Partitioned Pyrolysis Reactor for Uniform Char Heating
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Solution Overview
Problem
Existing pyrolysis reaction systems face issues with unsatisfactory heat transfer, particularly in larger scale reactors, leading to poor heat distribution and inconsistent quality of char products, and previous methods either require external energy input or result in unsatisfactory carbonaceous products due to exothermic reactions.
Innovation Solution
A pyrolysis reaction system with a partition between the pyrolysis chamber and a gas reactor, featuring apertures for fluid communication, allowing heat transfer by convection and conduction, and a gas reactor with controlled oxygen introduction for temperature regulation, enabling internal heat provision through combustion or carbon deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heat transfer is improved by using a shell-and-tube heat exchanger arrangement, then heat input to pyrolysis chamber is enhanced, but heat distribution remains poor and pyrolysis rate is low in larger scale reactors
Solution Approach 1:
The partition wall is segmented with multiple apertures distributed across its surface, allowing heat to be transferred to multiple locations simultaneously. This segmentation of the heat transfer interface enables uniform heat distribution throughout the pyrolysis chamber, resolving the issue of poor heat distribution in large-scale reactors while maintaining efficient heat input.
Solution Approach 2:
The partition wall with apertures acts as an intermediary structure between the combustion chamber and pyrolysis chamber. It facilitates direct heat transfer from combustion gases to the pyrolysis zone while maintaining physical separation, enabling efficient and uniform heat distribution without requiring complex heat exchanger arrangements.
2Temperature
If combustion reactions are allowed to occur in the pyrolysis chamber to control temperature, then temperature control is improved, but char product quality deteriorates due to exothermic oxidation
Solution Approach 1:
The reactor is divided into two separate chambers: a combustion chamber for exothermic reactions and a pyrolysis chamber for endothermic reactions. The partition wall with apertures allows thermal energy transfer while preventing mixing of reactants and products. This spatial segmentation enables independent optimization of each chamber's chemistry, maintaining char quality while achieving temperature control.
Solution Approach 2:
The partition wall serves as a thermal intermediary that transfers heat from the combustion chamber to the pyrolysis chamber without allowing direct contact between combustion gases and pyrolysis materials. This intermediary structure enables temperature control through heat transfer while preventing oxidative degradation of char products.
3Productivity
If external energy input is used to drive pyrolysis, then pyrolysis reaction is maintained, but energy efficiency decreases and external energy supply is required
Solution Approach 1:
The system merges the combustion process and pyrolysis process into a single integrated reactor system. The combustion chamber and pyrolysis chamber are coupled through the partition wall with apertures, allowing the exothermic combustion reactions to directly provide thermal energy to the endothermic pyrolysis reactions. This merging eliminates the need for external energy input while maintaining high pyrolysis reaction rates.
Solution Approach 2:
The system is designed to be self-sufficient by using the energy released from combustion of pyrolysis products (or separate fuel) to drive the pyrolysis reactions. The partition wall enables internal heat recycling, making the system self-serviceable without external energy supply while maintaining productive pyrolysis operation.
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
Enhances heat transfer efficiency, improves char product quality, and eliminates the need for external energy input, while maintaining controlled pyrolysis temperatures and producing high-quality carbonaceous products.
Implementation Method 1
Heat transfer by conduction
Implementation Method 2
Heat transfer by convection
Implementation Method 3
combustion of the pyrolysis gas or a separate fuel
Implementation Method 4
pyrolysis reaction of a pyrolysable organic feed to produce a carbonaceous product and a pyrolysis gas
Data Source
Figure 1~1A
Figure 2~2A
Figure 3
AI summary
The invention provides a pyrolysis reaction system, the system comprising: a pyrolysis chamber comprising a feed inlet, a gas inlet and a product outlet, wherein the pyrolysis chamber is configured i) to receive a pyrolysable organic feed and an inert gas via the feed inlet and gas inlet respectively, ii) to pyrolyse the organic feed at a pyrolysis temperature to produce a carbonaceous pyrolysis product and a pyrolysis gas, wherein the pyrolysis gas will combine with the inert gas to form a gas mixture having a pyrolysis chamber pressure in the pyrolysis chamber, and iii) to discharge the carbonaceous pyrolysis product via the product outlet; a gas reactor configured to react the pyrolysis gas by combustion and/or carbon deposition at a gas reaction temperature and a gas reactor pressure; and a first partition defining a boundary between the pyrolysis chamber and the gas reactor, the first partition comprising a plurality of first apertures to provide fluid communication between the pyrolysis chamber and the gas reactor, wherein the pyrolysis reaction system is operable with the gas reactor pressure less than the pyrolysis chamber pressure such that the gas mixture flows from the pyrolysis chamber to the gas reactor through the first apertures, thereby providing at least a portion of the pyrolysis gas for reaction in the gas reactor.