Configurable reactor that provides greater versatility of geometric arrangements

Abstract

The present invention provides a configurable reactor that provides greater versatility of geometric arrangements, characterised in that it comprises: a reaction chamber; a shaft positioned vertically inside the reaction chamber, wherein the shaft comprises a plurality of attachment positions distributed along an attachment portion of the length thereof; at least one support, which has a central perforation and is detachably positioned in at least one corresponding attachment position of the shaft; at least a plurality of fastening means designed to fix the position of the at least one support on the shaft; and rotation means, solidly fastened to the reaction chamber and operatively connected to the shaft.

Description

[0001] A CONFIGURABLE REACTOR THAT PROVIDES GREATER VERSATILITY OF GEOMETRIC ARRANGEMENTS

[0002] DESCRIPTIVE MEMORY

[0003] TECHNICAL FIELD OF THE INVENTION

[0004] The present invention relates to, but is not limited to, equipment and apparatus related to the gasification of materials and, in particular, provides a reactor and a pyrolysis system comprising the same.

[0005] BACKGROUND OF THE INVENTION

[0006] Pyrolysis is the technique or process of converting organic matter and / or synthetic derivatives into three products: one solid, called biochar, one liquid, called bio-oil, and one gaseous, called pyrolysis gas. This process has the advantage of converting a raw material (e.g., waste or residue) into three products, but the production of one of these products can also be enhanced by varying the reaction temperature, heating rate, residence time of solids, residence time of vapors and gases produced, particle size of the raw material, and the type of reactor.

[0007] The reactor type is fundamental as a basis for defining the aforementioned variables. Fluidized-bed reactors are characterized by providing an effective and high rate of heat transfer from the reactor to the feedstock, favoring molecular breakdown in high-temperature pyrolysis above a threshold temperature, for example, 450°C. Other examples of reactors include screw, ablative, fixed-bed, rotating drum, cyclone, rotating bed, and tubular reactors, which each have advantages and disadvantages and therefore have a limited range of operating conditions and effects on productivity and product composition.

[0008] Each of the existing reactor types has a structure with little variability in shape and design, therefore, low variability or balance between the types of heat used for the pyrolysis reaction, referring to the two main forms of heat transfer in a pyrolysis reactor: conduction and convection. Some state-of-the-art documents partially address this problem. For example, Pecha et al. (2019) raises the variability in process performance and products obtained between different reactor designs due to the effect of critical parameters such as heat transfer mechanisms (conductivity, convection, and thermal radiation). In this context, there are pyrolysis reactors with high heat transfer rates, such as fluidized bed reactors, which present high uncertainty in the control over devolatilization and the products to be obtained.Other types of reactors have a plate system, which allows to define with greater certainty the transfer area and the ratio between conductive and convective heat transfer. Even so, there is no equipment that adjusts to the conditions required for each reaction, having to be limited to the pre-established design of the reactor and the use of the variables of reaction temperature, residence time, particle size, among others. Where the publication Pecha et al, 2019 is Pecha, MB, Arbelaez, JIM, Garcia-Perez, M., Chejne, F, Ciesielski, PN (2019): Progress in understanding the four dominant intra-particle phenomena of lignocellulose pyrolysis: chemical reactions, heat transfer, mass transfer, and phase change. Green Chemistry 21(11), 2868-2898. doi: 10. 1039 / C9GC00585D.

[0009] On the other hand, recent studies report a significant effect of heat transfer mechanisms during pyrolysis and therefore on the reaction products (Jurtz et al., 2019; Caudle et al., 2020; Lu et al., 2020). It should be noted that the production of intermediate molecules through pyrolysis is even more complex and uncertain, because there is no direct control over the internal variables of the reactor. Consequently, a reactor and a system are required that can overcome the deficiencies of the state of the art. Where the publication Jurtz et al., 2019 is Jurtz, N., Kraume, M., Wehinger, GD (2019): Advances in fixed-bed reactor modeling using particle-resolved computational fluid dynamics (CFD). 35(2), 139-190. doi:10.1515 / revce-2017-0059. Where the publication Caudle et al., 2020 is Caudle, B., Gorensek, MB, Chen, C.-C. (2020): A Novel Approach to Modeling Biomass Pyrolysis in a Fluidized Bed Reactor.ACS Sustainable Chemistry & Engineering 8(38), 14605-14615. doi:10.1021 / acssuschemeng.0c05783. Where the publication Lu et al., 2020 is Lu, L., Gao, X., Shahnam, M., Rogers, WA (2020): Bridging particle and reactor scales in the simulation of biomass fast pyrolysis by coupling particle resolved simulation and coarse grained CFD-DEM. Chemical Engineering Science 216, 115471. doi: https: / / doi.org / 10. 1016 / j.ces.2020. 115471.

