyrolysis oil into the oil tank. The second outlet of the pyrolysis reactor is connected to the buffer tank via a pipeline for discharging primary carbon black into the buffer tank. In some examples, the pyrolysis reactor can be connected to auxiliary equipment to efficiently separate the oil and gas mixture produced by pyrolysis into liquid oil and combustible gas, and to separate the pyrolysis crude carbon black, i.e., primary carbon black. The discharge pipeline can be designed with heat tracing and insulation to prevent heavy components from condensing and clogging.

[0037] Oil tank 103 is connected to the thermal cracking reactor and is used to receive and store the cracked oil; In this embodiment of the invention, the oil tank can be used to receive and store pyrolysis oil.

[0038] In some examples, the oil tank includes an inlet connected to the first outlet of the pyrolysis reactor via a pipe, for receiving and storing the pyrolysis oil output from the pyrolysis reactor; In some examples, the oil tank also includes an air inlet connected to the waste heat recovery system via a pipeline, for receiving low-pressure steam output from the waste heat recovery system to keep the pyrolysis oil in the oil tank warm. The oil tank can utilize the low-pressure steam output from the waste heat recovery system to keep the pyrolysis oil in the tank warm.

[0039] The buffer chamber 104 is connected to the thermal pyrolysis reactor and is used to receive and store the primary carbon black.

[0040] In this embodiment of the invention, the buffer bin serves as a buffer unit between the pyrolysis system and the incineration system. Its working principle is to achieve temporary storage and stable supply of primary carbon black through a closed storage and pneumatic conveying system.

[0041] In some examples, the buffer chamber includes a discharge port connected via a pipe to a second discharge port of the pyrolysis reactor for receiving the primary carbon black output from the buffer chamber.

[0042] The circulating fluidized bed incineration system 20 is connected to the pyrolysis system and is used to receive and incinerate the primary carbon black to generate high-temperature flue gas; In this embodiment of the invention, the circulating fluidized bed incinerator is a key piece of equipment for achieving efficient combustion and burnout of pyrolysis crude carbon black. It consists of a furnace, a high-efficiency cyclone separator, and a return feeder. The pyrolysis crude carbon black is fed into the furnace for combustion through the feed inlet of the return feeder via pneumatic conveying.

[0043] In some examples, circulating fluidized bed incineration technology can achieve high-temperature incineration of 900~1000℃ by rationally arranging the furnace heating surface. With the support of a high-efficiency cyclone separator, the pyrolyzed crude carbon black can circulate in the high-temperature furnace, thereby extending its residence time in the high-temperature zone until it is completely burned.

[0044] In some embodiments, the circulating fluidized bed incineration system 20 may further include the following devices: The return feeder 201 is connected to the pyrolysis system, cyclone separator and incinerator through pipelines, and is used to receive the primary carbon black output from the pyrolysis system and the secondary carbon black output from the cyclone separator, and to transport the primary carbon black and the secondary carbon black to the incinerator. In the embodiments of the invention, the return feeder serves as the material circulation and mixing hub in the circulating fluidized bed incineration system. Its core working principle is to receive fresh primary carbon black from the pyrolysis system and recycled secondary carbon black from the cyclone separator through a combination of pneumatic conveying and mechanical control, and then uniformly mix the two and stably convey them to the incinerator.

[0045] In some embodiments, the return feeder includes a first inlet, a second inlet, and an outlet; the first inlet of the return feeder is used to receive primary carbon black output from the pyrolysis system; the second inlet of the return feeder is used to receive secondary carbon black output from the cyclone separator; the outlet of the return feeder is connected to the incinerator via a pipeline for outputting the primary carbon black and / or the secondary carbon black to the incinerator; In some examples, the first feed inlet is used to receive pyrolysis black from the pyrolysis system; the second feed inlet of the return feeder can be used to receive secondary black output from the cyclone separator; the discharge outlet of the return feeder is connected to the incinerator via a pipe for outputting the primary black and / or, secondary black to the incinerator.

[0046] Compared with traditional mechanical screw or gravity feeding methods, pneumatic conveying not only achieves rapid and uniform dispersion of materials, promoting their instantaneous fluidization and rapid ignition in the furnace, but also indirectly participates in the optimization of the primary air ratio in the furnace by adjusting the conveying air volume, thereby comprehensively improving combustion efficiency and reaction rate.

