Alternating Thermal Reactors for Organic Waste Heat Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrothermal carbonization systems for organic waste treatment are inefficient due to heat energy loss and complex multi-stage processes, leading to reduced energy efficiency and increased operational costs, especially in space-constrained environments like marine vessels.
Innovation Solution
A sequenced hydrothermal carbonization process using two parallel thermal reactors with alternating batch feeding and energy transfer through steam and water circulation between reactors, optimizing energy use by reusing heat energy from preceding batches and employing a heat exchange circuit for cooling and energy recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heat exchanger is used for pre-heating feeding material by recovering heat from discharged waste sludge, then energy recovery is achieved, but organic material accumulates on heat exchanger surfaces lowering energy efficiency
Solution Approach 1:
The patent extracts the heat recovery function from a traditional heat exchanger and relocates it to the reactor system itself. The discharged waste sludge is directly fed into the reactor where it undergoes hydrothermal carbonization, and the heat generated is retained within the reactor system to pre-heat incoming feed material, eliminating the separate heat exchanger component that suffers from organic accumulation.
Solution Approach 2:
The patent merges the hydrothermal carbonization process with the heat recovery function into a single integrated reactor system. The reactor serves dual purposes: converting organic waste to bio-char and simultaneously recovering heat for pre-heating feed material, thereby eliminating the need for separate heat exchange equipment where organic accumulation occurs.
2Productivity
If multi-stage thermal carbonization systems are implemented, then treatment capability is improved, but system complexity increases
Solution Approach 1:
The patent combines multiple process stages into a single reactor system. The reactor performs hydrothermal carbonization of organic waste while simultaneously recovering heat and using it for pre-heating incoming feed material. This integration maintains comprehensive treatment capability while eliminating the complexity of multiple separate stages and interconnecting equipment.
Solution Approach 2:
The reactor is designed as a multi-functional unit that simultaneously performs organic waste conversion to bio-char, heat recovery from discharged sludge, and pre-heating of incoming feed material. This universal design consolidates multiple functions into one device, reducing overall system complexity while maintaining full treatment capability.
3Loss of energy
If conventional heat recovery systems are used, then some energy is recovered, but considerable heat energy is still lost
Solution Approach 1:
The patent establishes a continuous heat circulation system where heat is constantly recovered from discharged waste sludge and immediately used to pre-heat incoming feed material. This continuous heat exchange process minimizes thermal losses by maintaining constant heat flow within the system, ensuring that useful thermal energy is continuously utilized rather than being lost to the environment.
Solution Approach 2:
The system is designed to be self-sufficient in heat management, where the heat generated from hydrothermal carbonization of discharged sludge automatically serves to pre-heat the incoming feed material. The system uses its own internal heat flow to sustain the process, minimizing external energy input and reducing overall heat energy loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances energy efficiency by reusing heat energy within the system, reducing the need for external energy sources and maintaining high temperatures and pressures, resulting in a compact and cost-effective treatment process suitable for marine vessels.
Implementation Method 1
heating and pressurizing for the thermal hydrolysis process is carried out by supplying steam from the first thermal reactor to the second thermal reactor or from the second thermal reactor to the first thermal reactor in an alternating manner
Implementation Method 2
hot and pressurized water from the first thermal reactor is supplied to the second thermal reactor or from the second thermal reactor to the first thermal reactor in an alternating manner
Implementation Method 3
the bio-char sludge is cooled in the bio-char cooler by a heat exchange circuit
Data Source
AI summary
Methods and systems for treatment of organic waste by means of hydrothermal carbonization include a mixing tank for receiving organic waste. A first batch of mixed wet waste is fed from the mixing tank to a first thermal reactor to undergo thermal hydrolysis. A second batch of mixed wet waste is fed from the mixing tank to a second thermal reactor to undergo thermal hydrolysis. Bio-char sludge is fed in an alternating manner from the first and second thermal reactors to a bio-char cooler. To save energy, hot and pressurized water from the first thermal reactor is subsequently supplied to the second thermal reactor or from the second thermal reactor to the first thermal reactor in an alternating manner for the respective hydrolysis processes.