[0010] SUMMARY OF THE INVENTION The present invention provides a configurable reactor that allows for greater versatility of geometric arrangements, characterized in that it comprises: a reaction chamber; a shaft positioned vertically inside the reaction chamber, wherein the shaft has a plurality of clamping positions distributed along a clamping portion of its length; at least one support that has a central perforation and that is removably positioned in at least one clamping position corresponding to the shaft, at least one locking means configured to fix the position of the at least one support on the shaft; and rotation means, fixed integrally with the reaction chamber and operatively connected to the shaft.

[0011] In a second object of protection, the present invention provides a pyrolysis system that allows to provide greater versatility of geometric arrangements, the pyrolysis system comprising: a feed section of a raw material; a reactor connected downstream of the feed section and configured to perform pyrolysis of the raw material; and an output section of at least one pyrolysis product from the reactor; wherein the pyrolysis system is characterized in that the reactor comprises: a reaction chamber; a shaft positioned vertically inside the reaction chamber, wherein the shaft has a plurality of clamping positions distributed along a clamping portion of its length;at least one support having a central perforation and removably positioned in at least one corresponding clamping position of the shaft, at least one locking means configured to fix the position of the at least one support on the shaft; and rotation means, fixed rotation means (9), fixed integrally with the reaction chamber (2) and operatively connected to the shaft (3).;

[0012] BRIEF DESCRIPTION OF THE FIGURES

[0013] Fig. 1 illustrates a schematic view of a first embodiment of the system that is the subject of the present invention.

[0014] Fig. 2 illustrates a schematic view of a first embodiment of the shaft and the at least one support that form part of the reactor that is the object of the present invention.

[0015] Fig. 3 illustrates a schematic view of a second embodiment of the shaft and the at least one support forming part of the reactor that is the object of the present invention. Fig. 4 illustrates a schematic view of a first embodiment of a support forming part of the reactor that is the object of the present invention.

[0016] Fig. 5 illustrates a schematic view of a second embodiment of a support that forms part of the reactor that is the object of the present invention.

[0017] Fig. 6 illustrates a schematic view of a third embodiment of a support that forms part of the reactor that is the object of the present invention.

[0018] Fig. 7 illustrates a schematic view of a fourth embodiment of a support that forms part of the reactor that is the object of the present invention.

[0019] Fig. 8 illustrates a schematic view of a fifth embodiment of a support that forms part of the reactor that is the object of the present invention.

[0020] Fig. 9 illustrates a schematic view of a sixth embodiment of a support that forms part of the reactor that is the object of the present invention.

[0021] Fig. 10 illustrates the distribution in space (distance) between supports (6) along the axis of the tree (3) of the bed for each level of the variable, exemplifying a clamping position (4A).

[0022] Fig. 11 illustrates two supports (6A, 6B) evaluated in the configuration of the internal reactor shaft (3), where the support (6A) is of smaller surface area covered by the spaces, and the support (6B) is of larger surface area covered by the spaces.

[0023] Fig. 12 illustrates a response graph, as a result, under different reactor configurations (1 ), which consider the area of ​​the supports (6) and the distribution along the axis of the reactor (1 ) tree (3).

[0024] Fig. 13A and 13B illustrate the GC / TCD chromatograms of the pyrolysis gas samples at previously validated retention times. 13A shows a higher propane yield at 2.378 minutes retention time and 13B shows a lower propane yield at 2.408 minutes retention time.

[0025] Fig. 14A illustrates a schematic view of the complete assembly comprising the pyrolysis system with its reactor (1) which is the object of the present invention, without an interior view of the reaction furnace (212).

[0026] Fig. 14B illustrates a schematic view of the complete assembly comprising the pyrolysis system with its reactor (1) which is the object of the present invention, with an interior view of the reaction furnace (212). Fig. 15 illustrates the reaction furnace on the left, and on the right a detailed schematic view of the shaft (3), where the catalyst basket (300) and the bed accessories can be distributed along the shaft (3) at different heights.

