Downer Pyrolysis Reactor with Locking Zone Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current laboratory-scale pyrolysis equipment is limited in its ability to handle cumbersome feedstocks like lignin, operate under high pressure, and collect all product phases efficiently, particularly for gram-scale research.
Innovation Solution
The apparatus consists of a downer with multiple zones, including a pre-treatment zone, a pyrolysis zone, and a cooling zone, equipped with locking systems for sealing and independent temperature and pressure control, allowing for semi-continuous operation and catalytic upgrading of pyrolysis vapors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dedicated feeding equipment such as screw conveyors is used in pressurized pyrolysis reactors, then feeding capability is improved, but device complexity increases and it becomes difficult to realize for laboratory gram-scale research equipment
Solution Approach 1:
The reactor is divided into multiple independently controllable zones (preheating zone, pyrolysis zone, cooling zone) separated by locking systems. This segmentation allows simple feeding mechanisms to work effectively while each zone performs its specific function independently, avoiding the need for complex continuous feeding equipment.
Solution Approach 2:
The locking systems between zones can dynamically open and close to control the movement of the container through different zones. This dynamic control enables semi-continuous operation where containers are fed simply, processed sequentially through zones, and removed after cooling, eliminating the need for complex continuous feeding mechanisms.
2Device complexity
If batch-wise operation is used in present laboratory-scale pyrolysis equipment, then device complexity is reduced, but productivity decreases and collection of all product phases becomes difficult
Solution Approach 1:
The system enables semi-continuous operation where multiple containers can be processed in sequence through the different zones. While each container undergoes batch processing, the overall system maintains continuous useful action as containers are fed, processed, and removed in an overlapping sequence, improving productivity without requiring complex continuous processing equipment.
3Adaptability or versatility
If high pressure operation is implemented, then hydropyrolysis capability is improved, but device complexity increases and existing laboratory equipment cannot operate under high pressure
Solution Approach 1:
The reactor is segmented into zones with independent pressure control capabilities. The pyrolysis zone can be pressurized independently for hydropyrolysis while other zones operate at different pressures, allowing high pressure operation without requiring the entire system to be complexly pressurized.
Solution Approach 2:
High pressure conditions are applied locally in the pyrolysis zone where needed for hydropyrolysis, rather than requiring the entire reactor system to be designed for high pressure operation. This localized approach reduces overall device complexity while maintaining hydropyrolysis capability.
4Device complexity
If the reactor cannot be operated under high pressure, then device complexity is reduced, but adaptability for hydropyrolysis is limited
Solution Approach 1:
The locking systems and pressure control are designed to be dynamically adjustable, allowing the reactor to operate in different pressure regimes depending on the experimental needs. The system can switch between atmospheric and pressurized operation by controlling the locking systems and pressure regulators, providing adaptability without requiring permanently complex high-pressure infrastructure.
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 setup enables efficient pyrolysis of feedstocks like lignin on a gram-scale, allowing for the collection of all product phases and operation under high pressure, thereby overcoming the limitations of existing equipment.
Implementation Method 1
The apparatus comprises heating means, cooling means and pressurizing means configured to adjust the temperature and pressure of at least the pyrolysis zone independently from the other zones
Implementation Method 2
The apparatus comprises heating means, cooling means and pressurizing means configured to adjust the temperature and pressure of at least the pyrolysis zone independently from the other zones
Implementation Method 3
The apparatus comprises heating means, cooling means and pressurizing means configured to adjust the temperature and pressure of at least the pyrolysis zone independently from the other zones
Implementation Method 4
the at least two locking systems are configured to simultaneously close for sealing the pyrolysis zone
Data Source
AI summary
The invention relates to an apparatus and method for pyrolyzing a feedstock in an open container. The apparatus comprises a downer reactor with an entry located at the top end of the downer for feeding and an exit located at the bottom end of the downer for removing the container from the downer, the downer being divided into at least three vertically arranged zones by at least two locking systems on either side of a middle pyrolysis zone, wherein the at least two locking systems are configured to simultaneously close for sealing the pyrolysis zone, wherein the at least two locking systems are further configured to let through the container in an open position, the apparatus comprising heating means, cooling means and pressurizing means configured to adjust the temperature and pressure of at least the pyrolysis zone independently from the other zones.