[0047] The incinerator 202 is connected to the return feeder via a pipeline and is used to receive and incinerate the primary carbon black to produce high-temperature flue gas and secondary carbon black. In this embodiment of the invention, the furnace of the incinerator 202 can achieve a design temperature of 900~1000℃ by rationally arranging the heating surfaces, while controlling the oxygen content of the flue gas at the furnace outlet to ≥5%, which is crucial for ensuring the combustion of pyrolyzed crude carbon black. The combustion air required for incineration is provided by a blower. Two cyclone separators are symmetrically connected to the furnace outlet. The cyclone separators are designed with an inlet velocity of approximately 30m / s and a design outlet velocity of approximately 40m / s, which is crucial for ensuring the separation efficiency of the cyclone separators.

[0048] In some embodiments, the incinerator includes a feed inlet and a gas outlet. The feed inlet of the incinerator is connected to the discharge outlet of the return feeder via a pipeline for receiving the primary carbon black. The gas outlet of the incinerator is connected to the cyclone separator via a pipeline for outputting high-temperature flue gas. In some embodiments, the incinerator feed inlet can be a specially designed material injection device located in the dense phase zone at the bottom of the furnace; the incinerator outlet can be located at the top of the furnace and is the channel through which high-temperature flue gas and the unburned fine particles it carries, i.e., secondary carbon black, leave the combustion chamber and enter the separation system.

[0049] Cyclone separator 203 is connected to the incinerator and is used to separate the high-temperature flue gas and the secondary carbon black generated by the incinerator.

[0050] In this embodiment of the invention, the cyclone separator is a key device for gas-solid separation. Its working principle utilizes the intense rotational motion generated when dust-laden flue gas enters tangentially. Under centrifugal force, denser, larger-diameter solid particles and secondary carbon black are thrown against the separator wall and separated. The purified flue gas is then discharged from the central exhaust pipe. The cyclone separator used in this embodiment is optimized for high-temperature, high-dust-concentration conditions. It can employ a large-diameter, eccentric volute structure and is manufactured using high-temperature and wear-resistant materials. Compared to conventional separators, it exhibits higher separation efficiency and a longer service life at high temperatures, ensuring stable circulating material volume and cleanliness of the heat exchange surfaces in the subsequent waste heat recovery system.

[0051] In some embodiments, the cyclone separator includes an air inlet, an air outlet, and a discharge outlet. The air inlet of the cyclone separator is connected to the air outlet of the incinerator via a pipe for receiving the high-temperature flue gas and secondary carbon black output from the incinerator. The air outlet of the cyclone separator is connected to the waste heat recovery system for outputting the high-temperature flue gas after cyclone separation. The discharge outlet of the cyclone separator is connected to the feed inlet of the return feeder for outputting the secondary carbon black separated from the high-temperature flue gas.

[0052] In some embodiments, the cyclone separator inlet can adopt a volute-type inlet design, tangent to the cylinder at a specific angle, allowing the high-temperature flue gas to enter the separator at an optimized speed and direction, forming a stable and intense rotating flow field. The cyclone separator outlet is located at the center of the top of the equipment and connects to the exhaust pipe. The clean, high-temperature flue gas, after efficient centrifugal separation, is discharged from here and enters the downstream waste heat recovery system. The cyclone separator discharge port can be located at the bottom of the cone, responsible for the continuous and stable discharge of the collected high-temperature secondary carbon black.

[0053] In some embodiments, a higher cyclone separator separation efficiency results in a greater circulation ratio, meaning a larger amount of circulating material returns to the furnace via the return feeder. This allows for preheating of the pyrolysis coarse carbon black particles fed into the furnace via the return feeder. Simultaneously, the high separation efficiency of the cyclone separator also ensures that unburned large particles of coarse carbon black are returned to the furnace for combustion, which is crucial for ensuring the combustion efficiency of the pyrolysis coarse carbon black particles. The return feeder is connected below the cyclone separator and employs a "one-in, two-out" design. The return ports are evenly distributed on the side of the furnace, ensuring a more uniform distribution of circulating material and pyrolysis coarse carbon black particles upon entering the furnace, which is beneficial for the complete combustion of the pyrolysis coarse carbon black particles.

