A flame curtain pyrolysis system where a hood system is integrated for obtaining active carbon

Abstract

The present invention relates to a flame curtain pyrolysis system (10) comprising an integrated hood system (12) in order to be able to obtain active carbon in flame curtain pyrolysis systems (10) where bio-char is obtained in the related technical field.

Description

[0001] A FLAME CURTAIN PYROLYSIS SYSTEM WHERE A HOOD SYSTEM IS INTEGRATED FOR OBTAINING ACTIVE CARBON

[0002] TECHNICAL FIELD

[0003] The present invention relates to a flame curtain pyrolysis system comprising an integrated hood system in order to be able to obtain active carbon in flame curtain pyrolysis systems where bio-char is obtained in the related technical field.

[0004] PRIOR ART

[0005] Bio-char is obtained by heating an organic material (essentially a bio-mass like plant residues) at high temperatures by means of a process called pyrolysis in a medium which does not include oxygen. Pyrolysis process provides formation of a structure which is rich in carbon and which is porous.

[0006] Active carbon is obtained from an organic material by means of carbonization process and then activation process. For obtaining active carbon, physical activation or chemical activation method is used and these processes increase the surface area of carbon. Active carbon has a high surface area and high adsorption capacity.

[0007] Bio-char is evaluated as raw material in obtaining active carbon, and bio-char provides obtaining of active carbon as a result of carbonization and activation processes. Active carbon has more porosity and surface area when compared with bio-char. At the same time, there are various technical fields where bio-char is also used.

[0008] In the related technical field, there are various technics and systems developed for obtaining active carbon. Realization of carbonization and activation processes with the highest efficiency forms the base of these systems.

[0009] Systems may differ according to whether they adopt physical activation approach or chemical activation approach. In systems which adopt physical activation approach, first of all, carbonization of the organic material is realized at high temperature and in a medium which does not include oxygen, and then, this carbonized material is subjected to higher temperatures in an oxidizing atmosphere (essentially vapor or CO2) in order to be activated, and active carbon can be obtained. Systems which adopt physical activation approach have disadvantages like the need for high energy and the process management is complex, equipment is needed which necessitates investment with high cost and maintenance with high cost due to high temperature and high pressure conditions that must be controlled.

[0010] In systems which adopt chemical activation approach, carbonization and activation processes are realized together. In this method, raw organic material is mixed with chemical activation substances like phosphoric acid, potassium hydroxide, and active carbon can be obtained as a result of processes realized at low temperatures. However, these systems have disadvantages like chemical waste management requirements and risks for labor health and labor safety due to the toxic chemicals being used.

[0011] The mutual disadvantages of these systems are that they have high energy consumption and costs. High energy consumption requirement decreases efficiency of systems, and in the same manner, this leads to high costs. Therefore, this leads to increase of unit costs for obtaining active carbon.

[0012] Flame curtain pyrolysis system is a pyrolysis method where the organic materials like biomass are thermally decomposed at high temperatures in the absence of oxygen. In this system, the bio-mass is burnt in conical or pit-shaped boilers. Combustion takes place at the upper surface region of the boiler. The flame curtain formed in this region prevents oxygen transfer to the lower layers and the pyrolysis process takes place at the lower layer. The basic characteristic of this method is that the material does not directly contact with the flame but the pyrolysis reaction takes place by utilizing the temperature of the flame. Although the flame curtain pyrolysis system is a substantially simple system, it has advantages like energy efficiency and low emission and low operational costs.

[0013] In the related technical field, it has been detected that studies must be made for obtaining active carbon with low costs and with low energy consumption. In the art, research and developments must be made for obtaining systems which shall form alternative to systems including physical activation-chemical activation approaches used for obtaining active carbon and which form low amount of waste and which do not give harm to the environment and which provide low energy consumption and which have a non-complex system for the enterprise by having simple designs and which enable obtaining of active carbon with low costs thanks to all of these characteristics thereof.

