Waste plastic pyrolysis reactor

Abstract

A pyrolysis reactor for processing plastic materials comprises a static pyrolysis zone (100) connected to a pyrolysis zone (200) is disclosed; wherein said static pyrolysis zone (100) comprises a first inlet (101), a first expansion frustum cone (102), a first static tube (103), a depletion frustum cone (106), a first outlet (107), an inner housing (108), and a first outer housing (109); wherein the pyrolysis zone (200) comprises a tubular zone with a screw conveyor (201), a first drive subsystem (202), a second outer housing (203), a pyrolysis gas outlet (206), and an ashes outlet (207). The pyrolysis reactor solves technical problems referred to an incomplete raw materials vaporization, wherein solid plastics remain and cannot be converted into fuels. The solution is achieved by incorporating the static pyrolysis zone (100), which contributes to an effective formation of a vapor and a liquid phase, which are introduced into the reactor zone.

Description

WASTE PLASTIC PYROLYSIS REACTOR

[0001] The present application discloses a pyrolysis reactor system for conducting a pyrolysis reaction, wherein plastics or other suitable materials are converted to pyrolysis oil, pyrolysis gas, and other products.

[0002] Pyrolysis is a process of converting plastic waste materials into usable fuel products by heating the material in the absence of oxygen. Pyrolysis reactors comprising screw conveyors are used to carry out this process. The screw conveyor system consists of a rotating spiral screw, which moves the plastic waste material along a heated barrel or cylinder. The heat causes the plastic to break down into smaller molecules, which are vaporized and condensed into fuel products.

[0003] There are several types of plastic raw materials that can be used in the process of pyrolysis. These include Polyethylene (PE), which is the most used plastic in the world and can be easily converted into fuel products by pyrolysis; Polypropylene (PP), wherein this plastic is commonly used in packaging and can be converted into high-quality fuels by pyrolysis; Polystyrene (PS), wherein this plastic is used in packaging, insulation, and disposable utensils and can be converted into a liquid fuel by pyrolysis. The pyrolysis process can have mixtures of different plastic as raw materials.

[0004] The fuels that can be obtained by the pyrolysis process depend on the type of raw material used and the reactor conditions. The main fuels that can be produced by pyrolysis are: Pyrolysis oil, which is a dark, viscous liquid comprising higher C-chain components in its composition, and that can be used as a fuel for heating or as a feedstock for further refining; Plastic Pyrolysis Oil, which is yellow orange color liquid comprising lower C-chain components in its composition; Syngas, which is a mixture of hydrogen, carbon monoxide, and other gases that can be used as a fuel for electricity generation or as a feedstock for chemical production; Char, which is a solid residue that remains after the pyrolysis process and can be used as a fuel for heating or as a soil amendment.

[0005] The quality and quantity of these fuels depend on several factors, including the type and quality of the plastic raw material, the reactor conditions, and the post-processing techniques used to refine the fuel products. However, the pyrolysis process provides a valuable way to convert plastic waste materials into usable fuel products, reducing the environmental impact of plastic waste and providing an alternative source of energy.

[0006] The present invention refers to a pyrolysis reactor adapted for processing plastic waste materials comprising a static pyrolysis zone connected to a pyrolysis zone. In the preferred embodiments, the pyrolysis reactor further comprises at least one of additional processing zones, namely a vapor thermal cracking zone, which is connected to the pyrolysis zone; an ashes discharge zone, which is connected to the pyrolysis zone, or a shear wall feeder subsystem, which is connected to the static pyrolysis zone. The present invention also refers to the vapor thermal cracking zone, and to the shear wall feeder subsystem.Technical Problems

[0007] One of the technical problems associated with pyrolysis reactors comprising screw conveyors is the incomplete vaporization of the plastic raw material. This occurs when the screw conveyor does not provide enough residence time or heat to completely break down the plastic into its constituent parts. As a result, some of the plastic remains in solid form and cannot be vaporized or converted into fuel products.

[0008] To address this issue, several solutions can be implemented. One approach is to increase the temperature of the reactor, which will provide more heat to break down the plastic into smaller molecules. Another solution is to increase the residence time of the plastic in the reactor by slowing down the speed of the screw conveyor or increasing the length of the barrel. Furthermore, it is essential to ensure that the feedstock is properly prepared before being fed into the reactor. The feedstock should be uniformly sized, free from contaminants, and have a consistent moisture content.

[0009] The pyrolysis reactors known in the prior art include raw materials feeders that transfer the plastic material directly into the screw conveyor included in the pyrolysis zone. A common technical problem arises when a sudden heat flow is transferred into the pyrolysis zone, resulting in the build-up of a sticky material on the reactor screw.

[0010] Other prior art problems are related with sticking of plastic raw materials into the flights of common feeders that can contribute to significant variations in the raw materials rates into the reaction zone, which can impair the efficiency of the system and desired process yields.

[0011] The European patent application EP2233547A1 reveals a pyrolysis reactor comprising at least one screw heating chamber for plastic materials introduced in the chemical reactor and at least one further screw chamber for the reaction and mixing of the heated reacting substances in in order to obtain reaction products. Therefore, this reactor demands a screw heating zone, which does not avoid that sticking of plastic raw materials into the flights results in variations in the raw materials rates into the reaction zone.

[0012] Other prior art problems referred to pyrolysis reactors systems known in the prior art are related to their vapor treatment sections, which are vertically attached to the vapor discharge of the pyrolysis reactor, wherein this separate treatment subsystem requires re-heating, an airlock seal, and extra piping and pumps. This arrangement has several disadvantages, namely because it does not control properly the dwell time, and an extra heat input must be done to maintain the desired temperature.

[0013] Other prior art problems referred to pyrolysis reactors systems known in the prior art are related to the feeders of plastic raw materials. It is common that solid plastics, which can be granulated or shredded, or particulate, melt along the feeder screw conveyor, wherein the undesired partial melting of the raw materials results in the sticking of wet plastics on the flights of the screw conveyor, leading to unsteady flows of raw materials into the pyrolysis reactor, and consequently deviations in the desired yields of the pyrolysis process.

[0014] There is a need for a pyrolysis reactor that is configured to address properly these technical problems referred to the incomplete vaporization of the plastic raw material in the screw conveyor in order to increase the yield of usable fuel products and minimize the amount of waste that remains in solid form.

[0015] There is also a need for a vapor thermal cracking zone configured to be connected to a pyrolysis zone of a pyrolysis reactor that provides more efficient use of the heat input in order to have an efficient thermal cracking of the pyrolysis products, namely producing lighter fuels, and to properly control the desired dwell times, which are relevant for standardizing the yields of the pyrolysis process.

[0016] The pyrolysis reactor according to an aspect of the invention solves the abovementioned technical problems by the incorporation of a static pyrolysis zone, which is arranged upstream of the pyrolysis zone, wherein the said static pyrolysis zone comprises a first inlet, a first expansion frustum cone, a first static tube, a depletion frustum cone, a first outlet, and an inner housing.

[0017] The plastic raw materials enter the static pyrolysis zone through the first inlet and are further displaced into a flowing zone arranged among the outer surface of the first expansion frustum cone, the first static tube, and the inner housing. This flowing zone is configurated to promote a higher heat transfer rate into the shredded plastic material, resulting in a more effective changing phase from the solid state into the liquid state. At the first static tube, the melting plastics begin to be formed, as the outer surface of said static tube is closer to the inner housing. The melting plastics are vaporized among the outer surfaces of the static tube, the depletion frustum cone, and the inner housing. As a result of this process, a stream of plastic raw material comprising a vapor and a liquid phase is introduced into the screw reactor zone.