[0054] In some embodiments, due to the temperature requirements of the SNCR (Selective Non-Catalytic Reduction) denitrification reaction, the SNCR device can be arranged at the horizontal flue connecting the furnace and the cyclone separator, or at the outlet of the cyclone separator, i.e., at a flue gas temperature of about 950°C.

[0055] The waste heat recovery system 30 is connected to the circulating fluidized bed incineration system and the pyrolysis system respectively. It is used to receive the high-temperature flue gas and exchange heat with the high-temperature flue gas to generate purified flue gas and water vapor, and use the water vapor to generate electricity.

[0056] In this embodiment of the invention, the waste heat recovery device adopts a multi-pass heat exchange design. By optimizing the tube bundle arrangement and flow rate control, it achieves maximum heat exchange efficiency within a limited space. An internal cleaning device is installed to periodically remove accumulated ash from the heat exchange surfaces, maintaining heat exchange performance.

[0057] In some embodiments, the waste heat recovery system may further include the following devices: Waste heat recovery device 301 is connected to the circulating fluidized bed incineration system through a pipeline, and is used to receive the high-temperature flue gas and boiler feedwater, and to exchange heat between the high-temperature flue gas and boiler feedwater to generate steam and low-temperature flue gas. In some examples, the waste heat recovery device can consist of a flue and convection heat exchange tubes, which can be further divided into an economizer, an evaporator, and a superheater. High-temperature combustion flue gas flows outside the tubes, while feedwater flows inside. The high-temperature combustion flue gas sequentially passes through the superheater, evaporator, and economizer, releasing heat and cooling to approximately 150°C. The feedwater sequentially flows through the economizer, evaporator, and superheater, absorbing heat, thus achieving heating, evaporation, and superheating, ultimately becoming high-temperature, high-pressure steam. Due to the temperature requirements of the SCR (Selective Catalytic Reduction) denitrification reaction, the SCR denitrification device is located between the evaporator and the economizer, i.e., at a flue gas temperature of 300–350°C.

[0058] In some examples, the waste heat recovery device includes an air inlet, a water inlet, a first air outlet, and a second air outlet. The air inlet of the waste heat recovery device is connected to the circulating fluidized bed incineration system via a pipeline to receive the high-temperature flue gas; the water inlet of the waste heat recovery device is used to receive the boiler feedwater; the first air outlet of the waste heat recovery device is connected to the steam turbine generator set via a pipeline to output the steam to the steam turbine generator set; and the second air outlet of the waste heat recovery device is connected to the flue gas purification device via a pipeline to output the heat-exchanged low-temperature flue gas. In some examples, the waste heat recovery unit can be equipped with a flue gas equalization device to ensure that the high-temperature flue gas is evenly distributed to each heat exchange tube bundle, avoiding local overheating or uneven heat exchange. The inlet duct adopts a composite insulation structure to minimize heat loss.

[0059] Flue gas purification device 302 is connected to the waste heat recovery device and is used to receive and purify the low-temperature flue gas discharged from the waste heat recovery device. In this embodiment of the invention, the flue gas purification device integrates multiple purification functions such as dust removal and acid removal, and can employ a dry purification process to avoid wastewater generation. The internal flow field of the device is optimized to ensure sufficient contact between the purifying agent and the flue gas.

[0060] In some examples, the flue gas purification device includes an inlet and an outlet. The inlet of the flue gas purification device is connected to the second outlet of the waste heat recovery device via a pipe for receiving the low-temperature flue gas; the outlet of the flue gas purification device is used to output purified flue gas. In some examples, the air intake system can employ a multi-channel air distribution design, controlling the residence time and velocity distribution of flue gas within the purification device by adjusting the opening of each air inlet. A pretreatment section is included in the air intake duct to remove large particulate matter from the flue gas.

[0061] The steam turbine generator set 303 is connected to the waste heat recovery device and is used to receive and utilize the steam to generate electricity and produce boiler feedwater and low-pressure steam.

[0062] In this embodiment of the invention, the steam turbine generator set can convert the thermal energy of steam into mechanical energy and then into electrical energy, while simultaneously providing process steam through extraction or back pressure methods. The unit employs an advanced regulation and control system, which can respond rapidly to changes in steam parameters. Compared with traditional simple generator sets, this system achieves combined heat and power (CHP), significantly improving the overall energy utilization efficiency.

