A system and a method for a continuance process of pyrolysis of plastic

Abstract

A continuous pyrolysis system including a liquefaction container comprising a first input opening, and a first output opening, a pyrolysis container comprising a second input opening, and a second output opening, and a transport part connecting the first output opening of the liquefaction container to the second input opening of the pyrolysis container in a manner that permits only liquid material to enter the pyrolysis container.

Description

[0001] A SYSTEM AND A METHOD FOR A CONTINUANCE PROCESS OF PYROLYSIS OF PLASTIC

[0002] FIELD

[0003] The method and apparatus disclosed herein are related to the field of Pyrolysis, and more particularly but not exclusively, to continuous Pyrolysis of plastic materials.

[0004] BACKGROUND

[0005] Methods and system of pyrolysis are known, however, operating in both batch and continuance modes. Continuous pyrolysis is advantageous over batch pyrolysis. Batch pyrolysis has an inherent disadvantage as it requires cooling before new material can be introduced onto the pyrolysis chamber, and then warming up to reach the pyrolysis temperature.

[0006] However, today the continuous pyrolysis process is always executed in a revolving reactor and has its own problems. Feeding the pyrolytic material in the presence of ambient air may introduce oxygen into the pyrolysis chamber and disturb the pyrolytic process causing low yield as well as blacking of the pyrolysis gas. The revolving reactor increases the introduction of oxygen into the reactor and thus reduces the process efficiency and stability.

[0007] The batch reactor based on a sealed tank revolving vertically or horizontally has a higher efficiency and a stable process. However, suffers a long duty cycle due to the need for cooling after pyrolysis process is terminated, and heating after filling before reaching the pyrolysis temperature.

[0008] There is thus a widely recognized need for, and it would be highly advantageous to have, a system and method for a continuous pyrolysis process, overcoming the above limitations. SUMMARY

[0009] According to one exemplary embodiment there is provided a method and a system for continuous pyrolysis including a pyrolysis container including an input opening, and an output opening, wherein the input opening is operative to receive liquid plastic only, and a heating element arranged to heat the pyrolysis container so that the liquid plastic materials sustain pyrolysis.

[0010] According to another exemplary embodiment there is provided a method and a system for continuous pyrolysis including a liquefaction container comprising an input opening, and an output opening, and a heating element arranged to heat the liquefaction container so that solid plastic materials sustain liquefaction. And wherein the liquefaction container is operative to provide liquid plastic only to an input opening of a pyrolysis container.

[0011] According to yet another exemplary embodiment there is provided a method and a system for continuous pyrolysis including a liquefaction container comprising a first input opening, and a first output opening, a pyrolysis container comprising a second input opening, and a second output opening, a transport part connecting the first output opening of the liquefaction container to the second input opening of the pyrolysis container in a manner that permits only liquid material to enter the pyrolysis container, a first heating element arranged to heat the liquefaction container so that solid plastic materials sustain liquefaction, and a second heating element arranged to heat the pyrolysis container so that liquid plastic materials sustain pyrolysis.

[0012] According to still another exemplary embodiment there is provided a method and a system for continuous pyrolysis including a pyrolysis container comprising a second input opening, and a second output opening, a transport part comprising a first input opening for introducing solid plastic materials, a screw conveyor operative to push liquified plastic material via a first output opening connected to the second input opening of the pyrolysis container, in a manner that permits only liquid material to enter the pyrolysis container, a first heating element arranged to heat the transport part so that solid plastic materials sustain liquefaction, and a second heating element arranged to heat the pyrolysis container so that liquid plastic materials sustain pyrolysis.

[0013] Further according to another exemplary embodiment any of the first heating element and the second heating element is at least one of an electrical heating element, a gas heating element, and a petroleum heating element.

[0014] Yet further according to another exemplary embodiment at least one of the first liquefaction container is located within the first heating element, the second pyrolysis container is located within the second heating element, the first heating element is located within the first liquefaction container, and the second heating element is located within the second pyrolysis container.

[0015] Still further according to another exemplary embodiment the transport part includes at least one of a pipe, a valve, a flow regulator, a faucet, a pump, a gear pumps, and a screw conveyor.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the relevant art. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting. Except to the extent necessary or inherent in the processes themselves, no particular order to steps or stages of methods and processes described in this disclosure, including the figures, is intended or implied. In many cases the order of process steps may vary without changing the purpose or effect of the methods described.

[0017] BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Various embodiments are described herein, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments only, and are presented in order to provide what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the embodiment. In this regard, no attempt is made to show structural details of the embodiments in more detail than is necessary for a fundamental understanding of the subject matter, the description taken with the drawings making apparent to those skilled in the art how the several forms and structures may be embodied in practice.

