Pyrolyzer systems and methods

Abstract

Embodiments include a system having a pyrolyzer cell. The pyrolyzer cell may include a jacketed wall. The jacketed wall may include a first jacket. The first jacket may include a first inner wall, a first outer wall, and a first fluted medium between the first inner wall and the first outer wall. The first fluted medium forms a first plurality of channels, and each channel may be defined by alternating ridges and valleys formed in the first fluted medium. The system also may include a second jacket. The second jacket may include a second inner wall, a second outer wall, and a second fluted medium between the second inner wall and the second outer wall. The second fluted medium may form a second plurality of channels, and each channel may be defined by alternating ridges and valleys formed in the second fluted medium. Methods are also described.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to US Provisional Patent Application No. 63 / 742,733, entitled “PYROLYZER SYSTEMS AND METHODS,” filed January 7, 2025, the entire contents of which are incorporated herein by reference for all purposes.BACKGROUND

[0002] Pyrolysis is a thermal decomposition process that occurs in the absence of oxygen and is widely used for converting organic materials into valuable products such as biochar, bio-oil, and syngas. Pyrolysis systems have garnered significant attention due to their potential applications in waste management, renewable energy production, and carbon sequestration. These systems are used to process a variety of feedstocks, including agricultural residues, municipal solid waste, and industrial byproducts, making them versatile tools for sustainable material and energy recovery.

[0003] Despite their advantages, current pyrolysis systems face several challenges that limit their efficiency and environmental performance. One significant issue is heat management, as the process requires precise temperature control to optimize the conversion of feedstock into desired products. Inefficient heat distribution often results in energy losses, incomplete pyrolysis, and inconsistent product quality. Additionally, maintaining high temperatures can necessitate significant energy input, reducing the overall economic feasibility of the system.

[0004] Another problem is the production of carbon dioxide (CO₂) as a byproduct in some systems. Although pyrolysis is designed to operate in an oxygen-deprived environment, unintended reactions, including partial combustion or secondary gas-phase reactions, can lead to CO₂ emissions. This undermines the potential of pyrolysis systems as carbon-negative technologies and raises concerns about their contribution to greenhouse gas emissions.

[0005] These challenges highlight the need for innovations in pyrolysis system design, including improved thermal management strategies and mechanisms to minimize CO₂ generation. Addressing these issues can enhance the efficiency, sustainability, and economic viability of pyrolysis technologies, thereby expanding their application in industrial and environmental contexts.BRIEF SUMMARY

[0006] Systems and methods can efficiently pyrolyze a feedstock. Pyrolysis reactor units may be more efficient through a design that includes a first jacket with a fluted medium forming channels within the first jacket. The first jacket can provide structural rigidity while allowing for heat to be transferred from a fluid within the first jacket to the feedstock being pyrolyzed. A second jacket surrounding the first jacket may also have a fluted medium forming channels within the second jacket. The second jacket may include a material that undergoes a phase change. The phase change material may absorb heat from the first jacket and stabilize temperatures of the reactor. The second jacket may act as a thermal battery and a thermal modulator. A third jacket may surround the first jacket. The third jacket may also have a fluted medium defining channels within the third jacket. The fluted medium may provide integrity and strength cost efficiently. The third jacket may be held at vacuum, which helps insulate the rest of the pyrolyzer reactor. Through better heat management and materials usage, the systems and methods can be both thermally efficient and cost efficient.

[0007] Embodiments include a system. The system may include a pyrolyzer cell. The pyrolyzer cell may include a jacketed wall. The jacketed wall may include a first jacket. The first jacket may include a first inner wall, a first outer wall, and a first fluted medium between the first inner wall and the first outer wall. The first fluted medium forms a first plurality of channels, and each channel may be defined by alternating ridges and valleys formed in the first fluted medium. The system also may include a second jacket. The second jacket may include a second inner wall, a second outer wall, and a second fluted medium between the second inner wall and the second outer wall. The second fluted medium may form a second plurality of channels, and each channel may be defined by alternating ridges and valleys formed in the second fluted medium.