[0063] In some examples, the steam turbine generator set includes an air inlet, a water outlet, and an air outlet. The air inlet of the steam turbine generator set is connected to the first air outlet of the waste heat recovery device for receiving the steam. The water outlet of the steam turbine generator set is used to output boiler feedwater. The air outlet of the steam turbine generator set is used to output low-pressure steam.

[0064] In some examples, a steam turbine generator set may include a high-pressure cylinder and a low-pressure cylinder. High-temperature and high-pressure steam flows through the high-pressure cylinder and the low-pressure cylinder in sequence, converting the energy of the high-temperature and high-pressure steam into the mechanical energy of the steam turbine. The steam turbine drives the generator set to generate electricity, converting mechanical energy into electrical energy.

[0065] In some examples, the steam turbine generator set is used to output boiler feedwater to the waste heat recovery device; In some examples, the exhaust steam from the low-pressure cylinder of the steam turbine can be condensed, deoxygenated, and pressurized before being reused as boiler feedwater. The feedwater system can employ multi-stage heating and deoxygenation treatment, and the operating conditions of the waste heat recovery device can be optimized by precisely controlling the feedwater temperature and pressure.

[0066] In some examples, the steam turbine generator set is also connected to the pyrolysis system to output the low-pressure steam to the pyrolysis system to dry the rubber and plastic raw materials and keep the products in the pyrolysis system warm.

[0067] In some instances, a portion of low-pressure steam can be extracted from the low-pressure cylinder for heating the washing water of the raw materials and generating the drying hot air, as well as for heat tracing and insulation of the cracked oil storage tanks and pipelines.

[0068] In some examples, the steam turbine generator set further includes: the outlet of the steam turbine generator set is connected to the inlet of the waste heat recovery device via a pipeline for outputting boiler feedwater to the waste heat recovery device; the outlet of the steam turbine generator set is connected to the pyrolysis system via a pipeline for outputting low-pressure steam to the pyrolysis system.

[0069] In some examples, the steam turbine generator set can be selected from back-pressure type, extraction condensing type, or a combination thereof, depending on the specific needs of the project. When the production line heat load is stable, the back-pressure type is preferred to achieve the highest energy efficiency; when flexible adjustment of heat and power output or maximization of power revenue is required, the extraction condensing type is preferred.

[0070] In some examples, taking the construction of a 100,000-ton / year integrated rubber and plastics pyrolysis production line as an example, The carbon black processing system of this invention employs a 360° rotating pyrolysis furnace to pyrolyze pretreated raw materials. During the initial operation of the production line, natural gas is used as the pyrolysis heat source. Once the downstream process produces non-condensable gas, the non-condensable gas is used as the pyrolysis heat source. The production line has an annual processing capacity of 100,000 tons, producing approximately 133 tons of pyrolysis oil, 133 tons of pyrolysis crude carbon black, and 33 tons of non-condensable gas daily.

[0071] The pyrolysis crude carbon black produced by the pyrolysis furnace, along with the redundant non-condensable gas (after removing the heat source for pyrolysis), is fed into a circulating fluidized bed incinerator for combustion. Feedwater at 105°C absorbs heat from the high-temperature incineration flue gas and is converted into ultra-high temperature and ultra-high pressure steam at 13.7 MPaG and 571°C, with a steam output of up to 45 tons per hour. By equipping the unit with reheat steam pipelines, the steam-driven turbine generator set can generate up to 15 MW of electricity.

[0072] The steam turbine generator set has a rated power of approximately 15MW, while the production line's self-consumption of electricity (including raw material crushing, drive, fans, pumps, and control systems) totals approximately 10-12MW. Surplus electricity can be sold to the grid. An extraction-condensing steam turbine generator set is used, extracting 0.8MPaG saturated steam from the middle section of the low-pressure cylinder of the turbine. This steam is used as a heat source for raw material pretreatment and for steam tracing and insulation of the production line's storage tanks and pipelines. The remaining steam continues to perform work, maximizing power generation. The turbine exhaust steam is condensed, deaerated, and pressurized before being used again as feedwater.