[0018] The present invention solves the problems referred to the known raw materials feeders by incorporating a shear wall feeder subsystem comprising a plurality of shaft bars arranged along a tubular zone with a screw conveyor, which avoid the melting of solid raw materials, and consequently, the sticking of said raw materials in the screw conveyor comprised in the feeder. Moreover, the present invention also has preferably a vapor thermal cracking zone, which is arranged horizontally in relation to the pyrolysis zone, that allows a proper dwell time in a heated environment to have an efficient thermal cracking of the hydrocarbons, producing lighter fuels.

[0019] In another aspect of the invention, the vapor thermal cracking zone is arranged horizontally in relation to the pyrolysis zone, making it possible that dust particles to drop out of the vapor stream and go back to the pyrolysis zone.

[0020] The static pyrolysis zone solves the technical problems referred to the building-up of raw materials in the pyrolysis zone. The shredded plastic raw materials are fed into the static pyrolysis zone and present several air spaces among the plastic portions and fragments, wherein the plastic melting results in its volume decreasing. The first expansion frustum cone is used to displace the loss in volume, making it possible that the material flow rate along the static pyrolysis zone to be similar to the feeding rate. This zone also contributes to increased pressure inside it in relation to the pressure of the pyrolysis zone, resulting in higher cracking conversions in the pyrolysis zone, leading to lighter fuels.

[0021] The horizontal arrangement of the vapor thermal cracking zone contributes to proper control of the dwell time in a heated environment to have an efficient thermal cracking of the hydrocarbons, producing lighter fuels, besides allowing better thermal integration with a pyrolysis zone, as the heating fluids outlets of the pyrolysis zone can be used as heating fluids inlets of the vapor thermal cracking zone.

[0022] A further advantage of the pyrolysis reactor is referred to the preferred embodiments that comprise a shear wall feeder subsystem including shear bars that are configurated to allow a steady and uninterrupted feed of plastic raw materials into said static pyrolysis zone by incorporating longitudinal bars arranged along a tubular zone with a screw conveyor in order to prompt the plastic material bulk along the length of the feeder. A further advantage of the shear bars is referred to its capacity to drain liquids along the fifth tubular zone with a screw conveyor, consequently reducing the possibility of wet plastic material sticks on the flights. The shear wall feeder subsystem can be used in a plurality of other applications, besides feeding plastic raw materials to a pyrolysis reactor. As further examples, the shear wall feeder subsystem can be connected to injection molding devices, extruders of plastic pellets or granules, chemical manufacturing processes, and food processing, such as chocolate or caramel.

[0023] To promote an understanding of the principles by the embodiments of the present invention, reference will be made to the embodiments illustrated in the figures and to the language used to describe the same. Anyway, it must be understood that there is no intention of limiting the scope of the present invention to the contents of the figures. Any alterations or later changes of the inventive features illustrated herein, and any additional application of the principles and embodiments of the invention shown, which would occur normally for one skilled in the art when reading this description, are considered as being within the scope of the claimed invention.Fig.1

[0024] illustrates a side view of a pyrolysis reactor according to the invention.Fig.2

[0025] illustrates a perspective view of a pyrolysis reactor according to the invention.Fig.3

[0026] illustrates a static pyrolysis zone.Fig.4

[0027] illustrates a static pyrolysis zone and a surrounding inner housing.Fig.5

[0028] illustrates a first outer housing that is configured to be arranged around an inner housing.Fig.6

[0029] illustrates a set of components comprised in a pyrolysis zone.Fig.7

[0030] illustrates a side view of a pyrolysis reactor according to the invention.Fig.8

[0031] illustrates a side view of a pyrolysis reactor according to the invention.Fig.9

[0032] illustrates a side view of a set of components comprised in a vapor thermal cracking zone.Fig.10

[0033] illustrates a perspective view of a set of components comprised in a vapor thermal cracking zone.Fig.11

[0034] illustrates a side view of a pyrolysis reactor according to the invention.Fig.12

[0035] illustrates a perspective view of a set of components comprised in an ashes discharge zone.Fig.13

[0036] illustrates a shear wall feeder subsystem.Fig.14

[0037] illustrates a perspective view of a set of components comprised in a shear wall feeder subsystem.Fig.15

[0038] illustrates a flow of plastic materials in a static pyrolysis zone.Fig.16

[0039] illustrates a flow of raw materials and products in a pyrolysis reactor.Fig.17

[0040] illustrates a supporting clip for a second outer housing.Fig.18

[0041] illustrates a baffle comprised in a second outer housing.Fig.19

[0042] illustrates another embodiment of a shear wall feeder subsystem.Fig.20

[0043] illustrates a perspective view of a set of components comprised in another embodiment of a shear wall feeder subsystem.

[0044] Pyrolysis is a process in which organic materials, such as plastics, are heated in the absence of oxygen to break down into smaller molecules, which can then be used to produce fuels. The heating fluid used in pyrolysis reactors is typically a gas or a liquid that is circulated through the reactor to transfer heat to the material being processed.

[0045] Common heating fluids for pyrolysis reactors include gases such as nitrogen, carbon dioxide, or steam, and liquids such as hot oil or molten salt. The choice of heating fluid depends on the specific requirements of the pyrolysis process, such as the desired temperature range, heat transfer efficiency, and the properties of the materials being processed.

[0046] The temperature range for pyrolysis of plastics to produce fuels can vary depending on the type of plastic being processed and the desired products. However, typically, temperatures in the range of 350-550°C are used for the pyrolysis of plastics to produce liquid fuels, while higher temperatures in the range of 550-800°C are used to produce gaseous fuels.

[0047] We present some literature references informing different process parameters regarding pyrolysis of plastics in order to obtain fuels.

[0048] Feng Gao (Pyrolysis of Waste Plastics into Fuels, January 2010) reveals the pyrolysis of HDPE at 400ºC in a continuous pyrolysis apparatus as a semi-scale commercial plant yields fuels and other products having the following mass distribution: LPG (10 %wt), petrol (30 % wt), diesel (40 % wt) and wax (20 % wt), wherein wt means mass fraction.

[0049] Antzela Fivga, Ioanna Dimitriou (Pyrolysis of plastic waste for production of heavy fuel substitute: A techno-economic assessment, 2018) discloses a pyrolysis plant with a capacity of 100 kg / h plastic waste, wherein a mixture comprising HDPE / PP / PS (50% / 25% / 25%) undergoes pyrolysis at 400ºC being obtained ethane (6.49 % wt), n-octane (18.58 % wt), n-C14 (31.86 % wt), n-C18 (15.75 % wt), n-C25 (16.87 % wt), n-C30 (3.45 % wt) and char (7.00 % wt).

[0050] Yuan Xingzhong, Converting Waste Plastics into Liquid Fuel by Pyrolysis: Developments in China, 24 March 2006 presents data regarding pyrolysis of PE at 400ºC, having fuel gas(2.00 % wt), gasoline (46.00 % wt), diesel oil (34.00 % wt), and residual oil (18.00 % wt) as products.

[0051] Marco Maniscalcoet al(Slow pyrolysis of an LDPE / PP mixture: Kinetics and process performance, 2021) disclose the kinetic of the pyrolysis of a plastic mixture with a composition of 92.5 wt% LDPE and 7.5% PP at 420ºC, being obtained gas (37.80 % wt), oil (43.00 % wt), and a solid fraction (7.40 % wt).

