Pyrolysis Apparatus Electric Heating and Liquid Seal
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Solution Overview
Problem
Existing pyrolysis apparatuses for processing shredded waste materials like plastic and rubber are inefficient due to high energy consumption, uneven heat distribution, and sealing issues, particularly when using gas-generated heat, which results in poor overall efficiency and quality of end products.
Innovation Solution
A continuous pyrolysis apparatus with a screw conveyor feed system that uses electric heating and thermal insulation, allowing for precise and even heat application, and a gas collector with a liquid-filled tub to recover and condense vapors, reducing energy waste and improving sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If gas-generated heating is used in the pyrolysis reactor, then the process can utilize the gas produced during pyrolysis, but energy consumption increases and heat distribution becomes uneven
Solution Approach 1:
The patent replaces the gas flame heating system with an electric heating system. The combustion chamber and smokestack structures are eliminated, and electric heating elements are installed directly in the pyrolysis reactor. This substitution achieves uniform heat distribution throughout the reactor while reducing energy waste, as electric heating can be precisely controlled and distributed evenly through the reactor volume without the structural losses inherent in gas flame systems.
2Use of energy by moving object
If a combustion chamber and smokestack are used for gas heating, then gas can be burned for heat, but energy efficiency decreases due to structural heat loss
Solution Approach 1:
The patent extracts and removes the combustion chamber and smokestack structures from the system. By eliminating these components, the patent eliminates the associated heat losses that occur through these structures. The gas produced during pyrolysis is no longer burned in a separate combustion chamber but is instead utilized differently, and the heating function is transferred to electric heating elements directly within the reactor, thereby improving overall energy efficiency.
3Temperature
If the pyrolysis chamber is rotated to distribute heat evenly, then heat distribution improves, but sealing problems arise
Solution Approach 1:
Instead of rotating the pyrolysis chamber to achieve heat distribution, the patent inverts the approach by using stationary electric heating elements that can be positioned and controlled to provide uniform heat distribution throughout the chamber. This eliminates the need for chamber rotation, thereby maintaining reliable sealing at the feed device and outlet portion while achieving the desired even heat distribution through the reactor volume.
4Productivity
If continuous operation is implemented, then productivity increases, but sealing and air trap maintenance become more difficult
Solution Approach 1:
The patent implements a liquid air trap system in the feed device where liquid automatically seals the interface between the atmosphere and the inert atmosphere inside the reactor. This self-service sealing mechanism maintains the air trap functionality continuously without requiring manual intervention or complex mechanical sealing systems. The liquid seal automatically accommodates the continuous operation while maintaining the integrity of the inert atmosphere, thereby supporting continuous productivity without compromising sealing reliability.
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 solution achieves significant energy savings, improved efficiency, and enhanced product quality by using electric heating and a liquid-filled gas collector, enabling precise heat control and efficient gas recovery, thus making the process more profitable and effective.
Implementation Method 1
a conveyor, such as a screw conveyor screw that is at least partially placed in a liquid, such as oil, which forms an air trap to prevent air from entering into the reactor
Implementation Method 2
a conveyor, such as a conveyor screw, for moving the material and heating resistors for heating the reactor
Implementation Method 3
The steel pipe forming the pyrolysis reactor has been thermally insulated by coating it with heat-resistant industrial MT or HT insulation wool or ceramic wool
Implementation Method 4
a condensing collecting canopy which is used to condense into liquid and recover the vapour conveyed in connection with the removal of carbon
Implementation Method 5
a collecting member, such as another tub that has been turned upside down and equipped with a flotation device to collect the gas entering the gas collector
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Pyrolysis apparatus (10) for processing shredded waste material, such as plastic and/or rubber waste, in which apparatus the material is processed continuously in a pyrolysis apparatus (10) that includes a feed device (30), a reactor (30) and an outlet portion (40) that have been equipped with conveyors, such as screw conveyors, and that can be used continuously. The screw (23) of the feed device (20) is at least partially placed in a liquid (22), which forms an air trap to prevent air from entering into the reactor. The outlet portion has a condensing collecting canopy (45) which is used to condense into liquid and recover the vapour formed in the reactor.