[0008] Embodiments may include a method of pyrolysis. The method may include raising the temperature of the pyrolyzer cell to a first temperature. The pyrolyzer cell may contain a feedstock. Raising the temperature may include flowing a fluid to a first jacket surrounding the pyrolyzer cell. The method may include flowing a material undergoing a phase change through a second jacket surrounding the first jacket. The method may also include flowing char from a pyrolysis reaction through an outlet of the pyrolyzer cell. The method may also include flowing a gaseous product from the pyrolysis reaction out of the pyrolyzer cell. The method may also include condensing the gaseous product to a liquid.TERMS AND DEFINITIONS

[0009] "Fluidic communication" refers to the transfer or conveyance of a fluid (liquid or gas) between two or more components, systems, or devices. It encompasses mechanisms, pathways, and interfaces designed to enable the controlled flow of fluid for various purposes, such as functionality, signaling, or energy transfer. Fluidic communication may include conduits or channels or interfaces or connectors.

[0010] "Supercritical carbon dioxide" (ScCO2) refers to a fluid state of carbon dioxide here it is held at or above its critical temperature (304.128 K) and critical pressure (7.3773 MPa).

[0011] The term “about” or “approximately” can mean within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within 1 or more than 1 standard deviation, per the practice in the art. Alternatively, “about” can mean a range of up to 20%, up to 10%, up to 5%, or up to 1% of a given value. Alternatively, particularly with respect to biological systems or processes, the term “about” or “approximately” can mean within an order of magnitude, within 5-fold, and more preferably within 2-fold, of a value. Where particular values are described in the application and claims, unless otherwise stated the term “about” meaning within an acceptable error range for the particular value should be assumed. The term “about” can have the meaning as commonly understood by one of ordinary skill in the art. The term “about” can refer to ±10%. The term “about” can refer to ±5%. Any exact number described herein may be modified with “about” or “approximately.”BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0012] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0013] FIG. 1 illustrates a system according to embodiments of the present invention.

[0014] FIG. 2 illustrates a multi-effect pyrolyzer unit according to embodiments of the present invention.

[0015] FIG. 3A illustrates a pyrolyzer cell according to embodiments of the present invention.

[0016] FIG. 3B illustrates a pyrolyzer cell according to embodiments of the present invention.

[0017] FIG. 4 illustrates a method according to embodiments of the present inventionDETAILED DESCRIPTION

[0018] Typical pyrolysis systems convert organic materials into valuable products at thermal efficiencies no higher than 50%. These low thermal efficiencies translate to higher material usage for the pyrolysis systems, lower yield, higher costs, and lower profit. These shortcomings are obstacles to pyrolysis use in the renewable fuels, renewable products, and polymer recycling industries.

[0019] Embodiments of the present invention result in pyrolysis systems with much higher thermal efficiencies (e.g., over 80%). These efficiencies may be the result of a jacketed configuration of a pyrolyzer. The pyrolyzer may have one or more jackets surrounding the chamber with a feedstock to undergo pyrolysis. Each jacket may have a fluted medium, forming a plurality of channels within the jacket. This configuration allows for structural integrity while using less material than if the jacket was solely an inner wall and an outer wall.

[0020] A first inner jacket may include a fluid for temperature control. The fluid may be supercritical carbon dioxide (ScCO2), supercritical steam, or other fluid. The jacket may withstand high pressures and / or high temperatures of the fluid.

[0021] A second jacket, surrounding the first inner jacket, may include a phase change material. The phase change material (PCM) may include a wax or any material undergoing a phase change. The PCM may moderate temperature changes in the first jacket and in the reaction chamber.

[0022] A third jacket may surround the second jacket. The third jacket may be held at vacuum to prevent heat loss from the pyrolyzer to the surroundings.