[0027] DETAILED DESCRIPTION OF THE INVENTION

[0028] The present invention will now be described in detail, with reference to the figures accompanying this application.

[0029] The present invention provides a configurable reactor (1) that allows providing greater versatility of geometric arrangements, wherein the reactor (1) comprises:

[0030] - a reaction chamber (2);

[0031] - a shaft (3) positioned vertically inside the reaction chamber (2), wherein the shaft (3) has a plurality of clamping positions (4A, 4B, 4C) distributed along a clamping portion (5) of its length, generating configurable volumes for each sub-chamber;

[0032] - at least one support (6) having a central bore (7) and which is removably positioned in at least one corresponding holding position (4A, 4B, 4C) of the shaft (3),

[0033] - at least one locking means (8) configured to fix the position of the at least one support (6) on the shaft (3); and

[0034] - rotation means (9), fixed in solidarity with the reaction chamber (2) and operatively connected to the shaft (3).

[0035] In the context of this application, without limiting its scope, the term "at least one" shall be understood as one or more of the elements referred to. The number of elements referred to by the term "at least one" does not limit the scope of this application. Additionally, when more than one element referred to by the term "at least one" is provided, said elements may or may not be identical to each other, without limiting the scope of this application.

[0036] In the context of this application, without limiting its scope, the term "plurality" shall be understood as two or more of the elements referred to. The number of elements referred to by the term "plurality" does not limit the scope of this application. Additionally, said elements that form part of the plurality may or may not be identical to each other, without limiting the scope of this application.

[0037] In the context of the present invention, without limiting its scope, an intermediate portion or position of an element shall be understood to be a portion or position comprised between two ends of said element. Said intermediate portion or position may be located at or near the center of said element, which will be referred to as the central portion or position, or remote from the center, which will be referred to as the eccentric portion or position, without limiting the scope of the present invention.

[0038] In a preferred embodiment, without limiting the scope of the present invention, each of the plurality of fastening positions (4A, 4B, 4C) can be selected from the group consisting of slots or depressions, projections, blind perforations, through perforations, disc bolt receiver with thread, as well as a combination thereof.

[0039] The shape and dimensions of the different elements that form part of the reactor (1) that is the object of the present invention do not limit the scope of the present invention and may depend, for example and without this limiting the scope of the present invention, on the intended use to which the reactor (1) that is the object of the present invention is put. For example, and without this limiting the scope of the present invention, the reaction chamber (2) may be a cylindrical or substantially cylindrical chamber. In this preferred embodiment, for example and without this limiting the scope of the present invention, the shaft (3) may be arranged in a substantially axial position of the reaction chamber (2).In a preferred embodiment in which the reaction chamber (2) is a cylindrical chamber, the at least one support (6) may have a disc or cylinder shape with a diameter extending substantially to an inner wall surface of the reaction chamber (2), thereby defining a plurality of reaction sub-chambers.

[0040] In a preferred embodiment, without limiting the scope of the present invention, the clamping portion (5) of the shaft (3) may comprise a plurality of through holes in a transverse direction of the shaft (3) defining the plurality of clamping positions (4A, 4B, 4C). In this preferred embodiment, for example, and without limiting the scope of the present invention, the locking means (8) may comprise at least one key operatively coupled to the at least one support (6) and inserted into one of the plurality of holes.

[0041] In another preferred embodiment, without limiting the scope of the present invention, the clamping portion (5) of the shaft (3) may comprise a plurality of diameter reductions defining the plurality of clamping positions (4A, 4B, 4C). In this preferred embodiment, for example, and without limiting the scope of the present invention, the locking means (8) may comprise a lock operatively coupled to the at least one support (6) and to one of the plurality of diameter reductions.

[0042] In a preferred embodiment, without limiting the scope of the present invention, the holding portion (5) of the shaft (3) may have a cross-section that is not rotationally symmetrical. In this preferred embodiment, for example, and without limiting the scope of the present invention, the central perforation (7) of the at least one support (6) may have a shape complementary to the cross-section of the holding portion (5) of the shaft (3), achieving integral rotation between the shaft (3) and the at least one support (6) when the at least one support is fixed to the shaft (3).