[0073] This invention provides a carbon black processing system that pre-treats, thermally pyrolyzes, separates, and stores rubber and plastic raw materials through a pyrolysis system, achieving resource conversion from waste to primary carbon black and pyrolysis oil. The raw materials, after crushing and screening, enter a pyrolysis unit for decomposition in an anaerobic environment. The resulting oil and gas are separated; the oil is stored, and the non-condensable gas can be used as auxiliary fuel. The generated primary carbon black is temporarily stored in a buffer bin. Then, it is further connected to the pyrolysis system via a circulating fluidized bed incineration system to receive and incinerate the primary carbon black. The incinerator achieves efficient and continuous combustion of carbon black in a fluidized state, generating high-temperature flue gas. Unburned particles carried by the flue gas are collected by a high-temperature cyclone separator and returned to the furnace for recirculation combustion via a return feeder. This design significantly improves the carbon black burnout rate and overall processing efficiency. A waste heat recovery system is also connected to both the incineration and pyrolysis systems to achieve cascade utilization of the high-temperature flue gas's thermal energy. The high-temperature flue gas first enters a waste heat boiler to produce superheated steam, which drives a steam turbine generator set to generate electricity. A portion of the low-pressure steam extracted from the turbine unit is transported to the feedstock pretreatment unit and pyrolysis oil storage tank of the pyrolysis system, achieving internal recycling of thermal energy. The cooled flue gas is treated by a purification device before being discharged in compliance with standards.

[0074] In the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0075] Furthermore, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0076] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of the present invention.

[0077] Finally, it should be noted that in this document, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. Relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0078] The carbon black processing system provided by the present invention has been described in detail above. Specific examples have been used to illustrate the principle and implementation of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A carbon black processing system, characterized in that, include: The pyrolysis system is used to receive and pyrolyze rubber and plastic raw materials to produce primary carbon black; A circulating fluidized bed incineration system, connected to the pyrolysis system, is used to receive and incinerate the primary carbon black to generate high-temperature flue gas; The waste heat recovery system is connected to the circulating fluidized bed incineration system and the pyrolysis system respectively. It is used to receive the high-temperature flue gas and exchange heat with the high-temperature flue gas to generate purified flue gas and water vapor, and use the water vapor to generate electricity.

2. The carbon black processing system according to claim 1, characterized in that, The pyrolysis system includes: A pretreatment device is used to receive and pretreatment the rubber and plastic raw materials and output raw material granules; A thermal pyrolysis reactor, connected to the pretreatment unit, is used to receive and pyrolyze the raw material particles to generate primary carbon black and pyrolysis oil; An oil tank, connected to the pyrolysis reactor, is used to receive and store the pyrolysis oil; A buffer chamber, connected to the pyrolysis reactor, is used to receive and store the primary carbon black.

3. The carbon black processing system according to claim 1, characterized in that, The circulating fluidized bed incineration system includes: The return feeder is connected to the pyrolysis system, cyclone separator and incinerator via pipelines. It is used to receive the primary carbon black output from the pyrolysis system and the secondary carbon black output from the cyclone separator, and to transport the primary carbon black and the secondary carbon black to the incinerator. The incinerator, connected to the return feeder via a pipeline, is used to receive and incinerate the primary carbon black, producing high-temperature flue gas and secondary carbon black. A cyclone separator, connected to the incinerator, is used to separate the high-temperature flue gas and the secondary carbon black generated by the incinerator.

4. The carbon black processing system according to claim 1, characterized in that, The waste heat recovery system includes: The waste heat recovery device is connected to the circulating fluidized bed incineration system through a pipeline. It is used to receive the high-temperature flue gas and boiler feedwater, and to exchange heat between the high-temperature flue gas and boiler feedwater to generate steam and low-temperature flue gas. A flue gas purification device, connected to the waste heat recovery device, is used to receive and purify the low-temperature flue gas discharged from the waste heat recovery device. A steam turbine generator set is connected to the waste heat recovery device to receive and utilize the steam to generate electricity and produce boiler feedwater and low-pressure steam.

5. The carbon black processing system according to claim 4, characterized in that, The steam turbine generator set is used to output the boiler feedwater to the waste heat recovery device; The steam turbine generator set is also connected to the pyrolysis system to output the low-pressure steam to the pyrolysis system to dry the rubber and plastic raw materials and keep the products in the pyrolysis system warm.

