Continuous Pyrolysis Reactor for Rubber Waste Decomposition
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Solution Overview
Problem
Current methods for decomposing rubber products, such as used tires, are inefficient and generate noxious gases, and are limited by batch processing capabilities, which cannot keep pace with the rising volume of waste and do not effectively manage combustion byproducts.
Innovation Solution
A continuous fed pyrolysis reactor system that includes thermal inlets, feed and outlet ports, sealed cylinders operating under partial vacuum, and a conveyor system with a variable speed motor to continuously process rubber products at controlled temperatures between 500°C and 800°C, maximizing the extraction of oil vapor and syngas while chemically decomposing the materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing systems are used to decompose rubber products, then the system can handle the decomposition process, but the processing capacity is limited and cannot keep pace with rising waste volume
Solution Approach 1:
The patent implements a continuous processing system where shredded rubber products are continuously fed into the pyrolysis reactor through a feed hopper and conveyor system, eliminating the loading-unloading cycles of batch processing. The reactor maintains continuous operation with constant material flow through the heating zone, maximizing productivity and eliminating idle time between batches.
Solution Approach 2:
The system employs variable speed conveyors and adjustable feed rates that can dynamically adapt to different processing conditions and waste volumes. The conveyor speed and feed hopper discharge rate are controllable to optimize the continuous flow of material through the reactor, allowing the system to respond flexibly to changing production requirements.
2Object-generated harmful factors
If rubber products are combusted to destroy them, then the waste can be eliminated, but noxious gases such as hydrogen sulfide are generated requiring extensive flue gas treatment
Solution Approach 1:
The patent creates an inert atmosphere within the pyrolysis reactor by maintaining oxygen-deficient conditions during the decomposition process. This prevents complete combustion and the formation of noxious gases like hydrogen sulfide. The reactor is designed as a sealed system with controlled atmosphere, allowing thermal decomposition to occur without oxidation reactions that would generate harmful emissions.
Solution Approach 2:
The system controls the oxygen concentration and temperature parameters within specific ranges to achieve pyrolysis rather than combustion. By maintaining temperatures between 400-800°C and limiting oxygen availability, the process transforms the chemical reactions from oxidative combustion to thermal decomposition, fundamentally changing the product distribution from noxious gases to useful pyrolysis oils and carbon black.
3Productivity
If the conveyor speed is increased to process more material, then productivity improves, but the decomposition efficiency may decrease
Solution Approach 1:
The patent employs variable speed control on the conveyor system, allowing the feed rate to be dynamically adjusted based on processing conditions. The conveyor speed can be optimized for different material types and can be changed during operation to maintain optimal residence time in the reactor, balancing throughput with decomposition quality.
Solution Approach 2:
The system incorporates monitoring and control mechanisms that can detect decomposition efficiency and adjust conveyor speed accordingly. By providing feedback on process conditions and material decomposition state, the system can automatically optimize the feed rate to maintain high efficiency while maximizing productivity.
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 system enables efficient and continuous decomposition of rubber products into carbon black and syngas, effectively managing waste volume and reducing hazardous emissions by optimizing temperature control and conveyor speed to enhance pyrolysis efficiency.
Implementation Method 1
a thermal inlet (1-3) for receiving thermal energy to heat up the continuous fed pyrolysis reactor
Implementation Method 2
a first cylinder (2-1) to partially decompose the inlet product; a second cylinder (2-2) to completely decompose the inlet product
Implementation Method 3
a conveyor means comprising a drag chain to move and drag inlet product through to the first cylinder (2-1) and the second cylinder (2-2)
Implementation Method 4
a variable speed motor (5-0) for driving the conveyor means
Implementation Method 5
the first cylinder (2-1) and the second cylinder (2-2) are sealed and operate under partial vacuum, that is oxygen is below its stoichiometric level to permit combustion
Implementation Method 6
an outlet duct (7-0) for extracting oil vapour and synthesis gas after the inlet product is partially decomposed
Data Source
Figure 1
AI summary
The present invention relates to a carbonization reactor (1 -0) to decompose used rubber products and the like by heating the rubber products under constant high temperature and the reactor comprise a conveyor (2-0) which continuously move and drag the rubber products through cylinders (2-1, 2-2) where the decomposition process takes place to produce recyclable by products such as carbon black, oil vapour and the like.