[0023] FIG. 1 shows a system 100 for pyrolysis. Biomass may be loaded into biomass feed hopper 102. The biomass can be any type suitable for pyrolysis, such as agricultural residues, wood waste, or energy crops. Biomass may include corn stover, switchgrass, wood, bagasse, or any suitable feedstock. System 100 may be adapted for feedstocks that are not biomass. Nitrogen supply 104 may be provided to biomass feed hopper 102 to mitigate the risk of fire. A screw pump feeder 106 may convey feedstock to multi-effect pyrolyzer unit 108. Multi-effect pyrolyzer unit 108 is described in more detail with FIG. 2, FIG. 3A, and FIG. 3B.

[0024] Multi-effect pyrolyzer unit 108 may be heated with supercritical carbon dioxide from hot supercritical CO2 reservoir 110. Supercritical carbon dioxide (ScCO2) may be pumped using hot ScCO2 pump / compressor 112 from hot supercritical CO2 reservoir 110 through hot ScCO2 recuperator 114. ScCO2 passes through hot ScCO2 heater 116 and is brought to a pyrolyzation set temperature (e.g., 150 °C to 1,200 °C). Hot ScCO2 may pass through hot ScCO2 pyrolyzer bypass 118 to multi-effect pyrolyzer unit 108. The hot ScCO2 may pass through a hot ScCO2 absorption cooler bypass 120 to drive absorption chiller 122. Hot ScCO2 may then return through hot ScCO2 recuperator 114 to hot supercritical CO2 reservoir 110.

[0025] Solid materials (e.g., char) enters primary char collector 124. The char can then be burned for power generation or can be used as a soil supplement. The char can help the economics of the system.

[0026] Gases from multi-effect pyrolyzer unit 108 enter cyclone filter system 126. Remaining solids are sent to secondary char collector 128. Gases continue to condensers, including first stage condenser unit 130 and final stage condenser unit 132. Liquids after condensation are captured in first stage liquid collection 134 and final stage liquid collection 136. The system may include additional condenser units and liquid collection stages, but only two stages are illustrated in FIG. 1 for convenience.

[0027] Remaining room-temperature gases after the condensation stages may flow to bioreactor filter 138. The gases may go through exhaust 140 and continue to further filtration and collection systems. The gases may include syngas.

[0028] Coolant may be pumped using absorption chiller coolant pump 142. In embodiments, coolant may be sent from absorption chiller 122 through absorption chiller coolant radiator 144 or to systems that use a low temperature heat input.

[0029] Coolant may be pumped by chiller main coolant pump 146 through a series of controlled bypasses, including chiller first stage motorized bypass 148 and chiller final stage motorized bypass 150. Each bypass may feed a heat exchanger, including chiller first stage heat exchanger 152 and chiller final stage heat exchanger 154. The coolant may be pumped by chiller first stage coolant pump 156 and chiller final stage coolant pump 158 through the respective stage's condenser (e.g., first stage condenser unit 130 and final stage condenser unit 132) and return to the respective heat exchanger. Coolant may then return to absorption chiller 122. System 100 may exclude a cooling tower.

[0030] In some embodiments, feed may be preheated before entering multi-effect pyrolyzer unit 108. For example, material in biomass feed hopper 102 and / or screw pump feeder 106 may be preheated. Preheating may be performed using a heating coil, inner wall transfer channels (e.g., as described herein for pyrolyzers), or another heat source.

[0031] FIG. 2 shows a multi-effect pyrolyzer unit 200. The multi-effect pyrolyzer unit 200 may be multi-effect pyrolyzer unit 108 or any multi-effect pyrolyzer unit described herein. In embodiments, the multi-effect pyrolyzer unit 200 includes five pyrolyzer cells 202. A biomass inlet 204 may be the inlet to multi-effect pyrolyzer unit 200. Feedstock may be conveyed through biomass inlet 204.

[0032] The pyrolyzer cells 202 are connected in series, with the outlet of one pyrolyzer cell being the inlet of the next pyrolyzer cell. The feedstock may undergo pyrolysis in the first pyrolyzer cell. One auger motor of auger motors 206 may move the material through the first pyrolyzer cell. The products of the pyrolysis (e.g., char, gases) and any unreacted feedstock may leave the outlet of the first pyrolyzer cell and enter the inlet of the second pyrolyzer cell. This process repeats in the second through fifth pyrolyzer cells. The final products of pyrolysis may include solid char, which exits through char outlet 208. The final products may include gaseous products, which exit through gas exhaust 210. The gaseous products may include syngas and bio-oil in vapor form.