[0043] The number of clamping positions (4A, 4B, 4C) that the clamping portion (5) of the shaft has does not limit the scope of the present invention and may depend, for example, on the dimensions, as well as the intended use, of the reactor (1) that is the object of the present invention. In a preferred embodiment, without limiting the scope of the present invention, the clamping portion (5) of the shaft (3) comprises between 3 and 10 clamping positions.

[0044] The shape, dimensions and materials of the at least one support (6) do not limit the scope of the present invention and may depend, for example and without limiting the scope of the present invention, on the dimensions and intended use of the reactor (1) that is the object of the present invention. For example, as illustrated in Fig. 2 to 9, preferably in Figures 4 to 9 and without limiting the scope of the present invention, the at least one support (6) may be selected from the group consisting of closed discs (Fig. 4), perforated discs (Figs. 5 and 6), reticulated discs, closed-wall cylinders (Fig. 7), perforated-wall cylinders, reticulated-wall cylinders (Figs. 8 and 9), baskets, as well as a combination thereof. In a more preferred embodiment, without limiting the scope of the present invention, the reactor (1) may comprise a plurality of supports (6), each selected from the group of perforated discs.In this most preferred embodiment, without limiting the scope of the present invention, each support (6) of the plurality may have a different diameter, distribution and / or number of perforations.

[0045] The manner in which the rotation means (9) rotate the shaft (3) does not limit the scope of the present invention and will depend, for example, on the shape and intended use of the reactor (1) that is the object of the present invention. In a preferred embodiment, without limiting the scope of the present invention, the rotation means (9) may be configured to rotate the shaft (3) in alternating rotation directions.

[0046] The present invention further provides a pyrolysis system (100) comprising:

[0047] - a feed section (101) of a raw material;

[0048] - a reactor (1 ) connected downstream of the feed section (101 ) and configured to perform pyrolysis of the raw material; and

[0049] - an outlet section (102) of at least one pyrolysis product from the reactor (1)-

[0050] The reactor (1) of the pyrolysis system (100) may be in accordance with any of the previously described embodiments and may essentially comprise:

[0051] - a reaction chamber (2);

[0052] - a shaft (3) positioned vertically inside the reaction chamber (2), wherein the shaft (3) has a plurality of clamping positions (4A, 4B, 4C) distributed along a clamping portion (5) of its length, generating configurable volumes for each sub-chamber;

[0053] - at least one support (6) having a central bore (7) and which is removably positioned in at least one corresponding holding position (4A, 4B, 4C) of the shaft (3),

[0054] - at least one locking means (8) configured to fix the position of the at least one support (6) on the shaft (3); and

[0055] - rotation means (9), fixed in solidarity with the reaction chamber (2) and operatively connected to the shaft (3).

[0056] In a preferred embodiment, without limiting the scope of the present invention, the system (100) may comprise heating means operatively connected to the reactor (1). For example, and without limiting the scope of the present invention, the heating means may be selected from the group consisting of a microwave heater, hot plates, ovens, muffles, heating resistors, heat exchangers, as well as a combination thereof.

[0057] The system (100) that is the object of the present invention may further comprise temperature control means operatively coupled with the reactor (1 ) and with the heating means. Said temperature control means may comprise, for example and without limiting the scope of the present invention, both cooling means and heating means, as well as a combination thereof. The specific implementation of said heating means or said cooling means does not limit the scope of the present invention and may depend, for example, on the dimensions, materials and shape of the system (100) and / or the reactor (1 ) that are the object of the present invention.

[0058] All the options previously described for the reactor (1) that is the object of the present invention are applicable, through their corresponding adaptations, to the pyrolysis system (100) that is the object of the present invention.

[0059] According to the previously detailed description, it is possible to obtain a reactor (1) and a pyrolysis system (100) that allow overcoming the deficiencies of the state of the art.

[0060] It should be understood that the different options described for the technical characteristics of the reactor (1) and the pyrolysis system (100) can be combined with each other, or with other alternatives known to a person normally versed in the subject, without this limiting the scope of the protection requested.

[0061] Application examples of the present invention are provided below. These examples are provided solely for a better understanding of the technology, but in no case should they be construed as limiting the scope of the protection sought. Additionally, details of technical features described in different examples may be combined with each other, or with other options previously described or known to a person of ordinary skill in the art, in any manner contemplated, without limiting the scope of protection.