[0014] The subject matter with publication number CN104232124 A relates to bio-mass fragmentation, carbonization and gasification device. The subject matter device comprises a water vapor inlet-outlet and a coke activator where the horizontal and orthogonal plates are existing. The carbon form obtained in the device is subjected to activation process in this coke activator.

[0015] The subject matter with publication number CN 105036127 A relates to an integrated device which realizes coal pyrolysis and active carbon production. The subject matter device comprises an activation furnace used for activating half coke coal and an activation substance carriage pipe used for entering the activation substances to the activation furnace. The active carbon furnace is formed by an integrated furnace.

[0016] BRIEF DESCRIPTION OF THE INVENTION

[0017] In the related technical field, studies for obtaining active carbon with lower costs and with lower energy consumption must be realized. In order to provide this, the present invention owners recommend a flame curtain pyrolysis system which enables obtaining active carbon for the related technical field.

[0018] As known in the art, flame curtain pyrolysis system is a system used for obtaining bio-char. The present flame curtain pyrolysis systems cannot meet the required process conditions for obtaining active carbon. Because active carbon necessitates process conditions which provide higher atmosphere control and higher temperature when compared with bio-char.

[0019] The present invention owners provide a hood system which provides elimination of the technical problems related to not being able to use flame curtain pyrolysis systems for obtaining active carbon. As also described in the present invention, by means of the flame curtain pyrolysis system where hood system is integrated, the temperature control which is needed for obtaining active carbon from organic materials can be provided.

[0020] By means of the subject matter flame curtain pyrolysis system where hood system is integrated, the required atmosphere control for obtaining active carbon can be provided. By means of the subject matter flame curtain pyrolysis system where hood system is integrated, low emission of gases during obtaining active carbon can be provided.

[0021] By means of the subject matter flame curtain pyrolysis system where hood system is integrated, active carbon can be obtained with high efficiency by means of low energy consumption. By means of this, unit cost for obtaining active carbon is reduced.

[0022] BRIEF DESCRIPTION OF THE FIGURES

[0023] In Figure 1 , the representative view of the flame curtain pyrolysis system where the subject matter hood system is integrated is shared together with all elements thereof.

[0024] REFERENCE NUMBERS

[0025] 10 Flame curtain pyrolysis system

[0026] 11 Pyrolysis boiler

[0027] 12 Hood system

[0028] 121 Heat chamber cone

[0029] 122 High speed channel

[0030] 123 Distributor cone

[0031] 124 Flame feeding module

[0032] 125 Gas and temperature sensor

[0033] 126 Air input-output module

[0034] 13 Active carbon production system

[0035] 131 Carbon feeding module

[0036] 132 Carbon discharge module

[0037] 133 Disc conveyor

[0038] DETAILED DESCRIPTION OF THE INVENTION

[0039] In this detailed description, the subject matter relates to a flame curtain pyrolysis system (10) which is suitable for use for obtaining active carbon, is explained with references to examples without forming any restrictive effect only in order to make the subject more understandable.

[0040] For obtaining active carbon, organic material must be subjected to carbonization and activation processes. Said process steps can be realized by means of a system which provides high temperature and atmosphere control and by means of the elements of said system.

[0041] In the present invention, when intending to an organic material, all of the sources called as bio-mass and which comprise carbon are described. In the present invention, essentially herbal-based components are used as the organic material. As an example to these, wooden-trees or the wastes thereof, agricultural products or the wastes thereof, feed plants or the wastes thereof, food industry wastes and municipality solid wastes can be given. The subject matter of the present invention is independent from the organic material and is not limited with the examples given here. The sources used for obtaining active carbon in the art can also be used in this subject matter invention.

[0042] Said flame curtain pyrolysis system (10) is a system which provides thermal decomposition of organic materials at high temperatures and in a medium where oxygen amount is delimited. In the present art, the flame curtain pyrolysis system comprises pyrolysis boiler and simple designs which provide control of air passage over the pyrolysis boiler.

