Post-heater gasification for tar removal and carbon residual conversion
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Solution Overview
Problem
The existing pyrolysis processes face challenges in efficiently removing tar and utilizing the energy potential of carbon residual, as tar deposition and catalyst poisoning hinder gas purification and energy utilization, while carbon residual is often wasted or used inefficiently.
Innovation Solution
A process involving a post-heater device that heats pyrolysis products with a direct flame, uses vegetal or mineral oils for washing and gasification, and employs a settling bed to convert carbon residual into combustible gases, achieving tar removal and energy optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If pyrolysis is used to decompose organic substances, then energy can be recovered from the process, but tar and carbon residual are produced that require additional purification and energy treatment
Solution Approach 1:
The patent converts the harmful tar and carbon residual into useful energy resources. The carbon residual is gasified through combustion with air to produce combustible gases, and tar is burned to generate heat for the pyrolysis process. This transforms the waste products into energy sources, resolving the contradiction between energy recovery and harmful byproduct generation.
Solution Approach 2:
The patent recovers energy from the carbon residual and tar that would otherwise be discarded. Through gasification and combustion processes, the carbon residual and tar are converted into energy-rich gases and heat, which are then utilized to sustain the pyrolysis process and generate electricity, thereby recovering value from what would normally be waste.
2Use of energy by moving object
If gas is produced from pyrolysis for energy or chemical use, then energy value increases, but tar deposition prevents process operation and catalysts are poisoned
Solution Approach 1:
Instead of simply removing tar as a harmful substance, the patent converts it into a beneficial energy source. The tar is burned in a combustion chamber to generate heat, which is then used to maintain the pyrolysis temperature. This eliminates tar deposition issues while recovering energy from the tar that would otherwise be a problem.
Solution Approach 2:
The patent introduces an intermediary combustion chamber that processes tar before it can cause problems in the main pyrolysis process. This intermediate treatment step converts tar into heat energy, preventing tar deposition in the gas stream and protecting catalysts while maintaining process reliability.
3Use of energy by moving object
If carbon residual is used as fuel for combustion, then energy is recovered, but it represents lost energy potential and requires additional processing
Solution Approach 1:
The patent changes the physical and chemical parameters of the carbon residual through controlled combustion with air. By adjusting oxygen supply and temperature parameters, the carbon residual is converted from solid fuel into gaseous combustion products that can be directly integrated into the energy recovery system, simplifying the overall processing requirements.
Solution Approach 2:
The patent merges the carbon residual gasification process with the existing pyrolysis system. The combustion chamber is integrated into the pyrolysis unit, and the heat from carbon residual combustion is used to maintain pyrolysis temperature. This consolidation reduces the number of separate processing steps while maximizing energy recovery.
4Manufacturing precision
If tar removal is performed through conventional methods, then gas purification is achieved, but energy contained in tar and carbon residual is lost
Solution Approach 1:
The patent converts the energy loss problem into a benefit by burning tar and carbon residual to generate heat. This heat is then used to maintain the pyrolysis process temperature and generate electricity, thereby recovering the energy that would otherwise be lost during tar removal operations.
Solution Approach 2:
The patent maintains continuous energy recovery by continuously burning carbon residual and tar throughout the pyrolysis process. The combustion processes operate continuously to provide steady heat input, ensuring that energy is recovered from all carbon-containing materials without interruption, thereby eliminating energy loss.
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
This process achieves near-complete tar removal and efficient gasification of carbon residual, resulting in high energy values and low tar content in the final gas, with tar conversion efficiency exceeding 99.5% and residual tar reduced to less than 200 mg/Nm^3.
Implementation Method 1
a burner adapted to heat, preferably with direct flame, all gases present inside such gasifying chamber
Implementation Method 2
pyrolysis is a thermo-chemical decomposition process of organic substances, such as for example biomasses, generated inside reactors like pyrolysers and obtained by applying heat
Implementation Method 3
gasifying reactions occur for producing combustible gases GC, among which the main ones are: 1) C + O2 = CO2 2) CO2 + C = 2CO 3) H2O + C = CO + H2
Implementation Method 4
washing such combustible gases GC with vegetal or mineral oil for removing the tar still possibly present in such gas
Implementation Method 5
washing such combustible gases GC with vegetal or mineral oil for removing the tar still possibly present in such gas
Implementation Method 6
settling in a settling bed the combustion solids coming from such combustion atmosphere
Data Source
Figure 1~2
AI summary
A process is described for removing tar and gasifying the carbon residual coming from pyrolysis of organic substances, together with a post-heater device (1) comprising an upper gasifying chamber (3) of the carbon residual equipped with a first opening (5) for entering solid and gaseous pyrolysis products; a burner (7) adapted to heat gases present inside the gasifying chamber (3); a lower chamber (9) for forming a settling bed of the combustion solid coming from the gasifying chamber (3); a second opening (11) for exiting combustible gases (GC), possibly still containing tar, produced in the settling bed by crossing hot gases coming from the gasifying chamber (3); purifying means of the combustible gases (GC); washing means of the combustible gases (GC) with vegetal or mineral oil; withdrawing means of the vegetal or mineral oil used after having washed the combustible gases (GC) and inserted the vegetal or mineral oil, and possibly air, inside the gasifying chamber (3).