[0062] APPLICATION EXAMPLES

[0063] The effect of the tree configuration corresponding to the semi-moving bed of a pyrolysis reactor was evaluated through the production of biopropane by pyrolysis of carboxylate derivatives from the saponification of residual oil. In a first stage, the carboxylate production was carried out from the saponification reaction. The product was taken to a drying tunnel at 85 °C for 24 hours, where, once dry, it was ground and sieved to obtain particles with a size less than or equal to 3 mm. The dried product was used as raw material during the pyrolysis process. The pyrolysis reaction was carried out at 650 °C and 150 seconds of residence time in a reactor with a semi-moving bed of configurable areas, using gaseous nitrogen as a carrier gas. Additionally, the equipment consisted of a vapor condensation section to obtain bio-oil and pyrolysis gas sampling (propane).The pyrolysis gas produced was collected in a Tediar bag and characterised by flame chromatography-ignition detector (GC-FID) analysis.

[0064] Once the pyrolysis conditions were established, the feedstock (ground carboxylate from the carboxylate production stage) was injected into the pyrolysis reactor, where propane, butane, and other light olefins are produced, to be carried out of the reactor by the carrier gas. After the products transported by the carrier gas exited, they were taken to a condensation section, which cooled the products, retaining the condensable products. The flow of uncondensed products is taken to an electrostatic precipitator, precipitating aerosols and condensables that were not previously condensed. The transported products that have not been retained and / or precipitated are pyrolytic gases rich in propane / propene (approximately 26%), butane, pentane, and other olefins.

[0065] To evaluate the effect of the reactor bed tree configuration, a face-centered response surface methodology experimental design (MSR-CC) was implemented, where the variables were: spatial distribution (distance) between supports along the bed tree axis (Figure 10) and the surface area of ​​the supports (Figure 11 ) along the tree axis. The latter with level (-1 ) as the use only of lower surface area supports, level (0) with the use of high and low surface area supports in an interleaved manner and finally level (+1 ) with the use only of high surface area support. For each experiment established in the MSR, the pyrolysis methodology indicated in the previous paragraphs was carried out, where the only modification was the reactor configuration indicated.

[0066] The results showed a significant effect of the reactor configuration on the distribution of the products, specifically on the production of propane through carboxylate pyrolysis, as a response to the experimental design. Figure 12 shows the propane yields obtained from the process, both due to the spatial distribution of the supports on the shaft and the surface area of ​​the supports evaluated.

[0067] According to the results for the reactor evaluated and the required reaction, the highest propane productivity (27%) was obtained using a bed tree with a configuration using high surface area supports arranged in an intercalated manner. On the other hand, the lowest productivity (2%) was obtained by using only low surface area supports arranged in an intercalated manner, as can be seen in Table 1. Table 1. Propane yield obtained under different pyrolysis reactor configurations

[0068] Finally, the effect of the internal configuration of the reactor is observed in the composition of the gases shown in Figures 13A and 13B, which varies depending on the heat transfer area or accessory used and the distribution given at the time of assembling each sequence along the axis. These figures illustrate the chromatograms obtained by GC / TCD of the pyrolysis gas samples at retention times previously validated for the propane peak according to the validation tests. Figure 13A shows a higher propane yield at 2.378 minutes of retention time and Figure 13B shows a lower propane yield at 2.408 minutes of retention time.

[0069] COMPONENT LIST

[0070] 1 Configurable reactor 2 Reaction chamber

[0071] 3 Tree

[0072] 4A, 4B, 4C Holding Positions

[0073] 5 Holding portion

[0074] 6 Support 6A Support, a preferred configuration of the support (6) indicating a smaller surface area

[0075] 6B Support, another preferred configuration of the support (6) indicating a larger surface area