[0019] In the drawings:

[0020] Fig. 1 is a simplified illustration of a cut through a continuous pyrolysis system; and

[0021] Fig. 2 is a simplified illustration of a cut through a screw-driven continuous pyrolysis system.

[0022] DETAILED DESCRIPTION

[0023] The present embodiments comprise systems and methods for continuous pyrolysis, and particularly, though not limited to, continuous pyrolysis process of plastic materials, such as polyethylene, polypropylene, etc.

[0024] Before explaining at least one embodiment in detail, it is to be understood that the embodiments are not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. Other embodiments may be practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

[0025] In this document, an element of a drawing that is not described within the scope of the drawing and is labeled with a numeral that has been described in a previous drawing has the same use and description as in the previous drawings. Similarly, an element that is identified in the text by a numeral that does not appear in the drawing described by the text, has the same use and description as in the previous drawings where it was described.

[0026] The drawings in this document may not be of any scale. Different figures may use different scales and different scales can be used even within the same drawing, for example different scales for different views of the same object or different scales for the two adjacent objects.

[0027] The terms 'a' or ‘an1, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and / or having, as used herein, are defined as comprising.

[0028] The phrases “at least one” “one or more” and “and / or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C, “at least one of A, B, or C, “one or more of A, B, and C. “one or more of A, B, or C and “A, B, and / or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. The terms “a” or “an entity” refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more' and “at least one' can be used interchangeably herein.

[0029] It is also to be noted that the terms ‘comprising’, ‘including’, ‘containing’, ‘characterized by’, and ‘having’ are all inclusive, open-ended, do not exclude additional, unrecited elements or method steps, and can be used interchangeably. Particularly, these terms may imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term “comprising” such as “comprise” and “comprises”.

[0030] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic that is described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0031] The term ‘coupled’, as used herein, is defined as ‘connected’, although not necessarily directly, and not necessarily mechanically.

[0032] The terms ‘liquefaction’, ‘liquifying’, and ‘melting’ may be used interchangeably to denote the action of turning a solid material into a liquid material, or to the action of turning a solid phase into a liquid phase. Similarly, ‘liquefied’ and ‘liquified’ have the same meaning.

[0033] The terms ‘continuance’, and ‘continuous’ may be used interchangeably to denote a non-stop function, an uninterrupted process, etc.

[0034] Reference is now made to Fig. 1, which is a simplified illustration of a cut through a continuous pyrolysis system 10, according to one exemplary embodiment.

[0035] Pyrolysis system 10 is a combination of two reactors where one reactor is open and tolerate the penetration of oxygen, and the second reactor is a sealed reactor where no oxygen can penetrate. This configuration separates the pyrolysis process into two stages, liquefaction, and cracking (or pyrolysis). This method adopts the advantages of the two methods, being fast like a continuance process and efficient like a batch process.

[0036] Hence, the pyrolysis process is being executed through two stages. In the first stage solid plastic is fed continuously into the first reactor, the “liquification reactor “ The liquified plastic is then fed, also continuously, for example by a pump, into the second stage reactor. This second stage reactor is sealed, so that no oxygen or air can penetrate into it. The liquified plastic is then cracked into a pyrolysis gas.

[0037] As shown in Fig. 1, continuous pyrolysis system 10 may include a first container 11 operating as a melting chamber, or as a liquefaction chamber, and a second container 12 operating as a pyrolysis chamber. The terms ‘chamber’ and ‘container’ may be used herein interchangeably.

[0038] Melting chamber 11 may typically include a first input opening 13 and a first output opening 14. First input opening 13 may be connected to a feeding chamber 15. Solid plastic material 16 may be introduced into melting chamber 11 via feeding chamber 15 and first input opening 13. Feeding chamber 15 may be opened to ambient atmosphere and arranged to receive grinded and / or shredded plastic material.

[0039] It is appreciated that feeding chamber 15 may include a conveyer (not shown in Fig. 1) introducing the plastic materials into feeding chamber 15. For example, such conveyer may be a screw conveyer. One purpose of such conveyer is to introduce plastic materials into feeding chamber 15 in an evenly manner.

[0040] The grinded and / or shredded materials may typically be plastic materials such as polyethylene, polypropylene, etc. These materials may be grinded and / or shredded to pieces of substantially comparable size to achieve even distribution of heat among the grinded and / or shredded particles.

[0041] Pyrolysis chamber 12 may typically include a second input opening 17, and a second output opening 18. Second input opening 17 (of pyrolysis chamber 12) may be connected to first output opening 14 (of melting chamber 11) via a one-way liquid conveyor 19. Second output opening 18 may be used to eject useful gaseous material from pyrolysis chamber 12.