[0043] The flame curtain pyrolysis systems that exist in the art enables provision of the required process conditions for obtaining bio-char from organic materials. The flame curtain pyrolysis systems that exist in the present technical designs cannot meet the process conditions which enable obtaining active carbon.

[0044] The present invention owners provide a hood system (12) which is compliant to the present flame curtain pyrolysis systems. The representative view of a flame curtain pyrolysis system (10) configured in this manner is shared in Figure 1 together with its elements.

[0045] Accordingly, the subject matter flame curtain pyrolysis system (10) comprises at least one pyrolysis boiler (11), a hood system (12) and at least one active carbon production system (13).

[0046] In the present invention, as also known in the art, the pyrolysis boiler (11 ) is the reaction medium where the raw material organic material is put and where bio-char products are obtained as a result of processes. In the pyrolysis boiler (11), first of all, the carbonization processes are realized, and bio-char can be obtained as aimed. The flame-temperature obtained from the pyrolysis boiler (11) will be transferred to the hood system (12) which exists in the configuration of the present invention for use in active carbon production. By means of the active carbon production system (13) positioned in the hood system (12), the carbon sources effectively interact, and the target activation processes can take place. By means of this, pyrolysis flame-temperature formed for bio-char production can also be made usable for production of active carbon, and by means of this, active carbon production costs can be reduced since the flame-temperature can be controlled and used in an effective manner.

[0047] However, as also known in the art, complete burning processes cannot take place by means of the pyrolysis processes realized in the pyrolysis boiler (11). After the pyrolysis process, pyrolysis gases which do not completely burn are occurring. These pyrolysis gases are transferred to the hood system (12) and complete burning will be provided in this medium. By means of said complete burning, emission of gases is reduced and by means of this, the energy efficiency of the pyrolysis boiler is increased. Moreover, the flame-temperature obtained from the pyrolysis boiler (11 ) shall be transferred to the hood system (12) in order to be used in active carbon production and in burning of gases.

[0048] In the present invention, the dimensions and the design of the pyrolysis boiler (11 ) are not described. The pyrolysis boiler (11) used in the art can also be used in the subject matter systems (10), and it can have a high capacity design and it can have dimensions according to the amount of products desired to be obtained.

[0049] The subject matter system (10) comprises a hood system (12) positioned at the upper vicinity of the pyrolysis boiler (11) defined beforehand. As also mentioned beforehand, the main function of said hood system (12) is to provide controlled transfer of the flame-temperature obtained from the pyrolysis boiler (11) together with the elements thereof. The transferred flame-temperature is used in activation processes of active carbon.

[0050] Moreover, thanks to the formed reaction medium, the hood system (12) provides burning of the pyrolysis gases which are obtained from the pyrolysis boiler (11) and which are not completely burnt.

[0051] The subject matter hood system (12) provides drawing of the pyrolysis gases upwardly and at a high flow rate. By means of this, the amount of air feed needed for burning is also increased. This air feeding is provided through the adjustable opening that exists between the hood system (12) and the pyrolysis boiler (11 ). The heated air, that exists between the hood (12) and the isolation sheet that encircles the hood (12), is transferred to the combustion region by means of the pressure difference which results from the suctioning, and the combustion air flow rate is further increased.

[0052] The hood system (12) comprises elements where the flame and the heat occurring as a result of the processes in the pyrolysis boiler (11) are collected, and which provide increasing-decreasing of the speeds of combustion gases and which provide decreasingincreasing of the pressures of combustion gases.

[0053] The heat and pyrolysis gases that exit the pyrolysis boiler (11) are firstly transferred to at least one heat chamber cone (121) that exists in the hood system (12). As also seen in Figure 1 , the heat chamber cone (121 ) has conical geometrical form at diameter values which narrows as from the lower part thereof towards the upper part thereof. Said heat chamber cone (121) provides collection of flame and temperature at this section thanks to its conical geometrical structure. Thanks to its conical geometrical design, the heat chamber cone (121 ) increases the speed of combustion gases and the flame-temperature collected in its body and decreases the pressure thereof.

