Induction Heated Fluidized Bed Pyrolysis Reactor
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Solution Overview
Problem
Existing pyrolysis reactor systems face challenges with unwanted deposit build-up and temperature gradients, leading to inefficiencies and maintenance issues when treating carbonaceous waste materials like plastic and biomass.
Innovation Solution
A fluidised bed pyrolysis reactor system using an induction heater assembly to inductively heat particulate material susceptible to inductive heating, achieving temperatures from 350° C to 800° C and providing efficient, uniform heating without the need for combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating methods (gas burners, induction heating elements) are used in pyrolysis reactors, then heating capability is provided, but unwanted deposit build-up occurs on heated surfaces
Solution Approach 1:
The patent replaces conventional contact-based heating methods (gas burners, external induction heating elements) with a magnetic field-based heating system. Magnets are embedded within the particulate material itself, allowing heating through magnetic field interaction without direct contact between heating elements and material surfaces, thereby eliminating deposit build-up on heating surfaces.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the heating source and the particulate material. The magnetic field penetrates through the material without requiring physical contact, enabling heat transfer without the formation of deposits on heating surfaces while maintaining effective heating capability.
2Temperature
If conventional heating methods are used in pyrolysis reactors, then heating is provided, but temperature gradients form within the reactor zone
Solution Approach 1:
The patent distributes heating capability locally throughout the particulate material by embedding magnets within the material itself. This ensures that heat is generated at multiple locations simultaneously, creating uniform temperature distribution throughout the reactor zone rather than creating temperature gradients from external heating sources.
Solution Approach 2:
The heating function is segmented into multiple distributed magnetic elements within the particulate material rather than relying on a single external heating source. This segmentation of the heating mechanism ensures uniform heat distribution throughout the material and prevents the formation of temperature gradients.
3Productivity
If existing reactor designs are used, then pyrolysis processing is achieved, but maintenance difficulty increases due to deposit accumulation
Solution Approach 1:
The patent replaces contact-based heating systems with a non-contact magnetic field heating system, eliminating the formation of deposits on heating surfaces. This substitution dramatically reduces maintenance requirements by removing the source of deposit accumulation that would otherwise require frequent cleaning and maintenance interventions.
4Use of energy by moving object
If combustion methods are used for heating, then energy efficiency is achieved, but carbon footprint increases
Solution Approach 1:
The patent replaces combustion-based heating with magnetic field-based heating. This substitution eliminates carbon emissions associated with fuel combustion while maintaining energy efficiency through direct magnetic induction of heat within the particulate material, thereby reducing the carbon footprint of the pyrolysis process.
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 achieves efficient and uniform heating, reduces deposit build-up, and simplifies maintenance by directly heating particulate material, thereby improving energy efficiency and reducing carbon footprint.
Implementation Method 1
an induction heater assembly configured to inductively heat said particulate material susceptible to inductive heating
Data Source
AI summary
A reactor system for pyrolysis of carbonaceous waste, a method of treating waste comprising carbonaceous waste by pyrolysis in the reactor system, and uses of particulate material in the reactor system and/or method, are provided. The reactor system comprises a fluidised bed pyrolysis reactor. The fluidised bed pyrolysis reactor comprises a shell defining a heating chamber, the heating chamber having a fluidised bed zone configured to contain a fluidised bed of particulate material comprising particulate material susceptible to inductive heating. The reactor system also comprises a pyrolysis induction heater assembly comprising an induction emitter configured to inductively heat the particulate material. The shell of the reactor is made from an inductively inert material.