Stacked pyrolysis reactors

Abstract

A stacked pyrolysis reactor comprises of a gas supply device, a recovery device, a reaction device, and a gas collection device. The recovery device is connected to both the gas supply device and the reaction device, while the reaction device is connected to the gas collection device. The reaction device includes a plurality of stacked reaction plates. Each reaction plate include an alignment disk and a interlocking slot. The upper surface of alignment disk includes a collection port, multiple through holes, and several guide grooves, while the lower suface contains multiple protrusions aligned with the through holes. The through-holes, in combination with the protrusions, slow down the flow rate of the reaction gases, thereby improving the efficiency of the gas pyrolysis reaction.

Description

[Technical Field]

[0001] This invention relates to a stacked thermal pyrolysis reactor, particularly a reactor with gas conversion and product recovery functions. [Previous Technology]

[0002] Conventional methane thermal cracking reactors mostly employ a straight-through pipe design. However, the flow rate of methane gas during the reaction in the straight-through pipe is too fast, resulting in insufficient reaction time and thus reducing the methane conversion rate. In addition, due to the limited contact area for heat conduction, the temperature difference between the furnace tube wall and the center of the pipe is too large, and the temperature is uneven during the reaction, which further affects the completeness of the cracking reaction, causing methane to be unable to be completely decomposed into hydrogen and carbon. Furthermore, traditional reactors are mostly made of nickel-chromium alloy steel, and their operating temperature is limited to 1200℃, which reduces the thermal efficiency in the cracking process. The upper limit of the temperature also limits the hydrogen production efficiency.

[0003] Secondly, existing reactors typically increase the internal pressure of the furnace tubes to prolong the reaction time of methane. However, this method significantly increases energy consumption, resulting in low overall energy efficiency. During operation, carbon deposits easily form inside the furnace tubes due to the cracking reaction. These carbon deposits adhere to the tube walls, causing internal blockages and increasing maintenance costs. Furthermore, the carbon black produced after the reaction is difficult to collect, further affecting the stable operation of the system. [Summary of the Invention]

[0004] In view of this, the present invention provides a stacked thermal pyrolysis reactor that improves methane conversion efficiency and solves the problem of carbon black blockage.

[0005] According to the purpose of the present invention, a stacked thermal pyrolysis reactor is provided, comprising: a recovery device connected to a gas supply device; a reaction device having a reaction channel connected to the recovery device, and a heater arranged in a ring around the reaction channel, the reaction channel having a plurality of stacked reaction plates; and a gas collection device connected to the reaction channel.

[0006] Wherein, each of the reaction plates has: a pair of alignment discs; a fitting ring disposed below the alignment disc, the inner ring surface of the fitting ring and the alignment disc forming a fitting groove together; a collecting portion extending from the lower surface of the alignment disc, the collecting channel having a collecting opening through which the alignment disc and the collecting portion pass; a plurality of guide grooves disposed on the upper surface of the alignment disc and extending outward in a radial pattern with the collecting opening as the center, each guide groove having a plurality of through holes spaced apart; and a plurality of protrusions located on the lower surface of the alignment disc and corresponding to the positions of the through holes.

[0007] The upper surface of the alignment disk is inclined toward the collection port.

[0008] The material of the reaction channel is a high-melting-point composite ceramic, composite metal or high-melting-point carbide.

[0009] In this case, each of the alignment discs is surrounded by a groove and a clip that match the contour of the fitting ring.

[0010] The lower part of each collection section extends into the collection port of the other collection section below.

[0011] The reaction apparatus is connected to a potential device.

[0012] The recycling device includes a recycling channel, a recycling tank, a plurality of valves, a material extractor, a potential device, and an oscillator. The recycling tank is connected to the recycling channel, the material extractor is connected to both the recycling tank and the recycling channel, the valves are located between the components, and the oscillator and the potential device are located on the outer wall of the recycling channel.

[0013] The reaction apparatus further includes a recovery base located below the reaction channel and connected to the recovery channel, and a valve is provided between the recovery base and the recovery channel.

[0014] The material of the recycling base is a high-temperature resistant ceramic or composite material with low thermal conductivity.

[0015] The gas collection device has a collection channel with two bends, which are respectively connected to the reaction channel and a storage container.

[0016] A waste heat recovery device is provided between the two curved sections.

[0017] The material of the curved part near the reaction device is a high-temperature resistant ceramic or composite material with low thermal conductivity.

[0018] The thermal cracking reactor further includes a shell, the interior of which houses the reaction device, the recovery device, the insulation material, the heating device and the gas collection device, and the interior of the shell is filled with non-reactive gas or is a vacuum containment cavity.