[0052] Imtiaz Ahmadet al. (Pyrolysis Study of Polypropylene and Polyethylene Into Premium Oil Products, 2015) informs about the pyrolysis of polypropylene (PP) and high density polyethylene (HDPE) into fuel like products over temperature range of 250– 400°C. The product yields as a function of temperature were studied. The pyrolysis of PP at 350ºC yields gas (28.84 % wt), oil (69.82 % wt), and a solid fraction (1.34 % wt). The pyrolysis of HDPE at 300ºC yields gas (17.24 % wt), oil (80.88 % wt), and a solid fraction (1.88 % wt). The pyrolysis of PP at 350ºC yields gas (30.00 % wt), oil (67.74 % wt), and a solid fraction (1.56 % wt). The pyrolysis of HDPE at 350ºC yields gas (17.24 % wt), oil (80.88 % wt), and a solid fraction (1.88 % wt).

[0053] Seyed Mousa FakhrHoseini, and Majid Dastanian, (Predicting Pyrolysis Products of PE, PP, and PET Using NRTL Activity Coefficient Model, 2013) study the pyrolysis of LDPE at 550ºC, and at a heating time of 6ºC / min yielding gas (19.43 % wt), oil (80.41 % wt), and a solid fraction (0.16 % wt). The pyrolysis of PP at 500ºC was also evaluated at a heating time of 6ºC / min yielding gas (17.76 % wt), oil (82.12 % wt), and a solid fraction (0.12 % wt). The pyrolysis of PET at 550ºC was also evaluated at a heating time of 6ºC / min yielding gas (52.13 % wt), oil (38.89 % wt), and a solid fraction (8.98 % wt).

[0054] The dwell time, or the amount of time the material being processed spends in the pyrolysis reactor, can also vary depending on the specific process and materials. However, typically, dwell times of several minutes to several hours are used for the pyrolysis of plastics to produce fuels.

[0055]

[0056] The present invention refers, in a first aspect, to a pyrolysis reactor adapted for processing plastic waste materials comprising a static pyrolysis zone (100) connected to a pyrolysis zone (200), wherein

[0057] said static pyrolysis zone (100) comprises a first inlet (101), a first expansion frustum cone (102), a first static tube (103), a depletion frustum cone (106), a first outlet (107), an inner housing (108), and a first outer housing (109); and wherein

[0058] the first inlet (101) is configured to be connected to a source of a shredded plastic waste material and to the first expansion frustum cone (102); and wherein

[0059] the first expansion frustum cone (102) comprises a first section having a first diameter and a second section having a second diameter greater than the first diameter and said second section is connected to the first static tube (103); and wherein

[0060] the first static tube (103) is connected to the depletion frustum cone (106); and wherein

[0061] the depletion frustum cone (106) comprises a first section having a first diameter and a second section having a second diameter smaller than the first diameter and said second section is connected to the first outlet (107); and wherein

[0062] the inner housing (108) comprises closed ends and surrounds said first expansion frustum cone (102), said first static tube (103) and said depletion frustum cone (106); and wherein

[0063] the first outer housing (109) comprises closed ends, surrounds said inner housing (108), and further comprises connected a first heating fluid inlet (110) and a first heating fluid outlet (111); and

[0064] the pyrolysis zone (200) comprises a tubular zone with a screw conveyor (201), a first drive subsystem (202), a second outer housing (203), a pyrolysis gas outlet (206), and an ashes outlet (207); and wherein

[0065] the tubular zone with a screw conveyor (201) is connected to said first outlet (107) and is driven by the drive subsystem (202); and wherein

[0066] the second outer housing (203) comprises closed ends, surrounds said inner housing tubular zone with a screw conveyor (201), and further comprises connected a second heating fluid inlet (204) and a second heating fluid outlet (205); and wherein

[0067] the pyrolysis gas outlet (206), and the ashes outlet (207) are connected to the tubular zone with a screw conveyor (201), and are projected through the second outer housing (203).

[0068] In the preferred embodiments according to the present invention, as illustrated in, the static pyrolysis zone (100) further comprises a second expansion frustum cone (104), and a second static tube (105); and wherein

[0069] the second expansion frustum cone (104) is connected to the first static tube (103) and to the second static tube (105); and wherein

[0070] the second static tube (105) is connected to the depletion frustum cone (106); and wherein

[0071] the inner housing (108) comprises closed ends and surrounds said first expansion frustum cone (102), said first static tube (103), said second expansion frustum cone (104), said second static tube (105), and said depletion frustum cone (106).

[0072] The plastic raw materials enter the static pyrolysis zone (100) through the first inlet (101) and are further displaced into a flowing zone arranged among the outer surface of the first expansion frustum cone (102), the first static tube (103), and the inner housing (108). This flowing zone is configurated to promote a higher heat transfer rate into the shredded plastic material, resulting in a more effective changing phase from the solid state into the liquid state. At the outer surrounding of the first static tube (103), the melting plastics begin to be formed, as the outer surface of said static tube (103) is closer to the inner housing (108). The melting plastics are vaporized among the outer surfaces of the static tube (103), the depletion frustum cone (106) and the inner housing (108). As a result of this process, a stream of plastic raw material comprising a vapor and a liquid phase is introduced into the screw reactor of the pyrolysis zone (200).

[0073] More preferably, as illustrated in, an even higher heat transfer is promoted when said static pyrolysis zone (100) further comprises a second expansion frustum cone (104), and a second static tube (105). In these preferred embodiments, a proper combination of the size of the first static tube (103) and its connection to a melting of the second expansion frustum cone (104) results that the plastics melting occurring mainly between the outer surface the of second expansion frustum cone (104) and the inner housing (108), and the vaporization of raw material will take place mainly among the outer surfaces of the second static tube (105), the depletion frustum cone (106) and the inner housing (108). Therefore, the configuration of the static pyrolysis zone (100) promotes the flow of melted plastics along the outer surfaces of the static tubes and expansion frustum cones, whereas the residual solid materials precipitate due to their higher density. Considering that the melted plastic density is lower, phase separation occurs along said static pyrolysis zone (100), which contributes to a more efficient thermal cracking of the raw material along said static pyrolysis zone (100). As the plastic raw material is vaporized, the vapor stream flows over the liquid phase, resulting in a further phase separation inside the static pyrolysis zone (100), wherein the vapor stream is forced out from the static pyrolysis zone (100) through the expansion form between the outer surface of the depletion frustum cone (106) and the inner housing (108).

[0074] The static pyrolysis zone (100) solves the technical problems referred to building-up of raw materials in the pyrolysis zone. The shredded plastic raw materials are fed into the static pyrolysis zone (100) and present several air spaces among the plastic portions and fragments, wherein the plastic melting results in its volume decreasing. The first expansion frustum cone (102) is used to displace the loss in volume, making possible that the material flow rate along the static pyrolysis zone (100) be similar to the feeding rate.

[0075] The static pyrolysis zone (100) configuration also contributes to increased pressure inside it in relation to the pressure of the pyrolysis zone (200), because of compacting the incoming plastic material. The pressure gradient formed in the static pyrolysis zone (100) contributes to higher cracking conversions in the pyrolysis zone (200), resulting in the production of lighter fuels and syn-gas.

[0076] Preferably, the first expansion frustum cone (102) has a ratio between its diameter outlet section and its diameter inlet section in the range of 20:1 to 70:1, more preferably in the range of 30:1 to 60:1. Preferably, the second expansion frustum cone (104) has a ration between its diameter outlet section and its diameter inlet section in the range of 20:1 to 60:1, more preferably in the range of 30:1 to 40:1.

