Char Separator Auger Condensation for Fuel Vapor Purification
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Solution Overview
Problem
Existing methods for removing char particles from liquid fuel are inefficient, as filters clog, distillation is costly and occurs outside the reactor, cyclone systems can't handle small particles, and bag filters fail when exposed to liquid fuel, leading to suboptimal fuel quality.
Innovation Solution
The Char Separator employs three screw conveyor augers in a vertical split tube with controlled temperature and rotation to condense and collect hydrocarbon vapors, allowing char particles to adhere and be returned to the reactor for reprocessing, utilizing a unique clover-shaped construction and controlled heat zones for efficient carbon chain breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filters are used to remove larger particulate matter from fuel, then fuel quality is improved, but filters become clogged and require periodic cleaning
Solution Approach 1:
The patent extracts the harmful char particles from the fuel vapor stream using a cyclone separator before the fuel reaches filtering stages. By removing particles through centrifugal force in the cyclone, the subsequent filters operate cleaner for longer periods, resolving the clogging issue while maintaining fuel quality.
Solution Approach 2:
The cyclone separator performs preliminary particle removal before the fuel enters the filtering system. This preliminary action reduces the particle load on filters, extending their operational life and reducing cleaning frequency while maintaining effective fuel purification.
2Manufacturing precision
If distillation is used to remove carbon matter from fuel, then fuel quality is improved, but production cost increases due to sub-process outside reactor
Solution Approach 1:
The patent merges the particle separation function into the existing reactor system by integrating a cyclone separator directly into the reactor outlet stream. This eliminates the need for separate distillation processes outside the reactor, reducing production complexity while maintaining effective carbon matter removal through the cyclone separation mechanism.
Solution Approach 2:
The cyclone separator serves multiple functions: it separates char particles from fuel vapor, preconditions the fuel stream for subsequent processing, and integrates with the existing reactor system. This multi-functionality reduces the need for separate dedicated distillation equipment, simplifying the overall production process.
3Quantity of substance
If cyclone systems are used to remove particles from fuel vapor, then large particles are removed, but small particles (3 micron or smaller) remain and system complexity increases due to heat source requirements
Solution Approach 1:
The cyclone separator is designed to utilize the existing thermal energy and flow dynamics from the reactor outlet. The system self-regulates by using the inherent pressure and temperature conditions from the reactor to drive the cyclone separation process, eliminating the need for external heat sources while maintaining particle removal capability.
4Manufacturing precision
If bag filters are used to filter fuel vapor, then fuel quality is improved, but filters fail when exposed to liquid fuel due to heat and liquid absorption limitations
Solution Approach 1:
The cyclone separator extracts and removes char particles and condensable vapors before the fuel stream reaches the bag filter. By taking out the problematic components (particles and excess condensables) upstream, the bag filter is protected from exposure to conditions that would cause failure, extending its operational reliability.
Solution Approach 2:
The cyclone separator performs preliminary removal of char particles and excess fuel condensables before the vapor stream enters the bag filter. This preliminary action reduces the load and stress on the bag filter, preventing overheating and liquid saturation that would otherwise cause filter failure.
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 solution effectively removes char particles from fuel vapors, improving fuel quality by recycling and reprocessing char, reducing clogging and cost associated with distillation, and maintaining system integrity under high temperatures.
Implementation Method 1
As the vapors rise and the temperature of the vapors is reduced to the value at where a high carbon chain fuel will condense, it will collect on the augers
Implementation Method 2
the reactor's heat vaporizes the shredded plastic as it was designed to do
Implementation Method 3
cyclone systems are often used and try to remove most of the particles but can only remove large particles
Data Source
AI summary
The present invention relates to an apparatus that is part of a reusable fuel processing unit that allows the absorption of char contained within vapor that is leaving the reactor including a gear box, gearbox housing, support flange and seal, exhaust housing, exhaust port, connecting flange, screw top split housing, vertical steal housing, three augers with drive shafts on each auger contained within the steel housing, discharge flange, support ring, expansion cart, and cam followers.