[0054] The heat chamber cone (121) is the first combustion chamber for active carbon production. The carbon source that exists in active carbon production system respectively passes through the combustion chambers in order to be able to obtain activation in the hood system (12). The provision of efficient and controlled temperature-flame distribution in these combustion chambers is critical.

[0055] In the same manner, the gases, which are collected here and which are unburnt and which are discharged during pyrolysis, are burnt again by means of the collected flame and combustion temperature.

[0056] As shown in Figure 1 , the hood system (12) comprises at least one high speed channel (122). In the present invention, the high speed channel (122) has a design which has diameter value which further narrows (in order to form venture effect) with respect to the heat chamber cone (121) and the distributor cone (123) existing in the hood system (12). By means of this, gas and flame-temperature fluid speed and pressure can be controlled, the burning efficiency can be increased and the gas flow can be guided in an efficient manner. By means of the venture effect, the high speed channel (122) provides transfer of the gases and pyrolysis temperature coming from the heat chamber cone (121) to the distributor cone (123) in a rapid manner.

[0057] The hood system (12) comprises at least one distributor cone (123). As also seen in Figure 1 , the hood system (12) respectively comprises a heat chamber cone (121), a high speed channel (122) and a distributor cone (123) towards the upper part. Accordingly, the distributor cone (123) forms the topmost part of the hood system (12). Its design is inverse conical form. Thanks to its design, it provides the combustion gases, which are rapid and which have low pressure and which come through the high speed channel (122), to gain lower speed and higher pressures. By means of deceleration of the speed and increase of the pressure, a more effective combustion and heat distribution can be provided in the combustion chamber. Sensitive thermal area can be provided for obtaining active carbon. Deceleration of the speed of combustion gases provides control of emission of gases and provides reduction in gas emission.

[0058] Accordingly, for obtaining active carbon in the hood system (12), the activation processes respectively pass through the heat chamber cone (121), the high speed channel (122) and the distributor cone (123) combustion chambers and interacts with the temperature-flame here. By means of this, effective temperature-flame control can be provided for obtaining active carbon.

[0059] In more than one combustion chamber which respectively has designs of conical form heat chamber cone (121), narrowing diameter high speed channel (122) and inverse conical form distributor cone (123) in the hood system (12), the pyrolysis gases obtained from the pyrolysis boilers are interacted with the flame-combustion temperatures, obtained again from the pyrolysis boilers, at a higher efficiency. By means of this, efficient heat control can be provided and the needed energy consumption can be reduced. At the same time, by means of controlled transfer of combustion gases, the emission thereof can be substantially reduced.

[0060] Provision of activation temperature for obtaining active carbon is critical. At the same time, the complete burning of pyrolysis gases, which is one of the targets of the invention, is also important. Since the subject matter invention is a continuous system, the distribution of temperatures obtained from the pyrolysis boilers (11) can vary. The hood system (12) comprises at least one temperature and gas sensor (125) for the continuous systematic control of the required temperature. In a preferred application, the temperature and gas sensor (125) can be positioned between the high speed channel (122) and the heat chamber cone (121 ). Besides this positioning of the temperature and gas sensor (125), the temperature and gas sensor (125) can also be positioned in the hood system (12) such that there is more than one temperature and gas sensor (125) also at the other sections.

[0061] The hood system (12) comprises at least one flame feeding module (124) which provides feeding of flame-temperature to the system as needed in case it is detected by the sensor(s) that the flame-temperature is insufficient. In a preferred application, this flame feeding module (124) operates in an integrated manner with the temperature and gas sensor(s) (125). In this preferred application, these elements can also operate in an automated manner together with a control system.