[0077] The formed ash in the static pyrolysis zone (100) is pushed along this zone by the flow of the liquid phase, as plastic raw materials are fed to said static pyrolysis zone (100). The continuous flow of raw materials in their three phases inside the static pyrolysis zone (100) allows a balanced dwell time, higher pressure level, and higher heat transfer rates.

[0078] The closed ends of the inner housing (108), namely flanged ends, are configured to retain the static pyrolysis zone (100), allowing its thermal expansion or retraction, but avoiding its rotating as the plastic material flows along it. Preferably, the static pyrolysis zone (100) is made of high-temperature resistance stainless steel, and welded flanged ends are proper to easily replace a static pyrolysis zone (100), if needed.

[0079] Preferably, as illustrated in, a slip seal collar (116) is arranged at each flanged end of the inner housing (108), in order to allow the expansion of said inner housing (108). The terminals slip seal collars (116) fit inside a ring, for instance, a U-shaped ring, where a high-temperature rope packing is fitted tightly inside, wherein a clip (119) is arranged next to the respective seal collar to keep it centered. The sealing material contacts the metallic structure of the flanged end, preventing any metal-to-metal contact. Similarly, further slip seal collars can be arranged at least one of each flanged end of the second outer housing (203), of the third outer housing (304), of the fourth outer housing (312), or the fifth outer housing (404), wherein a respective clip (208,328,407) is arranged next to the respective seal collar to keep it centered, as illustrated in. The clips (208,328,407) are arranged on slide plates, which are configurated to slide according to the thermal expansion or thermal retraction of the respective outer housings to which said clips are connected. As it is illustrated in, a pair of clips (208), arranged at the ends of the second outer housing (203), compensate for its thermal expansion, avoiding damage to said structure.

[0080] Preferably, as illustrated in, a first thermal insulating layer (117), namely a ceramic fiber board, is connected to the interior walls of the said inner housing (108), in order to avoid loss of heat to the surrounding ambient. Moreover, a second thermal insulating layer (118) can be connected to the interior walls of each flanged end of the inner housing (108).

[0081] The inner housing (108) presents a tube-shaped form, and is preferably made of a metal or a metallic alloy, wherein its tube shape configuration is proper for the heating fluid flow around the outer surface of the static pyrolysis zone (100).

[0082] Preferably, said static pyrolysis zone (100) further comprises a support shaft, which is arranged longitudinally from the first inlet (101) to the connection between the first outlet (107) and the tubular zone with a screw conveyor (201).

[0083] As illustrated in, in the preferred embodiments according to the invention, at least one of the group selected of an anterior spacer plate (113) or a rear spacer plate (114) connect respectively the first expansion frustum cone (102) and the inner housing (108) or the depletion frustum cone (106) and the inner housing (108). As additional optional features, the first outer housing (109) delimits a tubular heating zone, wherein at least one first heating fluid inlet (110) is arranged tangentially at a bottom portion of a cross section of said first outer housing (109).

[0084] Heat is applied into the static pyrolysis zone (100) by feeding a heating fluid through a first heating fluid inlet (110), wherein the heating fluid flows along the interior of first outer housing (109) and heat is transferred to the walls of the static pyrolysis zone (100). As illustrated in, in the preferred embodiments according to the invention, the first heating fluid inlet (110) is arranged next to the depletion frustum cone (106) and the first heating fluid outlet (111) is arranged next to the first expansion frustum cone (102), which makes a counter-current heat transfer apparatus, resulting in a progressive heat increase along the flow of plastic raw materials in the static pyrolysis zone (100). Further advantages of this preferred embodiment are its contribution to a lower thermal shock, a lower material cracking, increased yields of fuels, and lower yields of syn-gas.

[0085] In the preferred embodiments, as illustrated in, the first heating fluid inlet (110) is arranged on an angle and mounted tangentially in relation to the outer wall of the first outer housing (109) in order to push the heating fluid, preferably hot air, in a spiral flow around the static pyrolysis zone (100). The first heating fluid outlet (111) is arranged at the opposite end of the first outer housing (109).

[0086] In the preferred embodiments, as illustrated in, the of anterior spacer plate (113) or rear spacer plate (114) are configured to keep the static pyrolysis zone (100) arranged in a centered position in relation to the inner housing (108), making possible that centered gaps formed in relation to the inner housing(108) be formed in order to make way to the plastic material flow.

[0087] Preferably, the support shaft is configured to act as an anchor point for the tubular zone with a screw conveyor (201), stabilizing said screw and keeping a smooth area for the material to flow through. The tubular zone with a screw conveyor (201) is maintained in a centered position by a bushing bearing for a speed screw (115), which is retained by the support shaft. The bushing bearing for a speed screw (115) avoids the tubular zone with a screw conveyor (201) contacting the walls of the second outer housing (203), besides reducing friction and allowing a proper expansion due to the thermal expansion.

[0088] Preferably, in the pyrolysis zone (200), the second outer housing (203) delimits a tubular heating zone, wherein at least one second heating fluid inlet (204) is arranged tangentially at a bottom portion of a cross section of said second outer housing (203). Comment: please illustrate element 204 in a Figure. Yes, you can use the same illustration used for the static zone after being adapted.

[0089] More preferably, the second outer housing (203) can be divided into two independent modules, as illustrated in, wherein each one of the modules can be heated by two independent burners, and wherein they are separated by an air gap between the second end of the first module and the first end of the second module, as it is illustrated in. A plurality of baffles (209) can be arranged in the second outer housing (203), as well in its divided two independent modules, as illustrated in, to increase the heat transfer rate of the heating fluid to the tubular zone with a screw conveyor (201). An example of a baffle (209) is illustrated in. A plurality of baffles (209) can be arranged in any one of the first outer housing (109), the second outer housing (203), the third outer housing (304), the fourth outer housing (312), or the fifth outer housing (404), wherein said baffles (209) contribute to the increasing to alterations in the direction of the flow of a heating fluid, increasing the convective heat transfer rates from the heating fluid to the respective tubular zones enclosed in each outer housing.

[0090] In the preferred embodiments of the invention, the static pyrolysis zone (100) and the pyrolysis zone (200) are arranged longitudinally and substantially horizontally in relation to the drive shaft of the screw conveyor comprised in the tubular zone with a screw conveyor (201).

[0091]

[0092] The present invention refers, in a second aspect, to a vapor thermal cracking zone (300) connected to a pyrolysis zone (200); and wherein said vapor thermal cracking zone (300) comprises a pyrolysis gas inlet and particulates outlet (301), a second tubular zone with a screw conveyor (302), a second drive subsystem (303), a third outer housing (304), a first cracked gas outlet (306), a third heating fluid inlet (307), a third heating fluid outlet (308) and a subsystem of removal of particulates (319); and wherein

[0093] the pyrolysis gas inlet and particulates outlet (301) is connected to a pyrolysis gas outlet (206) and is connected to the second tubular zone with a screw conveyor (302); and wherein

[0094] the second tubular zone with a screw conveyor (302) is driven by the second drive subsystem (303); and wherein

[0095] the third outer housing (304) comprises closed ends, surrounds said inner second tubular zone with a screw conveyor (302), and further comprises connected a third heating fluid inlet (307) and a third heating fluid outlet (308); and wherein

[0096] the first cracked gas outlet (306) is connected to the second tubular zone with a screw conveyor (302), and is projected through the third outer housing (304); and wherein

[0097] the subsystem of removal of particulates (319) is arranged orthogonally in relation to the second tubular zone with a screw conveyor (302), is arranged to be aligned with the pyrolysis gas inlet and particulates outlet (301), and is driven by a fourth drive subsystem (323); wherein said subsystem of removal of particulates (319) comprises a vertical cleaning screw (320), which comprises an intermediate rod (321) and a terminal spiral bar (322).

