Pyrolysis of Organics for Active Carbon via Self-Sustaining Heat Recovery
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Solution Overview
Problem
The existing pyrolysis processes for organic materials suffer from high energy consumption and issues related to tar production, including blockages and equipment corrosion, as they rely on external energy sources and fail to fully utilize the sensible heat and calorific value of combustible gases.
Innovation Solution
The method utilizes combustible gases produced during pyrolysis to provide energy through a high-temperature regenerative unit, reforming and purifying them to reduce tar content and increase calorific value, allowing for zero external energy supply and low-cost activated carbon production, employing a system comprising a pyrolysis unit, reforming unit, drying unit, purification unit, gas storage unit, and high-temperature regenerative combustion unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If external energy is used to provide heat for pyrolysis and activation, then the pyrolysis process can be maintained, but energy consumption is high
Solution Approach 1:
The patent converts the harmful effect of tar accumulation and the underutilized energy in combustible gas into beneficial effects. By using catalytic reforming, tars are converted into additional combustible gas, and the sensible heat of the combustible gas is fully utilized to provide process heat, transforming waste energy into useful energy for pyrolysis and activation processes
Solution Approach 2:
The system achieves self-sufficiency in energy supply by using the combustible gas produced during pyrolysis to provide heat for both the pyrolysis process and the activation process. The combustible gas is reformatted to increase its calorific value, and its sensible heat is recovered to preheat feedstock and provide process heat, eliminating the need for external energy supply
2Object-generated harmful factors
If combustible gases are used directly without reforming, then the process is simple, but tar content is high causing blockage and corrosion
Solution Approach 1:
The patent introduces a catalytic reforming unit as an intermediary between pyrolysis and activation processes. This catalyst bed serves as a mediator that converts tars into combustible gas through reforming reactions, thereby removing the harmful effect of tars while adding value to the combustible gas by increasing its calorific value
Solution Approach 2:
The patent changes the chemical composition parameters of the combustible gas by introducing catalytic reforming. The reforming process alters the gas composition by converting heavy hydrocarbon tars into lighter, more combustible components, thereby changing the quality parameters of the gas to reduce harmful effects while improving energy content
3Loss of energy
If sensible heat of combustible gas is not utilized, then the process is simple, but energy efficiency is low
Solution Approach 1:
The patent ensures continuous utilization of the combustible gas sensible heat through a series of heat exchange operations. The hot combustible gas sequentially heats the feedstock, provides heat for activation, and preheats air for combustion, maintaining continuous useful action and maximizing energy efficiency throughout the process
Solution Approach 2:
The patent applies preliminary heating actions by using the sensible heat of combustible gas to preheat the feedstock before pyrolysis and to preheat air before combustion. This preliminary action reduces the energy required for the main processes and maximizes the utilization of available thermal energy
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 approach achieves zero external energy consumption, reduces tar-related issues, and enhances the quality of flammable gases, enabling efficient and cost-effective production of activated carbon by recycling sensible heat and utilizing the calorific value of combustible gases.
Implementation Method 1
Pyrolysis is an effective method for recycling of the organic materials. Tars, combustible gases, chars and other products would be produced when the organic materials were disposed by pyrolysis.
Implementation Method 2
The reformed and purified combustible gases pass through the high temperature heat regenerative unit and are heated to a high temperature level, then the combustible gas as pyrolysis medium is used for pyrolysis of organic materials.
Implementation Method 3
Reforming unit is a reactor of high temperature reforming, and catalyst is used as reforming medium which catalyzes and reforms the tars in the combustible gas by reforming unit.
Implementation Method 4
The combustible gas goes through drying unit, and it will be cooled by heat transfer drying unit. The wet organic materials are dried through drying unit. In the process of drying, the combustible gas enters into drying unit through reforming unit. The sensible heat is recycled by drying unit.
Data Source
AI summary
A method of production of active carbon by pyrolysis of organic materials, includes pyrolysis unit, reforming unit, drying unit, purification unit, gas storage unit and high temperature regenerative combustion unit. Organic materials are subjected to pyrolysis reaction in pyrolysis unit to produce combustible gas, tar and char. Combustible gas is reformed through reforming unit then enters into the drying unit for drying organic materials. One part of the purified combustible gas is combusted in the direction of combustion channel in the high temperature regenerative combustion unit, and the combustion heat is produced. At the same time, another part of combustible gas exchanges heat in the direction of heat exchanger channel in the regenerative combustion unit. Then it is used as pyrolysis activation medium entering into the pyrolysis unit in process of pyrolysis and activation reaction. The char is activated by the combustible gas in the pyrolysis unit then forms activated carbon. The sensible heat of the combustible pyrolysis gas is fully released through drying unit. A part of the combustible gas is combusted to produce heat as the required energy source of pyrolysis process. The combustible gas is used as pyrolysis medium and activator in the generation process of active carbon.