Pyrolysis System Bio-Oil Extraction Recirculation
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Solution Overview
Problem
Current methods for extracting bio-oil components from pyrolyzed materials are economically unattractive due to high costs and inefficiencies, particularly in long-duration processes, and result in bio-oil/biodiesel mixtures that fail to meet fuel combustion standards.
Innovation Solution
A system and method involving a pyrolyzer, primary condenser, and recirculator that uses a non-polar high boiling point solvent to quench and recirculate bio-oil vapors, controlling temperature and injection rate to optimize bio-oil component extraction and separation, with further solvent extraction and recycling to improve the quality and stability of the bio-oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pure biodiesel is continuously fed into a quenching vessel to condense bio-oil vapors, then bio-oil condensation is achieved, but operational costs become prohibitive for long-duration processes
Solution Approach 1:
The patent changes the chemical composition parameters of the quenching medium by using hydrocarbon-rich pyrolysis vapors instead of pure biodiesel. This parameter change maintains condensation effectiveness while dramatically reducing operational costs for long-duration processes.
Solution Approach 2:
The system uses its own pyrolysis vapors (which are rich in hydrocarbons) to serve as the quenching medium, eliminating the need for external biodiesel feed. The pyrolysis process itself provides the resources needed for condensation, making the system self-sufficient.
2Quantity of substance
If significant volumes of biodiesel are employed for vapor condensation, then bio-oil extraction is effective, but the system becomes impractical due to material handling requirements
Solution Approach 1:
The pyrolysis vapors generated by the system itself are used as the quenching medium, eliminating the need to externally source, store, and handle large volumes of biodiesel. This self-service approach maintains extraction efficiency while dramatically simplifying material handling.
3Reliability
If slow pyrolysis technique is used to produce bio-oil, then vapor condensation is achieved, but the quantity of bio-oil produced is lower, negatively affecting system economics
Solution Approach 1:
The patent changes the condensation parameters by using hydrocarbon-rich pyrolysis vapors as the quenching medium instead of biodiesel. This parameter change increases the quantity of condensable vapors and improves overall bio-oil yield while maintaining condensation effectiveness.
4Productivity
If bio-oil is extracted via single-pass process, then condensation is achieved, but the resulting fuel mixture fails to meet combustion standards such as ASTM D975 or D6751
Solution Approach 1:
The patent implements a continuous recirculation process where non-condensed vapors are repeatedly exposed to the quenching medium. This continuous action ensures complete condensation of hydrocarbons while maintaining fuel quality compliance, unlike single-pass processes that leave residual vapors.
Solution Approach 2:
The system changes the chemical composition of the quenching medium to hydrocarbon-rich pyrolysis vapors, which alters the condensation characteristics and produces a fuel mixture that meets combustion standards. The recirculation further optimizes composition to ensure compliance.
5Productivity
If raw bio-oil is produced with high water and polar species content, then pyrolysis is complete, but the energy density is reduced to about half that of crude oil
Solution Approach 1:
The recirculation process selectively extracts and removes water and polar species from the bio-oil through repeated condensation cycles. These unwanted components are separated from the hydrocarbon fraction, concentrating the energy-dense components and doubling the effective energy density.
6Productivity
If raw bio-oil is produced with high acidity, then pyrolysis is complete, but the bio-oil becomes corrosive to standard motor and turbine components
Solution Approach 1:
The recirculation process extracts and removes acidic components and polar species from the bio-oil through selective condensation. This purification eliminates corrosiveness while maintaining pyrolysis completion, making the fuel compatible with standard engines and turbines.
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 reduces logistical and cost burdens, enhances bio-oil component extraction efficiency, and produces a stable, high-quality bio-oil that can be blended with diesel fuels, meeting stringent combustion standards.
Implementation Method 1
The condenser is further configured to condense the pyrolytic vapors by contacting the pyrolytic vapors with the solvent to form a condensed liquid
Implementation Method 2
A recirculator couples the capture vessel to the primary condenser input and is configured to receive the condensed liquid from the primary condenser, and to provide at least a portion of the condensed liquid as part of or all of the solvent in the primary condenser
Data Source
AI summary
A system is described that includes a pyrolyzer and a primary condenser. The primary condenser is coupled to the pyrolyzer and includes an input to receive pyrolytic vapors from the pyrolyzer and a solvent. The condenser is further configured to condense the pyrolytic vapors by contacting the pyrolytic vapors with the solvent to form a condensed liquid that exits the primary condenser via an output. A capture vessel receives the condensed liquid from the condenser output. A recirculator couples the capture vessel to the primary condenser input and is configured to receive the condensed liquid from the primary condenser, and to provide at least a portion of the condensed liquid as the solvent in the primary condenser. The solvent from the bio-oil component/solvent mixture is then extracted in a solvent extraction system and returned to the quenching system.