[0098] In other preferred embodiments according to the invention, as illustrated in, the pyrolysis reactor further comprises a vapor thermal cracking zone (300) connected to the pyrolysis zone (200); and wherein

[0099] said vapor thermal cracking zone (300) comprises a pyrolysis gas inlet and particulates outlet (301), a second tubular zone with a screw conveyor (302), a second drive subsystem (303), a third outer housing (304), a first cracked gas outlet (306), a third heating fluid inlet (307), a third heating fluid outlet (308) and a subsystem of removal of particulates (320); and wherein

[0100] the pyrolysis gas inlet and particulates outlet (301) is connected to the pyrolysis gas outlet (206) and is connected to the second tubular zone with a screw conveyor (302); and wherein

[0101] the second tubular zone with a screw conveyor (302) is driven by the second drive subsystem (303); and wherein

[0102] the third outer housing (304) comprises closed ends, surrounds said inner second tubular zone with a screw conveyor (302), and further comprises connected a third heating fluid inlet (307) and a third heating fluid outlet (308); and wherein

[0103] the first cracked gas outlet (306) is connected to the second tubular zone with a screw conveyor (302), and is projected through the third outer housing (304); and wherein

[0104] the subsystem of removal of particulates (319) is arranged orthogonally in relation to the second tubular zone with a screw conveyor (302), is arranged to be aligned with the pyrolysis gas inlet and particulates outlet (301), and is driven by a fourth drive subsystem (323); wherein said subsystem of removal of particulates (319) comprises a vertical cleaning screw (320), which comprises an intermediate rod (321) and a terminal spiral bar (322).

[0105]

[0106] The vapor thermal cracking zone (300) is arranged horizontally in relation to the pyrolysis zone (200), making possible that dust particles drop out of the vapor stream and go back to the pyrolysis zone, which allows a proper dwell time in a heated environment to have an efficient thermal cracking of the hydrocarbons, producing lighter fuels.

[0107] Any one of the anterior vent port (309), the intermediate vent port (310), and the terminal vent port (317) are configurated to vent vapors, if needed when there is not a necessity of carrying out a vapor treatment, wherein said vent can change the dwell time for a similar heat transfer rate into the second tubular zone with a screw conveyor (302).

[0108] A single or a first pair of screw conveyors (305) can be designed to have a large cross area to reduce the velocity of the leaving vapors, wherein a slower velocity will allow for dust and ash particles to drop out of the vapor stream. Moreover, in the embodiments comprising a first pair of screw conveyors (305), they can be operated in a counter flow screw flight, wherein his mode of operation allows that the collected dust and ash particles be collected, and delivered back to the pyrolysis zone (200). The counter flow screw speed can be increased or decreased to cause the vapor path to be longer or shorter because the vapors must flow around the flights to vent out of the vapor thermal cracking zone (300). The rotation forces the vapor to travel longer or shorter paths, which changes the dwell time, and consequently the time exposed to the thermal cracking.

[0109] The third outer housing (304) can be divided into two sections, wherein each section comprises a third heating fluid inlet (307), as illustrated in, in order to have two different conditions of temperature and pressure in each section.

[0110]

[0111] In the preferred embodiments of the pyrolysis reactor according to the invention, as illustrated in, the subsystem of removal of particulates (319) is arranged orthogonally in relation to the second tubular zone with a screw conveyor (302); and is arranged to be aligned with the pyrolysis gas inlet and particulates outlet (301), and is driven by a fourth drive subsystem (323); and wherein said subsystem of removal of particulates (319) comprises a vertical cleaning screw (320), which comprises an intermediate rod (321) and a terminal spiral bar (322). More preferably, the subsystem of removal of particulates (319) is arranged inside the interior vent port (309).

[0112] The vapor thermal cracking zone (300) further comprises in the most preferred embodiments, as illustrated in, a third tubular zone with a screw conveyor (311), a fourth outer housing (312), a second cracked gas outlet (314), a fourth heating fluid inlet (315), and a fourth heating fluid outlet (316); wherein; and wherein

[0113] the third tubular zone with a screw conveyor (311) is connected to the second tubular zone with a screw conveyor (302); and wherein

[0114] the third tubular zone with a screw conveyor (311) is driven by the second drive subsystem (303) or by an alternative drive subsystem; and wherein

[0115] the fourth outer housing (312) comprises closed ends, surrounds said inner third tubular zone with a screw conveyor (311), and further comprises connected a fourth heating fluid inlet (315) and a fourth heating fluid outlet (316); and wherein

[0116] the second cracked gas outlet (314) is connected to the third tubular zone with a screw conveyor (311), and is projected through the fourth outer housing (312).

[0117] As illustrated in, at least one of the second tubular zone with a screw conveyor (302) or the third tubular zone with a screw conveyor (311) comprises, respectively, a first pair of screw conveyors (305) or a second pair of screw conveyors (313), wherein any one of said first pair of screw conveyors (305) or said second pair of screw conveyors (313) comprises a first screw with a handedness referred to the direction in which the helical thread wraps around the screw shaft and a second screw with opposite handedness. More preferably, as illustrated in Figures 9 or 10, at least one of the group selected from an anterior vent port (309) or an intermediate vent port (310) is connected to the second tubular zone with a screw conveyor (302) and is projected through the third outer housing (304). As illustrated in Figures 8 and 9, a terminal vent port (317) is connected to the third tubular zone with a screw conveyor (311) and is projected through the fourth outer housing (312). In the preferred embodiments according to the invention, the intermediate vent port (310) corresponds to the first cracked gas outlet (306), and the terminal vent port (317) corresponds to the second cracked gas outlet (314).

[0118] As illustrated in Figures 7 and 8, the third heating fluid inlet (307), comprised in vapor thermal cracking zone (300) is connected to the second heating fluid outlet (205), comprised in the pyrolysis zone (200).

[0119] In other preferred embodiments according to the present invention, the vapor thermal cracking zone (300) and the static pyrolysis zone (100) are interconnected. As illustrated in Figures 7 and 8, the fourth heating fluid inlet (315), comprised in vapor thermal cracking zone (300) is connected to the first heating fluid outlet (111), comprised in the static pyrolysis zone (100), promoting said interconnection.

[0120]

[0121] The pyrolysis reactor further comprises in its most preferred embodiments, as illustrated in Figures 1 or 2, an ashes discharge zone (400) connected to the pyrolysis zone (200); and wherein

[0122] said ashes discharge zone (400) comprises an ashes inlet (401), a fourth tubular zone with a screw conveyor (402), a fifth drive subsystem (403), a fifth outer housing (404), and an ashes outlet (405); and wherein

[0123] the ashes inlet (401) is connected to the ashes outlet (207), comprised in the pyrolysis zone (200), and is connected to the fourth tubular zone with a screw conveyor (402) through the fifth outer housing (404); wherein

[0124] the fourth tubular zone with a screw conveyor (402) is driven by the fifth drive subsystem (403); wherein

[0125] the fifth outer housing (404) comprises closed ends, and surrounds said inner fourth tubular zone with a screw conveyor (402); wherein

[0126] the ashes outlet (405) is connected to an outlet airlock (500).

