Helical Scraper Stirring for Continuous Pyrolysis Residue Removal
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Solution Overview
Problem
Pyrolytic reactors face challenges in efficiently removing solid inert residues (SIR) such as clay and talc, which remain in the reactor during the pyrolysis process, leading to operational inefficiencies and potential shutdowns.
Innovation Solution
A plastic conversion vessel equipped with a conveying mechanism featuring rotatable shafts with scraper blades and retractable auxiliary scraper blades that move solid inert residues through the reactor, utilizing helical rakes and sweeping devices to ensure complete removal of SIR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pyrolysis operation is used, then plastic and hydrocarboneous waste material is vaporized to yield commercial products, but solid inert residues remain in the reactor and must be removed by shutdown
Solution Approach 1:
The patent introduces a rotating conveying mechanism with scraper blades that dynamically moves solid inert residues through the reactor during operation. The system transitions from static residue accumulation to dynamic residue transport, enabling continuous operation without shutdowns for manual or mechanical residue removal.
Solution Approach 2:
The conveying mechanism operates continuously during the pyrolysis process, maintaining uninterrupted vaporization of waste material. The scraper blades continuously scrape and transport residues through the reactor, ensuring that the useful pyrolysis action continues without interruption for residue clearance.
2Reliability
If solid inert residues are not removed, then continuous operation is maintained, but operational efficiency decreases and shutdowns are required
Solution Approach 1:
The system uses the existing thermal field and mechanical rotation to automatically transport and remove residues. The scraper blades utilize the reactor's thermal energy and rotational motion to convey residues through the heating zones, eliminating the need for external intervention or shutdowns to maintain operational efficiency.
3Manufacturing precision
If scraper blades are added to convey residues, then complete removal of solid inert residues is achieved, but device complexity increases
Solution Approach 1:
The conveying mechanism serves multiple functions: it conveys solid inert residues through the reactor, scrapes material from the reactor walls, and integrates with the existing rotational structure. This multi-functionality reduces the need for separate dedicated residue removal systems, thereby limiting the increase in overall device complexity.
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 effectively moves and removes solid inert residues, enhancing the efficiency and continuous operation of the pyrolysis process by ensuring complete vaporization and discharge of non-volatile materials.
Implementation Method 1
said attached scraper blades, independently, having a height so that they can scrape the bottom of said vessel upon rotation of said conveying device
Implementation Method 2
Pyrolytic reactors generally transform various plastic and hydrocarboneous waste materials into one or more substances by heat alone, that is without any oxidation
Implementation Method 3
the plastic and hydrocarboneous waste material is generally evaporated to yield various different products that have commercial use
Data Source
AI summary
A plastic pyrolytic conversion vessel comprises a conveying mechanism for moving a liquid, or a semi-molten, or a molten waste material, or a solid inert residue, or any combination thereof through the vessel. During pyrolyzation of the waste material, the same is heated and vaporized and undergoes in situ chemical reactions comprising cracking, recombination, reforming, recracking, and the like, and is subsequently removed from the vessel. A plurality of scraper blades serve to mix the liquid, or the semi-molten, or the molten waste material, or a solid inert residue, or any combination thereof and convey the waste material forward toward a vessel egress. In another embodiment, one or more sweeping devices serve to move forward the waste material that is located between adjacent rotating conveyor devices.