Mobile Pyrolysis Reactor with Zone Control
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Solution Overview
Problem
Current continuous feed pyrolysis processes are inefficient, lack control, and are immobile, requiring large amounts of feedstock to be transported to a permanently installed device.
Innovation Solution
A pyrolysis machine with a reactor tube made of steel, ceramic band heaters, resistance coils, and a temperature controller, allowing for temperature regulation and zone control, mounted on a trailer for mobility and efficient processing of plastic feedstock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous feed pyrolysis process is implemented, then processing efficiency is improved, but device complexity and immobility increase
Solution Approach 1:
The reactor tube is divided into multiple heating zones with independent temperature control, allowing different stages of pyrolysis to occur simultaneously at different temperatures. This segmentation improves processing efficiency while maintaining manageable system complexity through modular design
Solution Approach 2:
The system incorporates variable speed control for the screw auger and programmable temperature profiles for each zone, enabling dynamic adjustment of processing parameters to optimize efficiency for different feedstock types and production requirements
2Productivity
If continuous feed pyrolysis process is implemented, then processing efficiency is improved, but controllability deteriorates
Solution Approach 1:
The reactor is divided into multiple independently controlled heating zones, each with its own temperature controller. This allows precise control of temperature at different stages of the pyrolysis process while maintaining continuous operation, resolving the conflict between efficiency and controllability
Solution Approach 2:
Temperature sensors are installed in each zone and connected to controllers that regulate heating elements based on actual temperature readings, providing closed-loop control that maintains precision despite continuous operation
3Productivity
If permanently installed device is used, then processing capacity is improved, but mobility deteriorates
Solution Approach 1:
The pyrolysis system is designed as a mobile unit that can be transported to different locations and operated at various feedstock sources. The standardized reactor design with controlled heating zones maintains processing capacity while the mobility allows the system to serve multiple sites and feedstock types
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 machine achieves efficient and controlled pyrolysis of large quantities of plastic feedstock, enabling transportation and on-site processing, with programmable temperature and speed control for enhanced efficiency.
Implementation Method 1
a plurality of resistance coils located in the ceramic heaters configured to heat the ceramic heaters
Implementation Method 2
Pyrolysis is a process in which hydro-carbon based matter is decomposed in an anaerobic environment by the application of heat
Data Source
AI summary
Disclosed herein is a pyrolysis machine that includes a reactor tube configured to conduct pyrolysis on plastic feedstock, wherein the reactor tube is made of a steel material. The pyrolysis machine includes a plurality of ceramic band heaters located in the reactor tube configured to heat the steel material of the reactor tube. The pyrolysis machine includes a plurality of resistance coils located in the ceramic heaters configured to heat the ceramic heaters. Further, the pyrolysis machine includes a temperature sensor located in the reactor tube and a controller configured to regulate the temperature of the ceramic band heaters.