[0033] The pyrolyzer cells 202 may be heated using a supercritical fluid, such as supercritical carbon dioxide. The supercritical carbon dioxide may enter a jacket surrounding an individual pyrolyzer cell through hot ScCO2 inlet 212. The supercritical carbon dioxide may come from hot ScCO2 recuperator 114. The supercritical carbon dioxide may exit through hot ScCO2 outlet 214. The ScCO2 may return to hot ScCO2 heater 116.

[0034] FIG. 3A shows pyrolyzer cell 300, which may be one pyrolyzation chamber 302 of multi-effect pyrolyzer unit 200. FIG. 3A includes top view 304, front view 306, and detail view 308. FIG. 3A shows hot ScCO2 chamber 310, which may be a jacket surrounding pyrolyzation chamber 302. A phase change material (PCM) ScCO2 chamber 312 may surround hot ScCO2 chamber 310. A vacuum chamber 314 may surround phase change material (PCM) ScCO2 chamber 312.

[0035] Biomass may enter biomass feed inlet 316. An auger 318 may move feedstock through pyrolyzation chamber 302. Auger 318 may be coupled with auger drive rod 320. Char and gaseous products may exit through char outlet 322.

[0036] FIG. 3B shows a right view 324 and a detail view 326 of pyrolyzation chamber 302. Auger 318 is shown next to the wall of pyrolyzation chamber 302. A hot ScCO2 chamber 310 surrounds pyrolyzation chamber 302. A phase change material (PCM) ScCO2 chamber 312 surrounds hot ScCO2 chamber 310. A vacuum chamber 314 surrounds phase change material (PCM) ScCO2 chamber 312.

[0037] Each of the chambers 302, 310, and 312 show a fluted medium, similar to corrugation in cardboard. The fluted medium may be a corrugated sheet bonded to the walls or integrally formed with at least one wall (e.g., machined, additively manufactured). The fluted medium provides structural integrity and improves thermal management. The fluted medium may withstand high pressures (e.g., at least 1,100 psi), which allows for the use of fluids, including ScCO2, at high pressures. The fluted medium defines a plurality of channels that run lengthwise with pyrolyzation chamber 302. Each of the channels may contain the fluid associated with the particular chamber.

[0038] In some embodiments, vacuum chamber 314 may be surrounded by an additional vacuum chamber wall to reduce thermal losses from the outer wall of vacuum chamber 314 contacting the atmosphere.Example Systems

[0039] Systems may include a pyrolyzer cell. Systems may include system 100 or any system described herein. The pyrolyzer cell may include pyrolyzer cells 202, pyrolyzer cell 300, or any pyrolyzer cell described herein.

[0040] The pyrolyzer cell may include a jacketed wall. The jacketed wall may include a first jacket (e.g, hot ScCO2 chamber 310). The first jacket may include a first inner wall, a first outer wall, and a first fluted medium between the first inner wall and the first outer wall. The first fluted medium may form a first plurality of channels. Each channel may be defined by alternating ridges and valleys formed in the first fluted medium. In some embodiments, a cross section (e.g., a circular cross section) of a pyrolyzer cell may include 5 to 10, 10 to 20, 20 to 30, 30 to 40, 40 to 50, 50 to 60, 60 to 70, 70 to 80, 80 to 90, 90 to 100, or over 100 alternating ridges and / or valleys. The amplitude may be half the distance between the first inner wall and the first outer wall. The period may be 0.1 to 0.5, 0.5 to 1.0, 1.0 to 1.5, 1 to 2, 2 to 3, 3 to 4, 4 to 5, 5 to 10, or over 10 times the amplitude.

