Open-Cell Exhaust Aftertreatment for Pyrolysis Carbon Removal
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Solution Overview
Problem
After pyrolysis reactions, hydrocarbon compounds in exhaust gases partially decompose and settle on surfaces, causing complex cleaning challenges and potential damage to compressor elements due to their high adhesive properties, leading to increased maintenance efforts and downtime.
Innovation Solution
A method involving an open-cell structure where the exhaust gas stream is thermally decomposed at high temperatures, followed by oxidation with oxygen or an oxygen-rich gas mixture to break down hydrocarbons and carbon residues, using a pressure difference and electrical heating to maintain temperatures above 600°C, ensuring complete decomposition and oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pyrolysis is carried out under vacuum or inert atmosphere, then thermal decomposition can be performed, but hydrocarbon compounds accumulate on surfaces causing cleaning complexity and equipment damage
Solution Approach 1:
The patent converts the harmful hydrocarbon deposits into beneficial effects by introducing oxygen to oxidize them into CO and CO2, which are then removed by the vacuum system. The harmful accumulation is transformed into a useful cleaning process that protects equipment while maintaining production continuity
Solution Approach 2:
The patent implements periodic oxygen injection at specific time intervals during the pyrolysis cycle. This periodic action allows the system to alternate between hydrocarbon generation and oxidation phases, preventing accumulation while maintaining equipment reliability without continuous intervention
2Ease of manufacture
If pyrolysis is performed to decompose organic binders, then shaping can be achieved, but undecomposed hydrocarbons settle on compressor surfaces causing adhesion and damage
Solution Approach 1:
The patent introduces oxygen as an intermediary substance that mediates between the hydrocarbon compounds and the equipment surfaces. The oxygen reacts with hydrocarbons in the exhaust gas stream, preventing their direct contact and adhesion to compressor surfaces, thus eliminating the harmful effect while preserving the manufacturing process
Solution Approach 2:
The patent uses oxygen injection to accelerate the oxidation of hydrocarbon compounds. This strong oxidizing action rapidly converts undecomposed hydrocarbons into gaseous oxides that can be easily removed, preventing adhesion to surfaces and protecting equipment from damage
3Productivity
If exhaust gas is discharged directly to environment, then process simplicity is maintained, but hydrocarbon compounds condense and accumulate on discharge surfaces requiring frequent maintenance
Solution Approach 1:
The patent applies preliminary action by injecting oxygen into the exhaust gas stream before it reaches discharge surfaces. This pre-treatment oxidizes hydrocarbon compounds in advance, preventing their condensation and accumulation on surfaces, thereby eliminating the need for frequent maintenance and ensuring continuous production
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
Effectively reduces the accumulation of hydrocarbon compounds on surfaces, minimizing maintenance and preventing damage by ensuring complete thermal decomposition and oxidation of exhaust gas components, thus maintaining equipment integrity and efficiency.
Implementation Method 1
hydrocarbon compounds contained in the respective exhaust gas stream are thermally decomposed by passing the exhaust gas stream released during pyrolysis within a first interval through at least one open-cell structure by means of a pressure difference
Implementation Method 2
oxygen or an oxygen-containing gas mixture is passed through the at least one open-cell structure, and the carbon deposited on the surfaces of the at least one open-cell structure is oxidized at a temperature of at least 600 °C, preferably at least 800 °C, and particularly preferably at least 1000 °C
Implementation Method 3
The open-cell structure can be connected to an electrical voltage source for electrical resistance heating, and the respective minimum temperature can be maintained by means of electrical resistance heating or by means of an electrical AC voltage source and at least one electrical coil
Implementation Method 4
by passing the exhaust gas stream released during pyrolysis within a first interval through at least one open-cell structure by means of a pressure difference between a device in which the respective pyrolysis is carried out and an exhaust gas discharge connected to the environment
Data Source
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AI summary
In this process, hydrocarbon compounds are thermally decomposed by passing the exhaust gas stream released in a first interval through an open-cell structure and maintaining a temperature of at least 600 °C at the at least one open-cell structure, so that the contained hydrocarbon compounds are thermally decomposed and the carbon obtained is deposited on the open-cell structure.After an operating time has elapsed and/or a predefinable threshold value of a pressure difference of pressure P1 and pressure P2 in the flow direction after exiting the at least one open-cell structure has been determined, or a predefinable threshold value of pressure P1 has been determined, the supply of the exhaust gas flow to the at least one open-cell structure is stopped, and then in a second interval oxygen or an oxygen-containing gas mixture is passed through the one open-cell structure and, at a temperature of at least 600 °C, the carbon deposited on the surfaces of the one open-cell structure is oxidized and the oxide(s) formed as well as exhaust gas residues are removed.