Implementation Method

[0019] In order to make the description of this disclosure detailed and complete, the embodiments and specific examples of the present invention are described, but they are not the only forms of implementing or using the specific examples of the present invention, nor are they limited to the directions used. Other specific examples can be used to achieve the same or equivalent functions and steps. The descriptions of directions such as "front", "back", "up", "down", "left", and "right" mentioned in this document are only for convenience of understanding and are not limited to these directions.

[0020] Please refer to Figure 1, which illustrates a preferred embodiment of the stacked thermal pyrolysis reactor of the present invention. The stacked thermal pyrolysis reactor includes a gas supply device 10, a recovery device 20, a reaction device 30, and a gas collection device 40. The gas supply device 10 is connected to the recovery device 20, and the reaction device 30 is connected to both the recovery device 20 and the gas collection device 40.

[0021] The recycling device 20 has a recycling channel 21, a recycling tank 22, a material extractor 23, and a vibrator 26. The recycling channel 21 is connected to the gas supply device 10 via an air inlet pipe 11, so that the gas in the gas supply device 10 is delivered to the recycling channel 21. The lower part of the recycling channel 21 is connected to the recycling tank 22, and the lower part of the recycling tank 22 is connected to the material extractor 23 via a material extraction pipe 25. When the air pump in the material extractor 23 is activated, the gas and carbon black in the recycling tank 22 are extracted. Next, the sampler 23 filters out the carbon black and returns the gas to the recovery channel 21 via a return pipe 24. The inlet pipe 11, the return pipe 24, and the sampler 25 are respectively equipped with a first valve 111, a second valve 241, and a fourth valve 251 to connect or block the corresponding pipelines. The vibrator 26 and the potentiometer 27 are installed on the outer wall of the recovery channel 21, allowing the carbon black adhering to the reaction device 30 and the inner wall of the recovery channel 21 to detach smoothly and fall into the recovery tank 22. In other embodiments, the potentiometer 27 is connected to the reaction device 30, using changes in positive and negative potential to generate attraction or repulsion to prevent carbon black and other reaction products from adhering and blocking the flow.

[0022] The reaction device 30 comprises a reaction channel 31 as well as a heater 32 looped in a contact or non-contact manner in the reaction channel 31 for heating, and the material of the reaction channel 31 may be, but is not limited to, using a high melting point composite ceramic or Carbide materials such as tungsten carbide, thereby raising the temperature of the thermal cracking reaction to more than 2000°C, increasing the overall gas conversion rate to more than 90%, the reaction channel 31 is equipped from top to bottom with a top seat 311, stack-bonded plurality of reaction laminates 312, and a recovery bottom 313 , the recovery base 313 is connected to the recovery channel 21 , and a third valve 314 controls each other to control the communication and barrier of the reaction channel 31 and the recovery channel 21 , which can be made to pass by increasing the heating area by pushing these reaction laminates 312 The uniform heating of channel 31 avoids excessive temperature difference between the channel center and the channel wall surface, resulting in incomplete response of the gas and resulting in a decrease in efficiency, and increases the gas heating reaction time and stripping carbon black to avoid adhesion through the vortex disturbance formed between each stack of reaction laminates 312 .

[0023] Refer to FIGS Ring 3123 , the chimeric ring 3123 is provided below the registration disk 3122 , the collection portion 3121 extension is provided on the lower surface of the registration disk 3122 , wherein, the registration disk 3122 The outer ring plane as well as the inner ring plane of the chimeric ring 3123 each have a matching chimeric structure, each of the reaction laminate 312 plate is chimeric through the phase disc 3122 and the chimeric ring 3123, in that order The stacking forms the thermal cracking reaction zone of the reaction channel 31 , and each of the collection portions 3121 has a collection port 3121 a , threaded through the registration disc 3122 and the collection portion 3121 , each of the collection The lower end portion of portion 3121 extends into the collection port 3121a of another collection portion 3121 on the lower level, wherein, the upper surface of the registration plate 3122 is tilted toward the collection port 3121a obliquely provided and provided with a plurality of guide slots 3124 , which extend outwardly provided radially from the collection port 3121a as the center, the guide slots 3124 leaning against the inclined The upper surface of the registration disc 3122 may effectively direct the generated carbon black to the guide slot 3124 , the through hole 3125 or the collection port 3121a , and finally falls into the recovery slot 22 below, in this case In embodiments, the outer annular surface of the respective registration disc 3122 as well as the inner annular surface of the chimeric ring 3123 are threaded or snapped structures for chising the reactive laminate 312 of the upper and lower layers by means of bolt locks or snaps.