[0041] The alternating ridges and valleys may be formed through additive manufacturing methods or other suitable methods. The channels may extend longitudinally along most of the length of the pyrolyzer cell. For example, they may extend for 50% to 60%, 60% to 70%, 70% to 80%, 80% to 90%, 90% to 95%, 95% to 99%, or 99% to 100% of the length of the pyrolyzer cell. The distance from the first inner wall to the first outer wall may be 90% to 100%, 100% to 110%, 110% to 120%, 120% to 130%, 130% to 140%, 140% to 150%, or 150% to 200% the thickness of the first inner wall. The pyrolyzer cell may include a first port (e.g., hot ScCO2 inlet 212) in fluidic communication with the first plurality of channels. The port may be for flowing a fluid in to the first jacket. The first port may be in fluidic communication with a reservoir with the fluid. The system may include supercritical carbon dioxide, supercritical steam, or another supercritical fluid in the first plurality of channels. The fluid in the first plurality of channels may be at a pressure from 1,000 to 1,100 psi, 1,100 to 1,500 psi, or over 1,500 psi.

[0042] The system may include a second jacket (e.g., phase change material (PCM) ScCO2 chamber 312). The second jacket may include a second inner wall, a second outer wall, and a second fluted medium between the second inner wall and the second outer wall. The second fluted medium may form a second plurality of channels. Each channel may be defined by alternating ridges and valleys formed in the second fluted medium. The second inner wall may be the first outer wall such that the second jacket is adjacent to the first jacket. The second jacket may be geometrically similar to the first jacket. The second jacket, by surrounding the first jacket, may have a larger inner and outer diameter. In embodiments, the second jacket may have the same distance between the second inner wall and the second outer wall as between the first inner wall and the first outer wall. In embodiments, the distance may be different but may be any of the distances described for the first jacket above. The pyrolyzer cell may include a second port in fluidic communication with the second plurality of channels. The second port may be for conveying material from a reservoir to the second jacket. The second port may be in fluidic communication with a reservoir for the material. The system may include a material undergoing a change (e.g., phase change) in the second plurality of channels. For example, the material may be supercritical carbon dioxide undergoing a change to gaseous carbon dioxide, water (liquid, vapor, supercritical), or a wax. The phase change material may add temperature stability to the pyrolyzer cell.

[0043] The system may include a third jacket (e.g., vacuum chamber 314). The third jacket may include a third inner wall, a third outer wall, and a third fluted medium between the third inner wall and the third outer wall. The third fluted medium may form a third plurality of channels. Each channel may be defined by alternating ridges and valleys formed in the third fluted medium. The third inner wall may be the second outer wall such that the third jacket is adjacent to the second jacket. The third jacket may be geometrically similar to the second jacket and / or the first jacket. In embodiments, the third jacket may have the same distance between the third inner wall and the third outer wall as between the first inner wall and the first outer wall. In embodiments, the distance may be different but may be any of the distances described for the first jacket above. The pyrolyzer cell may include a third port in fluidic communication with the third plurality of channels. The port may be in fluidic communication with a pump to create a vacuum. The third plurality of channels may be at vacuum. For example, the pressure in the third jacket may be from 100 to 10 Torr.

[0044] Any or all of the first fluted medium, the second fluted medium, or the third fluted medium may include a metal. For example, the metal may be low temperature metals, tin, potassium, gallium, stainless steel, or other alloys.

[0045] The pyrolyzer cell may be cylindrical. Accordingly, any or all of the jackets may be an annular cylinder or ring-shaped cylinder. The pyrolyzer cell may include an inlet at a first end and an outlet at a second end. For example, the inlet may be biomass inlet 204. As another example, the outlet may include char outlet 208.

[0046] The pyrolyzer cell may contain a feedstock. The feedstock may include any biomass described herein. In some embodiments, the feedstock may be municipal solid waste, animal waste, or plastic or polymer waste for recycling or recovery. The pyrolyzer cell may contain char. The pyrolyzer cell may include gaseous products from pyrolysis.