[0127] Preferably, as illustrated in, a plurality of thermal sleeve (407) can be arranged along fourth tubular zone with a screw conveyor (402) to avoid that said tubular zone be bended under thermal stress.

[0128] The present invention refers, in a third aspect, as illustrated in figures 19 and 20, to a shear wall feeder subsystem (600) comprising a materials inlet port (608a), a tubular zone with a screw conveyor (609a), a drive subsystem (610a), an outer housing (613a), and a materials outlet (615a); and wherein

[0129] the materials inlet port (608a) is connected to the tubular zone with a screw conveyor (609a); and wherein

[0130] the tubular zone with a screw conveyor (609a) is driven by the drive subsystem (610a); and wherein

[0131] the outer housing (613a) comprises closed ends, surrounds said inner tubular zone with a screw conveyor (609a) and further comprises a plurality of shear bars (612) arranged longitudinally along the inner surface of said tubular zone with a screw conveyor (609a); and wherein

[0132] a gap is formed between a twist of the screw conveyor and the top surface of the shear bar at a transversal section of the tubular zone with a screw conveyor (609a).

[0133] The pyrolysis reactor further comprises in its most preferred embodiments, as illustrated in, a shear wall feeder subsystem (600) connected to the static pyrolysis zone (100); and wherein

[0134] said shear wall feeder subsystem (600) comprises a plastic waste materials inlet port (608), a fifth tubular zone with a screw conveyor (609), a seventh drive subsystem (610), a sixth outer housing (613), and a plastic waste materials outlet (615); and wherein

[0135] the plastic waste materials inlet port (608) is connected to the fifth tubular zone with a screw conveyor (609); and wherein

[0136] the fifth tubular zone with a screw conveyor (609) is driven by the seventh drive subsystem (610); and wherein

[0137] the sixth outer housing (613) comprises closed ends, surrounds said inner fifth tubular zone with a screw conveyor (609) and further comprises a plurality of shear bars (612) arranged longitudinally along the inner surface of said fifth tubular zone with a screw conveyor (609); and wherein

[0138] a gap is formed between a twist of the screw conveyor and the top surface of the shear bar at a transversal section of the fifth tubular zone with a screw conveyor (609), and wherein

[0139] the plastic waste materials outlet (615) is connected to the first inlet (101) of the static pyrolysis zone (100).

[0140] The shear bars (612) are configurated to allow a place for the plastic raw materials to drop out of the rotating material stream into the space between the bars, creating a way to stop the rotation of the material, but allowing it to be pushed down along the fifth tubular zone with a screw conveyor (609). Furthermore, when the fifth tubular zone with a screw conveyor (609) is completely fed, the rotation speed of the screw flights, the plastic material among screw flights encounters the plastic material disposed among the shear bars (612), wherein said contact prompts the plastic material bulk along the length of the fifth tubular zone with a screw conveyor (609). A further advantage of the shear bars (612) is referred to its capacity to drain liquids along the fifth tubular zone with a screw conveyor (609), consequently reducing the possibility of wet plastic material sticks on the flights. Therefore, the shear wall feeder subsystem (600) provides a cost-effective and simple design solution.

[0141] Preferably, the plastic raw materials shall be shredded, cleaned, and / or washed in order to standardize the stream to be fed to the pyrolysis process, as well as standardize the obtained products.

[0142] The shear wall feeder subsystem (600) can be designed according to size of particles of plastic raw materials, wherein said design considers shredded materials that interlock among them. As an example, if a shear bars (612) have 10 mm height, then the raw material should be shredded in the range of 15 to 20 mm size in order to achieve a proper interlock of the materials.

[0143]

[0144] Preferably, as illustrated in, the shear wall feeder subsystem (600) further comprises a plastic waste materials inlet airlock (601), a hopper (602), a vertical screw (603), a sixth drive subsystem (604), a breaker arm (605), and a slide gate (607); wherein

[0145] the plastic waste materials inlet airlock (601) is configured to be connected to a source of a shredded plastic waste material and to an upper portion of the hopper (602); and wherein

[0146] the hopper (602) comprises a vertical screw (603), which is driven by the sixth drive subsystem (604); and wherein

[0147] the vertical screw (603) is connected orthogonally to at least a breaker arm (605); and wherein

[0148] the slide gate (607) is connected to a lower portion of said hopper (602) and to the plastic waste materials inlet port (608). More preferably, the hopper (602) comprises a frustum cone including a first section having a first diameter and a second section having a second diameter greater than the first diameter, wherein the second section is arranged at the upper portion of said hopper (602) and the first section is arranged at the lower section of said hopper (602).

[0149]

[0150] The selection of materials for pyrolysis reactors is critical to ensure the safe and efficient operation of the process. Pyrolysis reactors are typically exposed to high temperatures, corrosive gases, and thermal stresses, which can cause materials to degrade or fail over time. Therefore, materials used in pyrolysis reactors must be able to withstand these conditions while maintaining their structural integrity.

[0151] The pyrolysis reactor according to the present invention can be made of stainless steel, nickel-based alloys, and refractory metals such as tungsten and molybdenum. These materials are known for their high-temperature resistance, corrosion resistance, and mechanical strength.

[0152] Stainless steel is a common material used in pyrolysis reactors because it is relatively inexpensive, readily available, and has good corrosion resistance. Nickel-based alloys, such as Inconel and Hastelloy, are used in pyrolysis reactors that require higher temperature and corrosion resistance. Refractory metals, such as tungsten and molybdenum, are used in reactors that require very high-temperature resistance.

[0153] As used in this description, the expression. “substantially” means that the real value is within an interval of about 10% of the desired value, variable or related limit, particularly within about 5% of the desired value, variable or related limit or particularly within about 1% of the desired value, variable or related limit.

[0154] Moreover, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B.

[0155] In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form.

[0156] Further, as used herein, the term “exemplary” is intended to mean serving as an illustration or example of something and is not intended to indicate a preference.

[0157] The subject matter described above is provided as an illustration of the present invention and must not be interpreted to limit it. The terminology used to describe specific embodiments, according to the present invention, must not be interpreted to limit the invention. As used in this description, the definite and indefinite articles, in their singular form, aim to include in the interpretation the plural forms, unless the context of the description explicitly indicates the contrary. It will be understood that the expressions “comprise” and “include” when used in this description, specify the presence of the characteristics, the elements, the components, the steps, and the related operations, but do not exclude the possibility of other characteristics, elements, components, steps, and operations from being also contemplated.

[0158] All modifications, providing that they do not modify the essential features of the following claims, must be considered within the scope of protection of the present invention.

[0159] The industrial applicability of a pyrolysis reactor is significant, as it offers several advantages over traditional methods of waste disposal and energy production. Here are some examples: Waste management: Pyrolysis can be used to process various types of waste, including plastic, rubber, and biomass. This process can reduce the volume of waste and produce useful products such as biochar, which can be used as a soil amendment; Biofuels production: Pyrolysis can also be used to produce biofuels, such as bio-oil, which can be used as a replacement for fossil fuels. This process can also be used to produce gases like methane, which can be used for energy generation; Chemical production: Pyrolysis can also be used to produce chemicals, such as acetic acid, which is used in the production of plastics, textiles, and other industrial products.

[0160] Overall, the industrial applicability of a pyrolysis reactor is vast, and this technology is being increasingly used as a sustainable and cost-effective way to manage waste, produce energy, and reduce greenhouse gas emissions.