[0024] To increase the gas's heating reaction time and facilitate complete thermal decomposition, the guide channels 3124 have a plurality of through holes 3125. These through holes 3125 are spaced apart and pass through the alignment plate 3122. Each of the through holes 3125 has a protrusion 3126 at its outlet. When the gas flows to these protrusions 3126, it generates eddy current disturbance between adjacent reaction plates 312 and between the bottom reaction plate 312 and the recovery base 313. This increases the heating efficiency of the gas contacting the reaction plates 312 and carries away the carbon black to the guide channels 3124, collection port 3121a, or... To avoid adhesion, the gas flows upward through the through-holes 3125, thereby increasing the conversion rate of thermal decomposition. This effectively replaces the conventional method of using pressure to slow down the gas flow rate, reducing energy consumption. In addition, the gas vortex disturbance can also reduce the adhesion and blockage of carbon black in the reaction channel 31. It is worth mentioning that the surface of each of the alignment disks 3122 has grooves 3129 around the inlet of the through-holes 3125. Since these grooves 3129 are connected to each of the collection ports 3121a through the guide grooves 3124, the larger carbon black generated by thermal decomposition can be better guided to the collection port 3121a or the next plate for collection.

[0025] Furthermore, please continue to refer to Figure 4, which illustrates another embodiment of the present invention. The free end of the collection part 3121 of the bottom reaction plate 312 can also be connected to a carbon black discharge pipe 315. The carbon black discharge pipe 315 extends from the collection part 3121 into the interior of the recovery channel 21. Gas moves upward from between the carbon black discharge pipe 315 and the recovery channel 21 and moves through the through holes 3125 to the other reaction plate 312 above. The carbon black and other products generated after the reaction are collected downward through the carbon black discharge pipe 315 into the recovery tank 22. When the gas moves upward, the carbon black and other products are transported upward together, which can lead to pipeline blockage.

[0026] In other embodiments, each of the alignment disks 3122 is surrounded by a accommodating groove 3127 and a snap-fit ​​insert 3128. When the reaction plates 312 are combined, a gap is formed between each accommodating groove 3127 and each snap-fit ​​insert 3128 to accommodate liquid metal M, thereby forming an airtight reaction space.

[0027] The gas collection device 40 is provided with a collection channel 41 and a storage container 42. The two ends of the collection channel 41 are respectively connected to the reaction channel 31 and the storage container 42. The collection channel 41 extends upward from the top seat 311 and then bends downward to form a first bend 411. Then, the collection channel 41 continues to extend downward and bends upward to form a second bend 412. Finally, it extends a certain distance and connects to the storage container 42. A waste heat recovery device 50 is also provided on the outer wall of the collection channel 41 between the first bend 411 and the second bend 412 to recover excess heat energy. The recovery base 313 and the first bend 411 are preferably made of a ceramic material with low thermal conductivity and high temperature resistance, such as zirconium oxide, to confine the heat energy in the reaction channel 31 and part of the gas collection channel 41, so as to prevent the storage container 42 and the recovery channel 21 from being damaged by high temperature.

[0028] In order to prevent the reaction process from being disturbed by oxygen and external gases, in other embodiments, the stacked thermal pyrolysis reactor is also provided with a shell 60. The interior of the shell 60 is used to accommodate the recovery channel 21, the recovery tank 22, the reaction device 30 and part of the collection channel 41. The interior of the shell 60 is evacuated or filled with non-reactive gases and heat insulation materials to provide an oxygen-free environment to prevent interference with the thermal pyrolysis reaction of gases and to avoid heat loss affecting efficiency.

[0029] Further explanation: In the use of the stacked thermal cracking reactor of the present invention, when preparing to carry out a thermal cracking reaction of a gas such as methane, the heater 32 is started and continuously heated to keep the reaction channel 31 above 2100°C. At the same time, the first valve 111 and the third valve 314 are opened, and the second valve 241 and the fourth valve 251 are closed. Then the gas supply device 10 supplies methane, which enters the reaction channel 31 sequentially through the gas inlet pipe 11 and the recovery channel 21. The methane undergoes a thermal cracking reaction between each of the reaction plates 312 to produce carbon black and hydrogen. The hydrogen sequentially enters the gas collection device 40 through the through holes 3125 and is stored in the storage tank 42, while the carbon black sequentially falls into the recovery tank 22 through the guide grooves 3124, through holes 3125, and collection port 3121a.

[0030] Next, when the carbon black recovery step is performed, the first valve 111 and the third valve 314 are closed, and the second valve 241 and the fourth valve 251 are opened. The air pump in the material collector 23 is started to draw the carbon black in the recovery tank 22 into the material collector 23 through the material collection pipe 25 for collection and filtration. The gas that accompanies the carbon black into the material collector 23 is returned to the recovery channel 21 through the return gas pipe 24, waiting for the third valve 314 to open again to allow the gas to enter the reaction channel 31 for reaction, reducing the consumption of excess gas. Since the control of these valves forms a circulation loop in the recovery device 20, it can prevent the back-drawing of hydrogen or the drawing in of external gas during the collection of carbon black, which would cause pollution.