[0047] The system may include a multi-effect pyrolyzer unit include a plurality of pyrolyzer cells. The outlet of one pyrolyzer cell may be in fluidic communication with the inlet of an adjacent pyrolyzer cell. The multi-effect pyrolyzer unit may be multi-effect pyrolyzer unit 108, multi-effect pyrolyzer unit 200, or any multi-effect pyrolyzer unit described herein. In some embodiments, the multi-effect pyrolyzer unit may include the pyrolyzer cells in series. In some embodiments, the multi-effect pyrolyzer unit may include at least some of the pyrolyzer cells in parallel. A multi-effect pyrolyzer unit may include 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 pyrolyzer cells.Example Methods

[0048] FIG. 4 shows a method 400 of pyrolysis. Method 400 may use system 100, multi-effect pyrolyzer unit 108, multi-effect pyrolyzer unit 200, pyrolyzer cells 202, pyrolyzer cell 300, or any system, multi-effect pyrolyzer unit, or pyrolyzer cell described herein.

[0049] In block 402, method 400 raises the temperature of the pyrolyzer cell to a first temperature, the pyrolyzer cell containing a feedstock. Method 400 may include feeding the feedstock into an inlet of the pyrolyzer cell. The feedstock may be any feedstock described herein, including any biomass, polymer, or plastic, described herein. Raising the temperature may include blocks 404 and 406.

[0050] In block 404, method 400 flows a fluid to a first jacket surrounding the pyrolyzer cell. Flowing the fluid to the first jacket may include flowing the fluid through a first plurality of channels defined by a first fluted medium. The fluid may be subcritical, supercritical, critical, and non-critical. The supercritical fluid may be supercritical carbon dioxide or supercritical steam. The fluid may be at a pressure of 1,000 to 1,100 psi, 1,100 to 1,200 psi, 1,200 to 1,300 psi, 1,300 to 1,400 psi, 1,400 to 1,500 psi, 1,500 to 2,000 psi, or over 2,000 psi.

[0051] In block 406, method 400 flows a material undergoing a phase change through a second jacket surrounding the first jacket. Flowing the material undergoing the phase change through the second jacket may include flowing the material through a second plurality of channels defined by a second fluted medium.

[0052] Method 400 may include maintaining a vacuum in a third jacket surrounding the second jacket.

[0053] In block 408, method 400 flows char from a pyrolysis reaction through an outlet of the pyrolyzer cell.

[0054] In block 410, method 400 flows a gaseous product from the pyrolysis reaction out of the pyrolyzer cell.

[0055] In block 412, method 400 condenses the gaseous product to a liquid. Method 400 may include collecting the liquid. The liquid may be a bio-oil, which may be further refined. Method 400 may include collecting uncondensed gaseous product, which may include syngas.

[0056] In embodiments, the pyrolyzer is a first pyrolyzer cell of a plurality of pyrolyzer cells. Flowing the gaseous product from the pyrolysis reaction may include flowing the gaseous product through the outlet of the first pyrolyzer cell. Method 400 may further include flowing the gaseous product and the char from the first pyrolyzer cell into a second pyrolyzer cell of the plurality of pyrolyzer cells. The temperature of the second pyrolyzer cell may be raised by flowing the supercritical fluid to a first jacket surrounding the second pyrolyzer cell. The temperature may be raised by flowing a material undergoing a phase change through a second jacket surrounding the first jacket surrounding the second pyrolyzer cell. The plurality of pyrolyzer cells may include at least 5 pyrolyzer cells.

[0057] Method 400 may include flowing a second gaseous product out of the plurality of pyrolyzer cells to a condenser. The second gaseous product may include the first gaseous product out of the first pyrolyzer cell. Flowing the second gaseous product to the condenser may include first flowing the second gaseous product to a filter.

[0058] Method 400 may be coordinated through a control system. The control system may include a computing system. The control system may send instructions and receive data from unit operations, including any component described with system 100, a pyrolyzer cell, or a multi-effect pyrolyzer unit.Examples

[0059] Embodiments described herein result in improved pyrolysis systems. Embodiments have a greater efficiency when compared to state-of-the-art pyrolysis systems. Different aspects of the systems described herein lead to different increases in efficiency.