[0042] It is appreciated that liquid conveyor 19 may be arranged to operate as a transport part conveying liquid plastic only, and not to convey any gaseous material from melting chamber 11 to pyrolysis chamber 12. It is appreciated that liquid conveyor 19 may be arranged to transport liquid plastic only when it is filled with liquid.

[0043] The first container 11 (melting chamber 11) may be provided in a first heating container 20. Similarly, the second container 12 (pyrolysis chamber 12) may be provided in a second heating container 21. Any method of heating may be used in any of the heating containers 20 and 21, such as electric heater, gasoline heater, oil heater, gas heater, etc. Fig. 1 shows a burner 22 for each of heating containers 20 and 21. It is appreciated that any of the heating means may be provided within and / or inside the respective container (11 and / or 12) rather than around the respective container.

[0044] The first container 11 (melting chamber 11) may be typically heated to 110 to 180 Celsius degrees to provide liquefaction of plastic materials 16 into plastic liquid 23. The second container 12 (pyrolysis chamber 12) may be heated to 380 to 500 Celsius degrees to provide pyrolysis of plastic liquid 22 into pyrolytic gas 24. However, any heating temperature is contemplated according to the liquefaction and pyrolysis needs as described above.

[0045] Pyrolytic gas 24 may be used as is or can be transferred to container 25 that may operate as a condenser, converting pyrolytic gas 24 into pyrolytic liquid 26, and as a storage of the pyrolytic liquid 26. Pump 27 may then provide pyrolytic liquid 26 to an external reservoir or to any external use.

[0046] The second container 12 (pyrolysis chamber 12) may operate in either positive pressure (above ambient pressure) or negative pressure (below ambient pressure, vacuum). Using positive pressure (typically about few millibars above ambient pressure) may operate without pump 27. Using negative pressure may require a vacuum pump 27. Liquid conveyor 19 may have the form of a pipe and may use gravity to move liquid plastic 23 from first container 11 (melting chamber 11) to second container 12 (pyrolysis chamber 12). For example, where the liquid level in the first container 11 is higher than the liquid level in the second container 12. Liquid conveyor 19 may also include a flow regulator, or controller, for example in the form of a faucet. Alternatively, or additionally, liquid conveyor 19 may include a liquid pump, for example, a gear pump or a screw conveyor.

[0047] It is appreciated that liquid conveyor 19 may also be heated, either by any of heating containers 20 and 21 or by a special heating apparatus (not shown in Fig. 1).

[0048] It is appreciated that any of the first container 11 (melting chamber 11) and / or the second container 12 (pyrolysis chamber 12) may include a stirrer (blender, mixer, not shown in Fig. 1).

[0049] It is appreciated that any of the first container 11 (melting chamber 11) and / or the second container 12 (pyrolysis chamber 12) and / or the liquid conveyor 19 may include various measuring devices (not shown in Fig. 1) such as temperature measuring device(s), liquid height measuring device(s), flow measuring device(s), pressure measuring device(s), etc. It is appreciated that any of the measuring devices may be coupled to one or more computerized controlled s) (not shown in Fig. 1).

[0050] Reference is now made to Fig. 2, which is a simplified illustration of a cut through a screw-driven continuous pyrolysis system 28, according to one exemplary embodiment.

[0051] As an option, the illustration of Fig. 2 may be viewed in the context of the previous Figure. Of course, however, the illustration of Fig. 2 may be viewed in the context of any desired environment. Further, the aforementioned definitions may equally apply to the description below.

[0052] As shown in Fig. 2, screw-driven continuous pyrolysis system 28 may include a feeding chamber 29 through which solid plastic materials 16 are fed to screw conveyor 30. Screw conveyor 30 has an input opening 31 and an output opening 32 that is connected to second container (pyrolysis chamber) 12. Screw conveyor 30 is driven by motor 33 and is heated by heater 34.

[0053] Heater 34 may heat screw conveyor 30 to 110 to 180 Celsius degrees to provide liquefaction of plastic materials 16 into plastic liquid 35. Such as in continuous pyrolysis system 10, heater 34 may use any heating technology. Screw conveyor 30 may be operative as a transport part, conveying liquid plastic only, and not introducing any gaseous material from melting chamber 11 to pyrolysis chamber 12.

[0054] It is appreciated that screw conveyor 30 may operate as both meting chamber 11 and conveyor 19 of continuous pyrolysis system 10. Second container (pyrolysis chamber) 12 and the rest of pyrolysis system 28 may operate in a similar manner to continuous pyrolysis system 10.