[0161] Reference SignDescription100A static pyrolysis zone101A first inlet102A first expansion frustum cone103A first static tube104A second expansion frustum cone105A second static tube106A depletion frustum cone107A first outlet108An inner housing109A first outer housing110A first heating fluid inlet111A first heating fluid outlet112A rear spacer stop113An anterior spacer plate114A rear spacer plate115A bushing bearing for a feed screw116A slip seal collar117A first thermal insulating layer118A second thermal insulating layer200A pyrolysis zone201A tubular zone with a screw conveyor202A first drive subsystem203A second outer housing204A second heating fluid inlet205A second heating fluid outlet206A pyrolysis gas outlet207An ashes outlet208A clip209A baffle300A vapor thermal cracking zone301A pyrolysis gas inlet and particulates outlet302A second tubular zone with a screw conveyor303A second drive subsystem304A third outer housing305A first pair of screw conveyors306A first cracked gas outlet307A third heating fluid inlet308A third heating fluid outlet309An anterior vent port310An intermediate vent port311A third tubular zone with a screw conveyor312A fourth outer housing313A second pair of screw conveyors314A second cracked gas outlet315A fourth heating fluid inlet316A fourth heating fluid outlet317A terminal vent port318A spring loaded seal plate319A subsystem of removal of particulates320A vertical cleaning screw321A rod322A spiral bar323A fourth drive subsystem324A first shaft portion deprived screw325A second shaft portion deprived screw326A drive shaft327A shaft seal and twin gear box drive328A clip400An ashes discharge zone401An ashes inlet402A fourth tubular zone with a screw conveyor402A fifth drive subsystem404A fifth outer housing405An ashes outlet406A screw conveyor407A thermal sleeve408A clip409A fifth heating fluid inlet410A fifth heating fluid outlet500An outlet airlock600A shear wall feeder subsystem601A plastic waste materials inlet airlock602A hopper603A vertical screw604A sixth drive subsystem605A breaker arm606A sensor607A slide gate608A flanged inlet port609A fifth tubular zone with a screw conveyor610A seventh drive subsystem611A drive shaft612A shear bar613A sixth outer housing614A flange615A plastic waste materials outlet601aA materials inlet airlock604aA drive subsystem608aA materials inlet port609aA tubular zone with a screw conveyor610aA drive subsystem613aAn outer housing615aA materials outlet

[0162] Citation List follows:

[0163] European patent application EP2233547A1 entitled “Method and chemical reactor for producing gaseous hydrocarbons derived from plastic materials” of Rebai Paolo, and published on September 29th 2010

[0164] Feng Gao, Pyrolysis of Waste Plastics into Fuels, January 2010

[0165] Antzela Fivga, Ioanna Dimitriou, Pyrolysis of plastic waste for production of heavy fuel substitute: A techno-economic assessment, Energy, Volume 149, 2018, Pages 865-874, ISSN 0360-5442

[0166] Yuan Xingzhong, Converting Waste Plastics into Liquid Fuel by Pyrolysis: Developments in China, 24 March 2006

[0167] Marco Maniscalco, Fabiola La Paglia, Pasquale Iannotta, Giuseppe Caputo, Francesca Scargiali, Franco Grisafi, Alberto Brucato, Slow pyrolysis of an LDPE / PP mixture: Kinetics and process performance, Journal of the Energy Institute, Volume 96, 2021, Pages 234-241, ISSN 1743-9671

[0168] Imtiaz Ahmad, M. Ismail Khan, Hizbullah Khan, M. Ishaq, Razia Tariq, Kashif Gul & Waqas Ahmad (2015) Pyrolysis Study of Polypropylene and Polyethylene Into Premium Oil Products, International Journal of Green Energy, 12:7, 663-671, DOI: 10.1080 / 15435075.2014.880146

[0169] Seyed Mousa FakhrHoseini, Majid Dastanian, "Predicting Pyrolysis Products of PE, PP, and PET Using NRTL Activity Coefficient Model", Journal of Chemistry, vol. 2013, Article ID 487676, 5 pages, 2013. https: / doi.org / 10.1155 / 2013 / 487676

