Positive-Pressure Pyrolysis Hopper for Oxygen-Free Continuous Feed

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Solution Overview

Problem

Existing pyrolysis reactors suffer from inefficiencies in energy use, uneven heat distribution, and inability to handle lightweight materials, leading to reduced productivity and quality of carbon black production, with additional inputs like nitrogen and glue required to prevent oxygen ingress.

Innovation Solution

A continuous flow pyrolysis reactor with multiple pyrolysis chambers arranged alternately and housed in an insulating housing, using gas from the pyrolysis process for heating, and a positive pressure hopper with an endless screw conveyor to ensure continuous, oxygen-free material feed, enhancing heat distribution and reducing oxygen ingress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If multiple pyrolysis chambers are arranged alternately in stacked configurations, then heat distribution uniformity is improved, but device complexity increases

Engineering Contradiction:

Improveheat distribution uniformityVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The reactor is divided into multiple pyrolysis chambers (first and second pyrolysis chambers) arranged alternately in stacked configurations. Each chamber can be independently controlled and optimized, allowing uniform heat distribution across different zones while maintaining manageable complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pyrolysis chambers are nested within a common reactor vessel structure, with the first and second pyrolysis chambers arranged alternately in stacked configurations. This nesting approach allows compact arrangement of multiple chambers within a single reactor footprint, improving heat distribution uniformity without proportionally increasing overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If continuous flow feeding is implemented, then productivity is improved, but device complexity increases

Engineering Contradiction:

ImproveproductivityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The reactor employs continuous flow feeding mechanisms that allow uninterrupted feedstock introduction into the pyrolysis chambers. This continuous operation maintains steady-state conditions, improves productivity by eliminating batch processing interruptions, and simplifies control compared to frequent batch loading/unloading operations.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If oxygen-free feeding is ensured through positive pressure hopper, then carbon black quality is improved, but device complexity increases

Engineering Contradiction:

Improvecarbon black qualityVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system employs positive pressure feeding through a hopper that maintains an oxygen-free atmosphere in the feed path. This inert environment prevents oxidation of the feedstock and produced carbon black, improving product quality. The positive pressure mechanism ensures consistent feeding while maintaining the oxygen-free condition without requiring complex active oxygen exclusion systems.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 high energy efficiency, producing high-quality carbon black and pyrolysis gas with minimal waste and operational interruptions, while handling both heavy and lightweight materials without the need for additional inputs, resulting in a stable and efficient pyrolysis process.

Implementation Method 1

an endless screw conveyor to ensure continuous, oxygen-free material feed

Methodology Applied

Scientific EffectScrew propulsion: Screw

Implementation Method 2

The phenomenon of pyrolysis consists in the thermal decomposition of the material to be pyrolyzed through heat, in the presence of an inert atmosphere

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 3

using gas from the pyrolysis process for heating

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 4

housed in an insulating housing

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12559684B2Continuous-flow pyrolysis reactor, positive-pressure feed hopper for pyrolysis reactor, kiln for pyrolysis reactor, and pyrolysis system

Publication Date: 2026.02.24 MARTINEZ LUIS FERNANDO

AI summary

A continuous flow pyrolytic reactor (200) equipped with one or more pyrolysis chamber assemblies (204) is disclosed. A positive pressure waste feeder hopper (100) for the pyrolytic reactor and its respective furnace, in addition to a pyrolysis system for the use of waste. The pyrolytic reactor (200) having a plurality of cylindrical pyrolysis chambers (201) provided, within it, with an endless screw conveyor (202) arranged longitudinally. The worm conveyor screw (202) is provided with a shaft (203), the shaft (203) being coupled to the bases of the pyrolysis chamber (201). The shaft (203) is further coupled to a rotation device that transfers torque to the shaft (203) by rotating the worm conveyor screw (202). The cylindrical pyrolysis chambers (201) are housed in an insulating housing (300) having within it two or more assemblies (204). The assemblies (204) are fed by a hopper (100) forming a pyrolysis system.