Multi-Tubular Pyrolysis Reactor for Heat Transfer and Dust Removal
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Solution Overview
Problem
Current pyrolysis technologies for solid hydrocarbon feedstock face challenges such as low yield of pyrolysis oil, high content of heavy components, poor quality, and high dust content, especially with small-particle feedstock, leading to operational difficulties and inefficiencies in industrial scale-up applications.
Innovation Solution
A pyrolysis apparatus utilizing a multi-tubular reactor design with a gas collecting internal component and regenerative burners, enabling efficient heat and mass transfer, selective cracking of heavy components, and in-situ dust removal, facilitated by self-generated pyrolysis gas combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional reactor size amplification is used for industrial scale-up, then processing capacity increases, but heat transfer efficiency decreases and operational difficulty increases
Solution Approach 1:
The patent divides the industrial reactor into multiple parallel tubular reactors, each operating at optimal scale. This segmentation allows each tube to maintain high heat transfer efficiency while the collective system achieves industrial processing capacity. The multi-tubular configuration with internal gas collecting components ensures uniform heat distribution across all tubes.
Solution Approach 2:
The patent transitions from a single large-volume reactor to a multi-tubular configuration, adding the dimension of parallel processing. This dimensional change allows the system to scale capacity through number of units rather than increasing individual reactor size, thereby maintaining heat transfer efficiency.
2Productivity
If small-particle feedstock is used, then pyrolysis oil yield improves, but dust content increases and pipeline blockage occurs
Solution Approach 1:
The patent introduces a gas collecting internal component as an intermediary structure within the tubular reactor. This component captures dust particles carried by the pyrolysis gas before they can escape or cause blockages. The internal component acts as a mediator between the pyrolysis zone and the gas outlet, removing harmful dust while maintaining oil yield.
3Object-generated harmful factors
If dust removal equipment is added, then dust content decreases, but process complexity increases and oil yield reduces
Solution Approach 1:
The patent merges the dust removal function with the existing reactor structure by integrating a gas collecting internal component into the tubular reactor. This combination eliminates the need for separate dust removal equipment, simplifying the overall process while effectively reducing dust content. The internal component is positioned to capture dust at the source without adding external complexity.
4Stability of the object's composition
If secondary reactions of pyrolysis products are allowed to occur, then gas phase reactions complete, but oil quality deteriorates and yield decreases
Solution Approach 1:
The patent extracts the pyrolysis gas from the reaction zone quickly using the multi-tubular configuration with internal gas collecting components. This rapid removal prevents the gas from undergoing extensive secondary reactions that would degrade oil quality. The structure enables fast gas evacuation while maintaining complete primary pyrolysis reactions.
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 apparatus achieves improved pyrolysis oil yield and quality, reduced dust content, and simplified industrial scale-up by enhancing heat transfer rates and reducing dust carrying, while maintaining energy efficiency.
Implementation Method 1
regenerative burners... self-generated pyrolysis gas combustion
Implementation Method 2
enhancing heat transfer rates... efficient heat and mass transfer
Implementation Method 3
Pyrolysis apparatus for solid hydrocarbon feedstock... thermally decomposed to produce a primary pyrolysis product
Implementation Method 4
an organic substance in the solid hydrocarbon feedstock is thermally decomposed to produce a primary pyrolysis product
Implementation Method 5
gas collecting internal component... in-situ dust removal... reduced dust carrying
Data Source
AI summary
A pyrolysis apparatus for solid hydrocarbon feedstock and a process method thereof are related to a pyrolysis apparatus and a process method thereof. A multi-tubular pyrolysis reactor of the apparatus is composed of one or more tubular pyrolysis reactors that are arranged in a tube-by-tube manner, its heating section being arranged in a heating chamber. A pyrolysis gas obtained from feedstock pyrolysis or an externally supplied fuel gas is combusted in the heating chamber through a regenerative combustion, so as to provide heat for the pyrolytic reaction. A gas collecting internal component is arranged at a center of each tubular pyrolysis reactor, and a pyrolysis gas product is regulated to radially flow across a moving particle bed so as to achieve in-situ filtering dust removal and selective cracking upgrading.