Thermochemical Reactor for Plastic Waste Pyrolysis
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Solution Overview
Problem
Current processes for converting plastic waste into liquid fuel face high energy consumption and long processing times, making them inefficient and economically unfeasible, with existing systems also being inflexible and not scalable or transportable.
Innovation Solution
A thermochemical reactor system that uses intermittent pulses of energy to heat the plastic waste, achieving thermocracking at reduced energy consumption and allowing for the efficient production of liquid fuel with shorter processing times, and the ability to be configured as both a mobile and fixed plant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional continuous heating processes are used to convert plastic waste into liquid fuel, then the conversion is thorough and complete, but the energy consumption is high and processing time is long
Solution Approach 1:
The patent applies periodic pulsed heating instead of continuous heating to reduce energy consumption while maintaining effective thermocracking. The system uses intermittent energy pulses at controlled intervals to break down plastic polymers, achieving the desired conversion with significantly lower energy input compared to conventional continuous heating methods.
Solution Approach 2:
The invention changes the heating parameters from continuous constant temperature to pulsed variable temperature cycles. By adjusting the pulse duration, frequency, and intensity, the system optimizes the thermocracking process to reduce both energy consumption and processing time simultaneously, transforming the thermal processing parameters to achieve better efficiency.
2Adaptability or versatility
If existing thermochemical systems are designed for fixed installation, then the processing capacity is sufficient, but the systems are not transportable or scalable
Solution Approach 1:
The patent divides the thermochemical processing system into modular segmented units that can be independently configured. The reactor, heating system, and fuel collection components are designed as separate modules that can be assembled in different configurations depending on the desired processing capacity, enabling both transportability and scalability without increasing overall system complexity.
Solution Approach 2:
The system is designed with universal multi-functional components that can serve different purposes based on configuration. The same basic reactor design can be adapted for various plastic waste types and scaled from small portable units to large fixed installations, making the system versatile and adaptable to different application requirements without redesigning the entire system.
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 system achieves a significant reduction in energy consumption, shorter processing times, and scalability, producing a liquid fuel with properties similar to kerosene or diesel, while being economically viable and environmentally friendly.
Implementation Method 1
start a temperature increase ramp to keep the reaction constant in a temperature range between 345 and 515° C. through the application of intermittent pulses of energy consumption for heating
Implementation Method 2
start thermal cracking of the plastic material inside the reactor, keeping the temperature constant for a time of between 30 and 50 minutes
Implementation Method 3
release of the gaseous fraction through an upper duct of the reactor; release of the liquid fraction through the upper duct of the reactor; transfer of the liquid fraction towards a cooling coil to decant
Data Source
AI summary
The invention relates to a method and system for obtaining a liquid fuel from waste from plastic or polymer material, which, according to its structure of steps and devices, allows lower energy use with respect to the disclosure in the prior art. In addition, by means of the method and system, the load of plastic and polymer waste in the environment, mainly waste that may be destined for landfill, is reduced. Thus, in addition to waste material being reduced, energy is recovered at highly favourable cost, as a result of the layout of electric heating elements for delivering the energy or heat needed to correctly transform the waste material, in short processing periods and with the adaptability of being able to be formed from moveable, transportable systems, even large industrial installations.