[0062] In a preferred application, the flame feeding module (125) is positioned at the upper end of the high speed channel (122). By means of this, in the distributor cone (123) where effective temperature control is more important, a temperature deficiency, which prevents complete burning and activation for obtaining active carbon, is prevented by the flame feeding module (125).

[0063] The hood system (12) comprises at least one air input-output module (126). Isolation air is included through the air input-output module (126). This air enters the system and is discharged through these modules. The air, which exists in the air input-output module (126) which exists at the hood system (12), realizes isolation function for the air system. This air is included to the hood system (12), through the upper part of the air input-output module (126). The air, entering the system, is heated and is transferred to the pyrolysis boiler (11) through the lower part of the air input-output module (126).

[0064] The subject matter system (10) comprises elements for production of active carbon. The representative of the active carbon production system (13) for the subject matter is shown in Figure 1 together with the elements thereof. There is at least one carbon feeding module (131) where the carbon sources are added to the active carbon production system (13) in order for these carbon sources to be used in the active carbon activation process. If preferred, there is more than one carbon feeding module (131).

[0065] As shall be estimated, the carbon feeding module (131 ) must be positioned at the section which has not yet been subjected to activation processes. This position is the section before the combustion chambers that exist in the hood system (12). In the present invention, when intending to a carbon source, it is desired to describe an intermediate product obtained after subjecting the carbon including wastes to the carbonization processes. The intermediate products like bio-char obtained from the pyrolysis boiler (11 ) are subjected to activation processes and can be used as raw material in obtaining active carbon. In said process step, all components which can be used as raw material can be evaluated as carbon source.

[0066] In the same manner, the active carbon production system (13) comprises at least one carbon discharge module (132) where the carbon sources are collected after being processed in combustion chambers for the activation processes. The product taken from the carbon discharge module (132) is an active product which has the targeted porosity and surface area.

[0067] One of the innovative characteristics of the subject matter system (10) is that the carbon sources, which are to be used as raw material in the active carbon system (13), are interacting with flame-temperature obtained from pyrolysis boilers (11) and transferred to the combustion chambers without said carbon sources interacting with direct flame. For providing this, the carbon source added from the carbon feeding module (131) moves in the combustion chambers respectively that exist in the hood system (12) and interacts with the flame-temperature and is subjected to activation processes. The active carbon production system (13) comprises a disc conveyor (133) where the carbon source can advance through the combustion chambers and where the activation processes can take place. The disc conveyor (133) has a design such that the hood system (12) can also pass through the combustion chambers as also shown in Figure 1. Inside the disc conveyor (133), there is the carbon source added from the carbon feeding module. The carbon source is advanced in the disc conveyor (133) and is subjected to activation processes with the flame-temperature in the combustion chambers. As it is aimed, the active carbon obtained by being subjected to activation processes is then taken from the carbon discharge module (132) in a continuous manner. Accordingly, the carbon feeding and discharge modules (131 , 132) are the openings provided on the disc conveyor (133) and which provide adding and collecting of carbon sources from the system. The disc conveyor (133) which exists in the present invention is configured such that the carbon source that exists therein can be in contact by means of thermal conduction at high efficiency as it is aimed. In a preferred application, there can be more than one active carbon production system (13). As shown in Figure 1 , the active carbon production system (13) which exists at the right part can also exist at the left part. In case there is more than one active carbon production system (13), more amount of active carbon production is enabled.

[0068] The material of which the combustion chambers, that exist at the hood system (12), are made and the material of which the parts, that form the outer wall of the hood system (12), are made are independent from the protection scope of the invention, and said materials are not limited. But as shall be estimated, the outer wall of the hood system (12) is made of materials which can provide isolation in a manner not affected by the outer temperatures or where the temperature, needed for the activation processes, is not released to outside in order to preserve the temperature inside the system.

[0069] In order to obtain high efficiency for the flame-temperature in combustion chambers, the disc conveyor (133) is made of materials in a manner providing highest efficiency interaction in active carbon activation.