6. The carbon black processing system according to claim 2, characterized in that: The pretreatment device includes an inlet and an outlet. The inlet of the pretreatment device is used to receive rubber and plastic raw materials; the outlet of the pretreatment device is used to output raw material granules. The pyrolysis reactor includes a first outlet and a second outlet. The first outlet of the pyrolysis reactor is connected to the oil tank via a pipeline for outputting pyrolysis oil to the oil tank. The second outlet of the pyrolysis reactor is connected to the buffer tank via a pipeline for outputting primary carbon black to the buffer tank. The oil tank includes an inlet, which is connected to the first outlet of the pyrolysis reactor via a pipeline, for receiving and storing the pyrolysis oil output by the pyrolysis reactor; The buffer chamber includes a discharge port, which is connected to the second discharge port of the pyrolysis reactor via a pipe, for receiving the primary carbon black output from the buffer chamber.

7. The carbon black processing system according to claim 3, characterized in that: The return feeder includes a first feed inlet, a second feed inlet, and a discharge outlet; the first feed inlet of the return feeder is used to receive primary carbon black output from the pyrolysis system; the second feed inlet of the return feeder is used to receive secondary carbon black output from the cyclone separator; the discharge outlet of the return feeder is connected to the incinerator via a pipeline for outputting the primary carbon black and / or the secondary carbon black to the incinerator; The incinerator includes a feed inlet and a gas outlet. The feed inlet of the incinerator is connected to the discharge outlet of the return feeder through a pipeline for receiving the primary carbon black. The gas outlet of the incinerator is connected to the cyclone separator through a pipeline for outputting high-temperature flue gas. The cyclone separator includes an air inlet, an air outlet, and a discharge outlet. The air inlet of the cyclone separator is connected to the air outlet of the incinerator via a pipe to receive the high-temperature flue gas and secondary carbon black output from the incinerator. The air outlet of the cyclone separator is connected to the waste heat recovery system to output the high-temperature flue gas after cyclone separation. The discharge outlet of the cyclone separator is connected to the feed inlet of the return feeder to output the secondary carbon black separated from the high-temperature flue gas.

8. The carbon black processing system according to claim 4, characterized in that: The waste heat recovery device includes an air inlet, a water inlet, a first air outlet, and a second air outlet. The air inlet of the waste heat recovery device is connected to the circulating fluidized bed incineration system via a pipeline for receiving the high-temperature flue gas. The water inlet of the waste heat recovery device is used to receive boiler feedwater. The first air outlet of the waste heat recovery device is connected to the steam turbine generator set via a pipeline for outputting steam to the steam turbine generator set. The second air outlet of the waste heat recovery device is connected to the flue gas purification device via a pipeline for outputting the heat-exchanged low-temperature flue gas. The flue gas purification device includes an air inlet and an air outlet. The air inlet of the flue gas purification device is connected to the second air outlet of the waste heat recovery device through a pipeline for receiving the low-temperature flue gas. The air outlet of the flue gas purification device is used to output purified flue gas. The steam turbine generator set includes an air inlet, a water outlet, and an air outlet. The air inlet of the steam turbine generator set is connected to the first air outlet of the waste heat recovery device for receiving the water vapor. The water outlet of the steam turbine generator set is used to output boiler feedwater; the steam outlet of the steam turbine generator set is used to output low-pressure steam.

9. The carbon black processing system according to claim 8, characterized in that, The steam turbine generator set further includes: the outlet of the steam turbine generator set is connected to the inlet of the waste heat recovery device through a pipeline for outputting boiler feedwater to the waste heat recovery device; the outlet of the steam turbine generator set is connected to the pyrolysis system through a pipeline for outputting low-pressure steam to the pyrolysis system.

10. The carbon black processing system according to claim 6, characterized in that, The oil tank also includes an air inlet, which is connected to the waste heat recovery system via a pipeline, for receiving low-pressure steam output by the waste heat recovery system to keep the pyrolysis oil in the oil tank warm; The pretreatment device also includes an air inlet connected to the waste heat recovery system via a pipeline, for receiving low-pressure steam output from the waste heat recovery system to dry the raw material particles in the pretreatment device.

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