Molten Salt Pyrolysis Reactor With Zigzag Furnace for Continuous Feeding
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Solution Overview
Problem
Conventional pyrolysis technologies face issues with batch-type processes that limit continuous feeding, uneven heating leading to clogging and adhesion, and inefficient energy consumption due to unidirectional transport mechanisms in pyrolysis furnaces.
Innovation Solution
A multi-stage continuous pyrolysis reactor using molten salt with a zigzag pyrolysis furnace and baffle plates in molten salt circulation passages, along with controlled temperature and transport speed, ensures uniform waste distribution and prevents clogging, enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a batch-type process is used to maintain vacuum inside the heating furnace, then pyrolysis can be performed under controlled conditions, but continuous feeding of waste materials is not allowed, reducing workability and productivity
Solution Approach 1:
The heating furnace is divided into multiple heating zones (first heating zone, second heating zone, third heating zone) with different temperature ranges. This segmentation allows different stages of pyrolysis to occur simultaneously in different zones, enabling continuous feeding while maintaining vacuum conditions in each zone.
Solution Approach 2:
The patent implements a continuous pyrolysis process where waste materials are continuously fed through the heating furnace and processed through multiple heating zones. The vacuum pump operates continuously to maintain vacuum conditions throughout the process, eliminating the batch-type operation limitations.
2Speed
If unidirectional transport mechanism is used in pyrolysis furnace, then waste materials can be moved through the furnace, but uneven heating occurs leading to clogging and adhesion
Solution Approach 1:
The patent employs a zigzag-shaped heating furnace instead of a straight unidirectional path. This asymmetric design causes the waste materials to follow a zigzag trajectory, exposing different portions of the material to heating zones at different times and improving overall heating uniformity while preventing localized clogging and adhesion.
Solution Approach 2:
The transport path is changed from a simple linear one-dimensional path to a zigzag two-dimensional path. This dimensional change increases the effective heating surface area and ensures more uniform heat distribution throughout the waste materials during transport.
3Quantity of substance
If separation unit based on density is used for vapor separation, then gas can be separated into heavy oil gas and diesel gas, but the separation process does not proceed smoothly, reducing productivity and increasing energy consumption
Solution Approach 1:
The patent implements a multi-stage condensation system where different condensation temperatures are applied at different stages. The first condensation unit operates at a higher temperature to condense heavy components, while subsequent units operate at progressively lower temperatures. This local differentiation of condensation conditions improves separation efficiency and maintains high productivity.
Solution Approach 2:
The separation process utilizes changes in temperature and pressure parameters across multiple condensation units. By progressively lowering the temperature and adjusting pressure in each subsequent condensation stage, the system efficiently separates different hydrocarbon components based on their condensation points, improving both separation quality and processing speed.
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 reactor achieves efficient pyrolysis with reduced time and costs, increased yield, and lower ash content by differential temperature control and stable molten salt flow, promoting smooth waste movement and uniform distribution.
Implementation Method 1
a molten salt circulation unit (400) connected to an exterior of the reactor body (100)
Implementation Method 2
configured to pyrolyze polymer waste while moving in a zigzag path
Implementation Method 3
heat transfer efficiency of the molten salt is improved
Data Source
AI summary
Disclosed is a multi-stage continuous pyrolysis reactor using molten salt, and more specifically to a multi-stage continuous pyrolysis reactor that thermally decomposes polymer waste, such as waste plastics, under anaerobic or oxygen-deficient conditions. The multi-stage continuous pyrolysis reactor using molten salt according to the present invention comprises: a reactor body (100), a multi-stage pyrolysis furnace (200), a drive sprocket (330), a driven sprocket (340), a chain (350), a plurality of transport members (360), and a molten salt circulation unit (400).