[0060] A closed-loop temperature and pressure controls with supercritical CO2 flow scenario has an energy efficiency gain of 15% to 20%. This efficiency increase may be the result of precise control over pyrolysis conditions, allowing optimization of reaction rates and product yields.

[0061] Variable auger speeds and integration with waste heat recovery units leads to an efficiency gain of 8% to 12%. The efficiency increase may result from adaptable processing conditions and minimized energy waste through heat recovery.

[0062] Optimization of supercritical CO2 heat exchanger design leads to an efficiency gain of 10% to 15% from real-time optimization of heat transfer processes and minimization of pressure drops.

[0063] Integrated energy recycling and reuse with cascading ScCO2 (e.g., cascading between augers and using energy recycling between each level) leads to an efficiency gain of 18% to 22% by increasing thermal energy transfer and contact time, significantly enhancing overall system efficiency.

[0064] Continuous feeding into stacked heated screw conveyors (e.g., final stage condenser unit 132) leads to an efficiency gain of 5% to 8% from continuous operation, reducing downtime and increasing throughput.

[0065] Advanced materials for high-temperature resistance and corrosion resistance extend the operational lifetime, reducing maintenance and replacement costs. Advanced materials may innclude 316L, 321L, some stainless steels, high performance alloys, and super alloys.

[0066] Bioremediation of off-gases (e.g., CO₂, NOx, SO₂) help with environmental compliance and additional revenue streams. Bioremediation creates the potential for carbon credits or additional income from eco-friendly services, though not directly influencing system efficiency.

[0067] The total efficiency gain compared to state-of-the-art systems may be from 66% to 87%.

[0068] Although presented as numbered steps, steps of methods herein can be performed at a same time or at different times or in a different order that is logically possible. Additionally, portions of these steps may be used with portions of other steps from other methods. Also, all or portions of a step may be optional. Additionally, any of the steps of any of the methods can be performed with modules, units, circuits, or other means of a system for performing these steps.

[0069] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present disclosure.

[0070] The above description of example embodiments of the present disclosure has been presented for the purposes of illustration and description and are set forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use embodiments of the present disclosure. It is not intended to be exhaustive or to limit the disclosure to the precise form described nor are they intended to represent that the experiments are all or the only experiments performed. Although the disclosure has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is readily apparent to those of ordinary skill in the art in light of the teachings of this disclosure that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.

[0071] Accordingly, the preceding merely illustrates the principles of the invention. It will be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended to aid the reader in understanding the principles of the disclosure being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. The scope of the present invention, therefore, is not intended to be limited to the exemplary embodiments shown and described herein. Rather, the scope and spirit of present invention is embodied by the appended claims.

[0072] A recitation of “a”, “an” or “the” is intended to mean “one or more” unless specifically indicated to the contrary. The use of “or” is intended to mean an “inclusive or,” and not an “exclusive or” unless specifically indicated to the contrary. Reference to a “first” component does not necessarily require that a second component be provided. Moreover, reference to a “first” or a “second” component does not limit the referenced component to a particular location unless expressly stated. The term “based on” is intended to mean “based at least in part on.”

[0073] The claims may be drafted to exclude any element which may be optional. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely”, “only”, and the like in connection with the recitation of claim elements, or the use of a “negative” limitation.

[0074] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed within embodiments of the present disclosure. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither, or both limits are included in the smaller ranges is also encompassed within the present disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the present disclosure.

[0075] All patents, patent applications, publications, and descriptions mentioned herein are hereby incorporated by reference in their entirety for all purposes as if each individual publication or patent were specifically and individually indicated to be incorporated by reference and are incorporated herein by reference to disclose and describe the methods and / or materials in connection with which the publications are cited. None is admitted to be prior art.

Claims

1. A system comprising:a pyrolyzer cell comprising a jacketed wall, the jacketed wall comprising:a first jacket comprising a first inner wall, a first outer wall, and a first fluted medium between the first inner wall and the first outer wall,wherein: the first fluted medium forms a first plurality of channels, andeach channel is defined by alternating ridges and valleys formed in the first fluted medium; anda second jacket comprising a second inner wall, a second outer wall, and a second fluted medium between the second inner wall and the second outer wall,wherein:the second fluted medium forms a second plurality of channels, andeach channel is defined by alternating ridges and valleys formed in the second fluted medium.