[0055] It is therefore appreciated that the continuous pyrolysis system, whether according to pyrolysis system 10, or pyrolysis system 28, may include a pyrolysis chamber 12 (Second container) which input may receive liquified plastic only. That is without any gaseous material, and particularly without oxygen. To achieve this requirement, the conveyor, or pipe feeding the input of the pyrolysis chamber 12 may be filled up with liquid plastic 23, so that nothing but liquid plastic 23 may enter pyrolysis chamber 12.

[0056] It is appreciated that certain features, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

[0057] Although descriptions have been provided above in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation, or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art.

Claims

CLAIMS:What is claimed is:

1. A system for continuous pyrolysis comprising: a pyrolysis container comprising an input opening, and an output opening, wherein the input opening is operative to receive liquid plastic only; and a heating element arranged to heat the pyrolysis container so that the liquid plastic materials sustain pyrolysis.

2. A system for continuous pyrolysis comprising: a liquefaction container comprising an input opening, and an output opening; and a heating element arranged to heat the liquefaction container so that solid plastic materials sustain liquefaction; wherein the liquefaction container is operative to provide liquid plastic only to an input opening of a pyrolysis container.

3. A system for continuous pyrolysis comprising: a liquefaction container comprising a first input opening, and a first output opening; a pyrolysis container comprising a second input opening, and a second output opening; a transport part connecting the first output opening of the liquefaction container to the second input opening of the pyrolysis container in a manner that permits only liquid material to enter the pyrolysis container; a first heating element arranged to heat the liquefaction container so that solid plastic materials sustain liquefaction; and a second heating element arranged to heat the pyrolysis container so that liquid plastic materials sustain pyrolysis.

4. A system for continuous pyrolysis comprising: a pyrolysis container comprising a second input opening, and a second output opening;a transport part comprising a first input opening for introducing solid plastic materials, a screw conveyor operative to push liquified plastic material via a first output opening connected to the second input opening of the pyrolysis container, in a manner that permits only liquid material to enter the pyrolysis container; a first heating element arranged to heat the transport part so that solid plastic materials sustain liquefaction; and a second heating element arranged to heat the pyrolysis container so that liquid plastic materials sustain pyrolysis.

5. The continuous pyrolysis system according to any of claims 1 to 4, wherein any of the first heating element and the second heating element is at least one of electrical heating element; gas heating element; and petroleum heating element.

6. The continuous pyrolysis system according to any of claims 1 to 4, wherein at least one of the first liquefaction container is located within the first heating element; the second pyrolysis container is located within the second heating element; the first heating element is located within the first liquefaction container; and the second heating element is located within the second pyrolysis container.

7. The continuous pyrolysis system according to any of claims 3 and 4, wherein the transport part comprises at least one of a pipe; a valve; a flow regulator; a faucet; a pump; a gear pumps; and a screw conveyor.

8. A method of continuous pyrolysis, the method comprising: providing a system for continuous pyrolysis comprising: a liquefaction container comprising a first input opening, and a first output opening; a pyrolysis container comprising a second input opening, and a second output opening; a transport part connecting the first output opening of the liquefaction container to the second input opening of the pyrolysis container in a manner that permits only liquid material to enter the pyrolysis container; a first heating element arranged to heat the liquefaction container so that solid plastic materials sustain liquefaction; and a second heating element arranged to heat the pyrolysis container so that liquid plastic materials sustain pyrolysis; feeding solid plastic materials into the first input opening; and extracting fluid plastic material from the second output opening.

9. A method of continuous pyrolysis, the method comprising: providing a system for continuous pyrolysis comprising: a pyrolysis container comprising a second input opening, and a second output opening; a transport part comprising a first input opening for introducing solid plastic materials, a screw conveyor operative to push liquified plastic material via a first output opening connected to the second input opening of the pyrolysis container, in a manner that permits only liquid material to enter the pyrolysis container; a first heating element arranged to heat the transport part so that solid plastic materials sustain liquefaction; and a second heating element arranged to heat the pyrolysis container so that liquid plastic materials sustain pyrolysis; feeding solid plastic materials into the first input opening; and extracting fluid plastic material from the second output opening.

10. The method according to and of claims 8 and 9, wherein any of the first heating element and the second heating element is at least one of: electrical heating element; gas heating element; and petroleum heating element.

11. The method according to and of claims 8 and 9, wherein at least one of: the first liquefaction container is located within the first heating element; the second pyrolysis container is located within the second heating element; the first heating element is located within the first liquefaction container; and the second heating element is located within the second pyrolysis container.

12. The method according to and of claims 8 and 9, wherein the transport part comprises at least one of: a pipe; a valve; a flow regulator; a faucet; a pump; a gear pumps; and a screw conveyor.

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