Carbon Catalyst for Distributed Microwave Pyrolysis

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional pyrolysis systems face challenges in efficiently processing municipal and domestic waste using microwaves due to low thermal response, high energy consumption, and the endothermic nature of high-moisture materials, which limits their application in small to medium-scale, distributed waste management.

Innovation Solution

A distributed pyrolysis device and process utilizing a carbon-based catalyst to absorb microwaves and initiate pyrolysis reactions, with a reactor system that includes a microwave source, anaerobic purging, and a temperature probe, allowing for efficient conversion of waste into carbonaceous by-products, gas, and oil without the need for oxygen, and enabling localized, small to medium-scale waste processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If unassisted microwave processing is used on microwave-transparent waste materials, then the system remains simple and compact, but the energy consumption becomes excessively high and pyrolysis cannot be initiated at low powers

Engineering Contradiction:

Improvesystem simplicityVSAvoidenergy consumption

Core Design Contradiction:

Device complexityVSUse of energy by moving object

Solution Approach 1:

A carbon-based catalyst is introduced as an intermediary substance that absorbs microwaves and converts them to heat, which then transfers to the waste material to initiate pyrolysis. This mediator enables low-power microwave processing of microwave-transparent materials by providing a thermal bridge that overcomes the lack of direct microwave absorption in the waste feedstock.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the physical-chemical parameters of the processing system by adding a carbon-based catalyst with specific properties (high microwave absorption coefficient, thermal stability). This parameter change enables the system to operate at low microwave powers while still achieving effective pyrolysis, resolving the contradiction between system simplicity and energy consumption.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high microwave power is applied to achieve pyrolysis of microwave-transparent materials, then pyrolysis can be initiated, but the energy consumption becomes substantial and economically unviable

Engineering Contradiction:

Improvepyrolysis reaction rateVSAvoidmicrowave power input

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The carbon-based catalyst serves as a microwave-to-heat converter, absorbing microwave energy efficiently and transferring it thermally to the waste material. This intermediary mechanism allows pyrolysis to proceed at low microwave power levels, maintaining productivity while dramatically reducing energy input requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces direct microwave heating (mechanical energy transfer) with a two-step process: microwave absorption by carbon catalyst followed by thermal conduction to waste material. This substitution of heating mechanism enables efficient energy transfer at low power levels, resolving the contradiction between reaction rate and energy input.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If conventional fuel-based heating is used for pyrolysis, then the process is autothermal and energy efficient, but the system becomes large-scale and centralized rather than distributed

Engineering Contradiction:

Improveenergy efficiencyVSAvoidsystem scale

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The microwave pyrolysis system with carbon catalyst enables the process to be self-sufficient at distributed locations. The carbon catalyst continuously absorbs microwave energy and maintains reaction temperatures, allowing the system to serve itself without external fuel input. This self-service capability enables small-scale distributed deployment while maintaining energy efficiency comparable to autothermal conventional systems.

Inventive Principle:

Principle #25Self-service

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

The solution achieves a significant reduction in waste volume, energy-efficient processing, and the production of valuable by-products, such as carbonaceous materials and hydrocarbon oils, with an energy content of 8-22 megajoules/kg, while minimizing energy consumption and operational risks.

Implementation Method 1

a carbon-based catalyst to absorb microwaves, transfer heat to microwave-transparent waste and initiate a pyrolysis reaction

Methodology Applied

Scientific EffectMicrowave absorption: Absorption (EM radiation)

Implementation Method 2

transfer heat to microwave-transparent waste

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

distributed pyrolysis of waste using microwaves as a source of heating

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 4

anaerobic means for purging the reactor vessel of air

Methodology Applied

Scientific EffectAnaerobic conditions: Anaerobic Digestion

Data Source

PatentUS9487708B2Catalyst for distributed batch microwave pyrolysis, system and process thereof

Publication Date: 2016.11.08 PYROWAVE

AI summary

The present document describes a catalyst to initiate microwave pyrolysis of waste, a process for the microwave pyrolysis of waste using the catalyst, as well as a microwave pyrolysis system.