Claims

A pyrolysis reactor adapted for processing plastic waste materials comprising a static pyrolysis zone (100) connected to a pyrolysis zone (200), characterized in thatsaid static pyrolysis zone (100) comprises a first inlet (101), a first expansion frustum cone (102), a first static tube (103), a depletion frustum cone (106), a first outlet (107), an inner housing (108), and a first outer housing (109); and whereinthe first inlet (101) is configured to be connected to a source of a shredded plastic waste material and to the first expansion frustum cone (102); and whereinthe first expansion frustum cone (102) comprises a first section having a first diameter and a second section having a second diameter greater than the first diameter and said second section is connected to the first static tube (103); and whereinthe first static tube (103) is connected to the depletion frustum cone (106); and whereinthe depletion frustum cone (106) comprises a first section having a first diameter and a second section having a second diameter smaller than the first diameter and said second section is connected to the first outlet (107); and whereinthe inner housing (108) comprises closed ends and surrounds said first expansion frustum cone (102), said first static tube (103) and said depletion frustum cone (106); and whereinthe first outer housing (109) comprises closed ends, surrounds said inner housing (108), and further comprises connected a first heating fluid inlet (110) and a first heating fluid outlet (111); andthe pyrolysis zone (200) comprises a tubular zone with a screw conveyor (201), a first drive subsystem (202), a second outer housing (203), a pyrolysis gas outlet (206), and an ashes outlet (207); and whereinthe tubular zone with a screw conveyor (201) is connected to said first outlet (107) and is driven by the drive subsystem (202); and whereinthe second outer housing (203) comprises closed ends, surrounds said inner housing tubular zone with a screw conveyor (201), and further comprises connected a second heating fluid inlet (204) and a second heating fluid outlet (205); and whereinthe pyrolysis gas outlet (206), and the ashes outlet (207) are connected to the tubular zone with a screw conveyor (201), and are projected through the second outer housing (203).The pyrolysis reactor, according to the previous claim, wherein said static pyrolysis zone (100) further comprises a second expansion frustum cone (104), and a second static tube (105); and whereinthe second expansion frustum cone (104) is connected to the first static tube (103) and to the second static tube (105); and whereinthe second static tube (105) is connected to the depletion frustum cone (106); and whereinthe inner housing (108) comprises closed ends and surrounds said first expansion frustum cone (102), said first static tube (103), said second expansion frustum cone (104), said second static tube (105), and said depletion frustum cone (106).The pyrolysis reactor, according to any of the previous claims, wherein a support shaft (112) is arranged longitudinally from the first inlet (101) to the connection between the first outlet (107) and the tubular zone with a screw conveyor (201).The pyrolysis reactor, according to any of the previous claims, wherein at least one of the group selected of an anterior spacer plate (113) or a rear spacer plate (114) connect respectively the first expansion frustum cone (102) and the inner housing (108) or the depletion frustum cone (106) and the inner housing (108).The pyrolysis reactor, according to any of the previous claims, wherein the first outer housing (109) delimits a tubular heating zone, wherein at least one first heating fluid inlet (110) is arranged tangentially at a bottom portion of a cross section of said first outer housing (109).The pyrolysis reactor, according to any of the previous claims, wherein the second outer housing (203) delimits a tubular heating zone, wherein at least one second heating fluid inlet (204) is arranged tangentially at a bottom portion of a cross section of said second outer housing (203).The pyrolysis reactor, according to any of the previous claims, wherein the static pyrolysis zone (100) and the pyrolysis zone (200) are arranged longitudinally and substantially horizontally in relation to the drive shaft of the screw conveyor comprised in the tubular zone with a screw conveyor (201).The pyrolysis reactor, according to any of the previous claims, wherein it further comprises a vapor thermal cracking zone (300) connected to the pyrolysis zone (200); and whereinsaid vapor thermal cracking zone (300) comprises a pyrolysis gas inlet and particulates outlet (301), a second tubular zone with a screw conveyor (302), a second drive subsystem (303), a third outer housing (304), a first cracked gas outlet (306), a third heating fluid inlet (307), a third heating fluid outlet (308) and a subsystem of removal of particulates (319); and whereinthe pyrolysis gas inlet and particulates outlet (301) is connected to the pyrolysis gas outlet (206) and is connected to the second tubular zone with a screw conveyor (302); and whereinthe second tubular zone with a screw conveyor (302) is driven by the second drive subsystem (303); and whereinthe third outer housing (304) comprises closed ends, surrounds said inner second tubular zone with a screw conveyor (302), and further comprises connected a third heating fluid inlet (307) and a third heating fluid outlet (308); and whereinthe first cracked gas outlet (306) is connected to the second tubular zone with a screw conveyor (302), and is projected through the third outer housing (304); and whereinthe subsystem of removal of particulates (319) is arranged orthogonally in relation to the second tubular zone with a screw conveyor (302), is arranged to be aligned with the pyrolysis gas inlet and particulates outlet (301), and is driven by a fourth drive subsystem (323); wherein said subsystem of removal of particulates (319) comprises a vertical cleaning screw (320), which comprises an intermediate rod (321) and a terminal spiral bar (322).The pyrolysis reactor, according to the previous claims, wherein the vapor thermal cracking zone (300) further comprises a third tubular zone with a screw conveyor (311), a fourth outer housing (312), a second cracked gas outlet (314), a fourth heating fluid inlet (315), and a fourth heating fluid outlet (316); wherein; and whereinthe third tubular zone with a screw conveyor (311) is connected to the second tubular zone with a screw conveyor (302); and whereinthe third tubular zone with a screw conveyor (311) is driven by the second drive subsystem (303) or by an alternative drive subsystem; and whereinthe fourth outer housing (312) comprises closed ends, surrounds said inner third tubular zone with a screw conveyor (311), and further comprises connected a fourth heating fluid inlet (315) and a fourth heating fluid outlet (316); and whereinthe second cracked gas outlet (314) is connected to the third tubular zone with a screw conveyor (311), and is projected through the fourth outer housing (312).The pyrolysis reactor, according to any of the claims 8 or 9, wherein at least one of the second tubular zone with a screw conveyor (302) or the third tubular zone with a screw conveyor (311) comprises, respectively, a first pair of screw conveyors (305) or a second pair of screw conveyors (313), wherein any one of said first pair of screw conveyors (305) or said second pair of screw conveyors (313) comprises a first screw with a handedness referred to the direction in which the helical thread wraps around the screw shaft and a second screw with opposite handedness.The pyrolysis reactor, according to any of the claims 8 to 10, wherein at least one of the group selected from an anterior vent port (309) or an intermediate vent port (310) is connected to the second tubular zone with a screw conveyor (302) and is projected through the third outer housing (304).The pyrolysis reactor, according to any of claims 9 to 11, wherein a terminal vent port (317) is connected to the third tubular zone with a screw conveyor (311) and is projected through the fourth outer housing (312).The pyrolysis reactor, according to any of claims 8 to 12, wherein the third heating fluid inlet (307), comprised in vapor thermal cracking zone (300) is connected to the second heating fluid outlet (205), comprised in the pyrolysis zone (200).The pyrolysis reactor, according to any of claims 6 to 13, wherein the fourth heating fluid inlet (315), comprised in vapor thermal cracking zone (300) is connected to the first heating fluid outlet (111), comprised in the static pyrolysis zone (100).The pyrolysis reactor, according to any of the previous claims, wherein it further comprises an ashes discharge zone (400) connected to the pyrolysis zone (200); and whereinsaid ashes discharge zone (400) comprises an ashes inlet (401), a fourth tubular zone with a screw conveyor (402), a fifth drive subsystem (403), a fifth outer housing (404), and an ashes outlet (405); and whereinthe ashes inlet (401) is connected to the ashes outlet (207), comprised in the pyrolysis zone (200), and is connected to the fourth tubular zone with a screw conveyor (402) through the fifth outer housing (404); whereinthe fourth tubular zone with a screw conveyor (402) is driven by the fifth drive subsystem (403); whereinthe fifth outer housing (404) comprises closed ends, and surrounds said inner fourth tubular zone with a screw conveyor (402); whereinthe ashes outlet (405) is connected to an outlet airlock (500).The pyrolysis reactor, according to any one of claims 8 to 15, wherein the subsystem of removal of particulates (319) is arranged orthogonally in relation to the second tubular zone with a screw conveyor (302); and is arranged to be aligned with the pyrolysis gas inlet and particulates outlet (301), and is driven by a fourth drive subsystem (323); and wherein said subsystem of removal of particulates (319) comprises a vertical cleaning screw (320), which comprises an intermediate rod (321) and a terminal spiral bar (322).The pyrolysis reactor, according to any of the previous claims, wherein it further comprises a shear wall feeder subsystem (600) connected to the static pyrolysis zone (100); and whereinsaid shear wall feeder subsystem (600) comprises a plastic waste materials inlet port (608), a fifth tubular zone with a screw conveyor (609), a seventh drive subsystem (610), a sixth outer housing (613), and a plastic waste materials outlet (615); and whereinthe plastic waste materials inlet port (608) is connected to the fifth tubular zone with a screw conveyor (609); and whereinthe fifth tubular zone with a screw conveyor (609) is driven by the seventh drive subsystem (610); and whereinthe sixth outer housing (613) comprises closed ends, surrounds said inner fifth tubular zone with a screw conveyor (609) and further comprises a plurality of shear bars (612) arranged longitudinally along the inner surface of said fifth tubular zone with a screw conveyor (609); and whereina gap is formed between a twist of the screw conveyor and the top surface of the shear bar at a transversal section of the fifth tubular zone with a screw conveyor (609), and whereinthe plastic waste materials outlet (615) is connected to the first inlet (101) of the static pyrolysis zone (100).The pyrolysis reactor, according to the previous claim, wherein the shear wall feeder subsystem (600) further comprises a plastic waste materials inlet airlock (601), a hopper (602), a vertical screw (603), a sixth drive subsystem (604), a breaker arm (605), and a slide gate (607); whereinthe plastic waste materials inlet airlock (601) is configured to be connected to a source of a shredded plastic waste material and to an upper portion of the hopper (602); and whereinthe hopper (602) comprises a vertical screw (603), which is driven by the sixth drive subsystem (604); and whereinthe vertical screw (603) is connected orthogonally to at least a breaker arm (605); and whereinthe slide gate (607) is connected to a lower portion of said hopper (602) and to the plastic waste materials inlet port (608).The pyrolysis reactor, according to any one of claims 17 to 18, wherein the hopper (602) comprises a frustum cone including a first section having a first diameter and a second section having a second diameter greater than the first diameter, wherein the second section is arranged at the upper portion of said hopper (602) and the first section is arranged at the lower section of said hopper (602).

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