Char Collector Water Gas Trap for Pyrolysis Safety
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Solution Overview
Problem
Existing char collectors in pyrolysis systems face challenges with handling high-temperature char, particularly due to finely divided particles that are flammable and prone to spontaneous combustion, and inefficiencies in cooling and mechanical airlock mechanisms.
Innovation Solution
A char collector design featuring a container with a water-filled gas trap and a longitudinal conveyor unit, where hot char is introduced at the top and cooled by mixing with water, allowing gravity-assisted transfer to a lower outlet, and incorporating sensors for temperature and moisture control to prevent gas passage and ensure safe handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical airlocks are used to handle hot char, then char can be transferred from high-temperature zones, but the device complexity increases and reliability decreases due to moving parts
Solution Approach 1:
The patent removes the mechanical airlock component entirely from the system. Instead of using a mechanical device to transfer char between pressure zones, the system uses a fluidized bed reactor design where char is continuously circulated through the reaction zone and then discharged through a simple gravity-fed outlet, eliminating complex moving parts while maintaining reliable operation
Solution Approach 2:
The patent replaces the mechanical airlock system with a fluid-based solution. Char transfer is achieved through fluidized bed dynamics and gravity-driven flow rather than mechanical sealing and pumping mechanisms, substituting complex mechanical systems with simpler fluid dynamics-based transport
2Reliability
If char is cooled efficiently, then safety improves by preventing spontaneous combustion, but the cooling process time increases
Solution Approach 1:
The patent performs preliminary cooling by introducing cooling media (such as inert gas or liquid) directly into the char discharge stream as it leaves the reactor. This immediate cooling action occurs at the point of discharge, preventing the char from reaching temperatures that would cause spontaneous combustion during subsequent handling and storage operations
Solution Approach 2:
The patent uses an intermediary cooling medium (inert gas or liquid) that is introduced between the hot char and the ambient environment. This intermediary substance absorbs heat from the char and prevents direct contact between hot char and oxygen-containing air, enabling rapid cooling without extending the overall process time
3Reliability
If fines are removed from char, then handling safety improves, but the productivity decreases due to material loss
Solution Approach 1:
The patent modifies the physical parameters of the char particles through controlled grinding and classification processes. By adjusting particle size distribution and morphology, the system maintains the safety benefits of reduced fines while maximizing the recovery and utilization of combustible material, thereby balancing safety requirements with productivity concerns
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 effectively cools and handles char by maintaining a moisture content above 15 wt% and temperature between 50-80°C, preventing spontaneous combustion and eliminating the need for mechanical airlocks, thus enhancing safety and efficiency in char collection.
Implementation Method 1
hot char is introduced at the top and cooled by mixing with water
Implementation Method 2
cooled by mixing with water
Implementation Method 3
allowing gravity-assisted transfer to a lower outlet
Implementation Method 4
maintaining a moisture content above 15 wt% and temperature between 50-80°C, preventing spontaneous combustion
Data Source
AI summary
The present invention provides a char collector (1) for a pyrolysis system (2), the pyrolysis system (2) featuring a pyrolysis reactor (17) comprising a hot char outlet (3), the char collector comprises a container (4) and a longitudinal char conveyor unit (5), and —the container (4) comprises a chamber (6), a first inlet (7) connectable to the hot char outlet (3) and a first outlet (8), wherein the first inlet (7) is arranged in an upper portion of the chamber (6) and the first outlet (8) is arranged in a lower portion of the chamber (6); and —the char conveyor unit (5) comprises a first end section (9) connected to the first outlet (8), a second end section (10) featuring a second outlet (11) for cooled char and a conveying mechanism (12) configured to transport char from the first end section (9) to the second outlet (11) during use; wherein the second outlet (11) is at a level above the first outlet (8), such that a gas trap is formed between the first inlet (7) and the second outlet (11) when the chamber (6) is filled with water up to a level above the first outlet (8) during use.