[0070] In the subject matter flame curtain pyrolysis system (10), there is a space at specific distances between the hood system (12) and the pyrolysis boiler (11). Combustion air can enter through said space. This space can be adjusted according to the flame-temperature performance in the pyrolysis boiler (11) and the combustion chambers. The elements which adjust the distance of this space can exist in the pyrolysis boiler (11 ) and in the hood system (12). In case it is preferred, these elements can be integrated to automation by means of the control system. Moreover, in more advanced technical teachings of the invention, these elements can also be integrated with the sensor(s) which exist(s) in the hood system (12). In the same manner, sensor can be integrated to the pyrolysis boiler (11), and by means of the detection of the flame-temperature performance of these sensors in the system, said space distance can be adjusted.

[0071] In the subject matter flame curtain pyrolysis system (10) where the hood system (12) is integrated, both bio-char and active carbon can be obtained by means of the same thermal energy. The temperature obtained from the pyrolysis boiler (11) can be used as thermal energy also in active carbon production. By means of this, unit costs can be reduced for obtaining active carbon. It has been detected that the flame-temperature obtained from the pyrolysis boiler (11) is suitable for use for activation processes in obtaining active carbon with high efficiency. It has been proven that the surface area of the active carbon obtained by means of the subject matter system is at a value between 300 and 2000 m2 / g.

[0072] In the subject matter system, bio-char can be obtained also from the pyrolysis boiler (11). It has been proven that the surface area of bio-char obtained in this system is at a value between 200 and 1000 m2 / g.

[0073] In the flame curtain pyrolysis systems (10) that exist in the present art, the gas emission which results from non-completely burning of the gases which occur as a result of the pyrolysis processes and not being able to provide atmosphere control is very high. By means of the combustion chambers of the subject matter flame curtain pyrolysis systems (10) comprising the hood system (12) and by means of the geometric designs thereof, the combustion performance is increased and the combustion reactions are realized in a complete manner.

[0074] The protection scope of the present invention is set forth in the annexed claims and cannot be restricted to the illustrative disclosures given above, under the detailed description. It is because a person skilled in the relevant art can obviously produce similar embodiments under the light of the foregoing disclosures, without departing from the main principles of the present invention.

Claims

CLAIMS1. The present invention is a flame curtain pyrolysis system (10) which provides active carbon and bio-char production in the same thermal energy system, and comprising,- at least one pyrolysis boiler (11 ) where bio-char production is realized by subjecting the organic materials to pyrolysis processes and where the required flametemperature is provided for the system,- a hood system (12) comprising at least one heat chamber cone (121), at least one high speed channel (122) and at least one distributor cone (123) combustion chambers, positioned at the upper vicinity of the pyrolysis boiler (11) and where the flame-temperature obtained from the pyrolysis boiler (11) is used for the activation of the carbon sources and for complete burning processes of the pyrolysis gases,- and at least one active carbon production system (13) where the transportation and activation processes of the carbon sources are realized and where at least one part thereof is positioned in a manner placed inside the combustion chambers provided in the hood system (12).

2. The flame curtain pyrolysis system (10) according to claim 1 , wherein said heat chamber cone (121 ) has geometrical conical form with diameters that narrow from the lower part towards the upper part.

3. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said distributor cone (121) has inverse conical geometrical form with respect to the geometrical conical form of the heat chamber cone and has diameters that narrow from the upper part towards the lower part.

4. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said high speed channel (122) has diameter value in a manner corresponding to the upper part of the heat chamber cone (121 ) and to the lower part of the distributor cone (123).

5. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said hood system (12) comprises at least one gas and temperature sensor (125).

6. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said hood system (12) comprises at least one flame feeding module (124).

7. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said hood system (12) comprises at least one air input-output module (126).

8. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said active carbon production system (13) comprises at least one carbon feeding module (131).

9. The flame curtain pyrolysis system (10) according to any one of the preceding claims, wherein said active carbon production system (13) comprises at least one carbon discharge module (132).

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