[0031] Accordingly, the stacked pyrolysis reactor of the present invention has a stacked reaction channel 31 that provides a larger heat contact area and a pyrolysis reaction zone with uniform temperature. The design of the through holes 3125 and the protrusions 3126 can generate eddies to increase the gas contact heating efficiency and improve the gas conversion efficiency. The guide grooves 3124 guide the carbon black on the pits 3129 or the alignment plate 3122 to the through holes 3125 or the collection port 3121a, providing a better carbon black collection method. In addition, the valve settings in the recovery device 20 can not only guide unreacted gas back to the reaction channel 31 to reduce raw material waste, but also avoid back-drawing hydrogen or drawing in external gas to cause pollution, thereby stabilizing the overall operating efficiency and safety. [Simplified Explanation of the Diagram]

[0032] Figure 1 is a schematic diagram of the stacked thermal pyrolysis reactor of the present invention.

[0033] Figure 2 is a top view of the reaction plate of the present invention.

[0034] Figure 3 is a cross-sectional side view of the reaction plates of the present invention when stacked.

[0035] Figure 4 is an enlarged schematic diagram of another embodiment of the stacked thermal pyrolysis reactor of the present invention.

Claims

1. A stacked pyrolysis reactor, comprising: a recovery device connected to a gas supply device; a reaction device having a reaction channel connected to the recovery device, and a heater annularly disposed in the reaction channel, the reaction channel having a plurality of stacked reaction plates; and a gas collection device connected to the reaction channel; wherein, The reaction apparatus is connected to a potential device.

2. The stacked thermal pyrolysis reactor as claimed in claim 1, wherein each of the reaction plates has: a pair of alignment plates; a fitting ring disposed below the alignment plate; a collecting portion extending from the lower surface of the alignment plate, the collecting portion having a collecting port passing through the alignment plate and the collecting portion; a plurality of guide grooves disposed on the upper surface of the alignment plate and extending radially outward from the collecting port, each guide groove having a plurality of through holes spaced apart; and a plurality of protrusions located on the lower surface of the alignment plate and corresponding to the positions of the through holes.

3. The stacked thermal pyrolysis reactor as described in claim 2, wherein the upper surface of the alignment plate is inclined toward the collection port.

4. The stacked thermal pyrolysis reactor as described in claim 1, wherein the material of the reaction channel is a high-melting-point composite ceramic, a composite metal, or a high-melting-point carbide.

5. The stacked thermal pyrolysis reactor as described in claim 2, wherein each of the alignment disks is further provided with a groove and a retaining insert that match the contour of the interlocking ring around its periphery.

6. The stacked thermal pyrolysis reactor as described in claim 2, wherein the lower portion of each of the collecting sections extends into the collecting port of the other collecting section below.

7. The stacked thermal pyrolysis reactor as described in claim 1, wherein the recovery device is provided with a recovery channel, a recovery tank, a plurality of valves, a material feeder, a potential device and an oscillator, the recovery tank is connected to the recovery channel, the material feeder is connected to both the recovery tank and the recovery channel, the valves are located between the components, and the oscillator and the potential device are provided on the outer wall of the recovery channel.

8. The stacked thermal pyrolysis reactor as described in claim 7, wherein the reactor further includes a recovery base disposed below the reaction channel and connected to the recovery channel, and a valve is provided between the recovery base and the recovery channel.

9. The stacked thermal pyrolysis reactor as described in claim 8, wherein the recovery base is made of a high-temperature resistant ceramic or composite material with low thermal conductivity.

10. The stacked thermal pyrolysis reactor as claimed in claim 1, wherein the gas collection device has a collection channel having two bends and respectively connecting the reaction channel and a storage tank.

11. The stacked thermal pyrolysis reactor as described in claim 10, wherein a waste heat recovery unit is provided between the two curved sections.

12. The stacked thermal pyrolysis reactor as described in claim 10, wherein the material of the bend near the reactor is a high-temperature resistant ceramic or composite material with low thermal conductivity.

13. The stacked pyrolysis reactor as described in any one of claims 1 to 12, wherein the pyrolysis reactor further comprises a shell, the interior of which houses the reaction apparatus, the recovery apparatus, the insulation material, the heating apparatus, and the gas collection apparatus, the interior of which is filled with non-reactive gas or is a vacuum containment cavity.

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