2. The system of claim 1, wherein the second inner wall is the first outer wall.

3. The system of claim 1, wherein the pyrolyzer cell is cylindrical.

4. The system of claim 1, wherein the first fluted medium comprises a metal.

5. The system of claim 1, wherein the jacketed wall further comprises:a third jacket comprising a third inner wall, a third outer wall, and a third fluted medium between the third inner wall and the third outer wall,wherein: the third fluted medium forms a third plurality of channels, andeach channel is defined by alternating ridges and valleys formed in the third fluted medium.

6. The system of claim 5, wherein:the second inner wall is the first outer wall, andthe third inner wall is the second outer wall.

7. The system of claim 6, further comprising:supercritical carbon dioxide in the first plurality of channels, anda material undergoing a phase change in the second plurality of channels, wherein the third plurality of channels is at a pressure less than 100 Torr.

8. The system of claim 6, further comprising:supercritical steam in the first plurality of channels.

9. The system of claim 1, wherein:the pyrolyzer cell further comprises a first port and a second port, the first plurality of channels is in fluidic communication with the first port, andthe second plurality of channels is in fluidic communication with the second port.

10. The system of claim 9, wherein:the pyrolyzer cell further comprises an inlet at a first end and an outlet at a second end.

11. The system of claim 1, further comprising:a multi-effect pyrolyzer unit comprising a plurality of identical pyrolyzer cells, wherein the plurality of identical pyrolyzer cells includes the pyrolyzer cell,wherein an outlet of one identical pyrolyzer cell is in fluidic communication with an inlet of an adjacent identical pyrolyzer cell.

12. A method of pyrolysis, the method comprising:raising the temperature of a pyrolyzer cell to a first temperature, the pyrolyzer cell containing a feedstock, wherein raising the temperature comprises:flowing a fluid to a first jacket surrounding the pyrolyzer cell, andflowing a material undergoing a phase change through a second jacket surrounding the first jacket;flowing char from a pyrolysis reaction through an outlet of the pyrolyzer cell;flowing a gaseous product from the pyrolysis reaction out of the pyrolyzer cell; andcondensing the gaseous product to a liquid.

13. The method of claim 12, wherein the fluid is a supercritical fluid.

14. The method of claim 12, wherein the fluid is supercritical carbon dioxide.

15. The method of claim 12, wherein the feedstock is biomass, and the method further comprises feeding the biomass into an inlet of the pyrolyzer cell.

16. The method of claim 12, further comprising:maintaining a vacuum in a third jacket surrounding the second jacket.

17. The method of claim 12, wherein:the pyrolyzer cell is a first pyrolyzer cell of a plurality of pyrolyzer cells, andflowing the gaseous product from the pyrolysis reaction comprises flowing the gaseous product through the outlet of the first pyrolyzer cell,the method further comprising:flowing the gaseous product and the char from the first pyrolyzer cell into a second pyrolyzer cell of the plurality of pyrolyzer cells,raising the temperature of the second pyrolyzer cell by:flowing supercritical fluid to a first jacket surrounding the second pyrolyzer cell, andflowing a material undergoing a phase change through a second jacket surrounding the first jacket surrounding the second pyrolyzer cell.

18. The method of claim 17, wherein the plurality of pyrolyzer cells comprises at least five pyrolyzer cells.

19. The method of claim 17, wherein:the gaseous product is a first gaseous product,the method further comprising:flowing a second gaseous product out of the plurality of pyrolyzer cells to a condenser, wherein the second gaseous product comprises the first gaseous product.

20. The method of claim 12, wherein: flowing the fluid to the first jacket comprises flowing the fluid through a first plurality of channels defined by a first fluted medium, andflowing the material undergoing the phase change through the second jacket comprises flowing the material through a second plurality of channels defined by a second fluted medium.

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