[0076] 7 Central drilling of the support

[0077] 8 Locking Means

[0078] 9 Rotation Media

[0079] 100 Pyrolysis system

[0080] 101 Food Section

[0081] 102 Product output section

[0082] 201 Liquid cooling system for condensers and biomass injection

[0083] 202 Security Support and Container

[0084] 203 Isolated system of electronic control and power supply means

[0085] 204 Carrier Gas Expander

[0086] 205 Sample hopper

[0087] 206 Sample transporter

[0088] 207 Sample injector

[0089] 208 Carrier gas preheating oven

[0090] 209A, 209B Evaporative Condensers

[0091] 210 Non-condensable gas outlet

[0092] 211 Aerosol precipitator

[0093] 212 Reaction furnace

[0094] 213 Container for condensable products

[0095] 214 Solid cyclone trap

[0096] 215 Reactor furnace

[0097] 216 Pyrolytic solids container lid 300 Basket

[0098] 301 Heat transfer mechanism bed

[0099] 302 Mobile conductive bed

[0100] 303 Porous fixed conductive bed 304 Cooling media

Claims

MODIFIED CLAIMS received by the International Bureau on April 25, 2025 (04 / 25 / 2025) 1. A configurable reactor (1) that allows providing greater versatility of geometric arrangements, to improve the performance of the pyrolysis process, CHARACTERIZED in that it comprises: - a reaction chamber (2); - a shaft (3) positioned vertically inside the reaction chamber (2), wherein the shaft (3) has a plurality of clamping positions (4A, 4B, 4C) distributed along a clamping portion (5) of its length, generating configurable volumes for each sub-chamber; - at least one support (6) having a central bore (7) and which is removably positioned in at least one corresponding holding position (4A, 4B, 4C) of the shaft (3), - at least one locking means (8) configured to fix the position of the at least one support (6) on the shaft (3); and - rotation means (9), fixed integrally with the reaction chamber (2) and operatively connected to the shaft (3), wherein the clamping portion (5) of the shaft (3) comprises a plurality of through perforations in a transverse direction of the shaft (3) that define the plurality of clamping positions (4A, 4B, 4C) and because the locking means (8) comprise at least one key operatively coupled with the at least one support (6) and that is inserted into one of the plurality of perforations.

2. The reactor (1) of claim 1, CHARACTERIZED in that the clamping portion (5) of the shaft (3) comprises a plurality of diameter reductions that define the plurality of clamping positions (4A, 4B, 4C) and in that the locking means (8) comprise a lock operatively coupled with the at least one support (6) and with one of the plurality of diameter reductions.

3. The reactor (1) of claim 1, CHARACTERIZED in that the clamping portion (5) of the shaft (3) comprises between 3 and 10 clamping positions.

4. The reactor (1) of claim 1, CHARACTERIZED in that the holding portion (5) of the tree (3) has a non-symmetrical cross-section in rotation and because the central perforation (7) of the at least one support (6) has a shape complementary to the cross-section of the holding portion (5) of the tree (3), achieving a solidary rotation between the tree (3) and the at least one support (6).

5. The reactor (1) of claim 1, CHARACTERIZED in that the at least one support (6) is selected from the group consisting of closed discs, perforated discs, discs reticulated, closed-wall cylinders, perforated-wall cylinders, reticulated-wall cylinders, baskets, as well as a combination thereof.

6. The reactor (1) of claim 1, CHARACTERIZED in that the rotation means (9) are configured to rotate the shaft (3) in alternating rotation directions.

7. The reactor (1) of claim 1, CHARACTERIZED in that it comprises a plurality of supports (6), each one being selected from the group of perforated discs, wherein each support (6) of the plurality has a different diameter, distribution and / or quantity of perforations.

8. A pyrolysis system (100) that allows providing greater versatility of geometric arrangements, the pyrolysis system (100) comprising: - a feed section (101) of a raw material; - a reactor (1 ) connected downstream of the feed section (101 ) and configured to perform pyrolysis of the raw material; and - an outlet section (102) for at least one pyrolysis product from the reactor (1); the pyrolysis system (100) being characterised in that the reactor (1) comprises: - a reaction chamber (2); - a shaft (3) positioned vertically inside the reaction chamber (2), wherein the shaft (3) has a plurality of clamping positions (4A, 4B, 4C) distributed along a clamping portion (5) of its length, generating configurable volumes for each sub-chamber; - at least one support (6) having a central bore (7) and which is removably positioned in at least one corresponding holding position (4A, 4B, 4C) of the shaft (3), - at least one locking means (8) configured to fix the position of the at least one support (6) on the shaft (3); and - rotation means (9), fixed integrally with the reaction chamber (2) and operatively connected to the shaft (3).

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