Pyrolysis Injector Feed Design for Continuous Plastic Waste Conversion
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Solution Overview
Problem
Existing pyrolysis technologies are inefficient for recycling plastic waste, particularly non-separable plastic wastes, leading to high pollution and limited recycling options, with mechanical recuperation being difficult and often impossible, and there is a need for improved injectors, reactors, and processes for continuous and efficient conversion of polymeric materials into petroleum products.
Innovation Solution
A pyrolysis injector and reactor system that includes a feeder unit for mixing particulate polymeric material with oil, a pyrolysis reactor with a paddle conveyor auger, and a condensation system for producing pyrolysis fluids, allowing for continuous operation, reduced energy consumption, and the reuse of pyrolysis fluids to enhance production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical recuperation is used for plastic waste recycling, then separable plastic waste can be recovered, but non-separable plastic waste cannot be processed and pollutes the environment
Solution Approach 1:
The patent changes the processing method from mechanical separation to thermal decomposition (pyrolysis), transforming the parameters of waste processing. By heating plastic waste to high temperatures in an oxygen-free environment, both separable and non-separable plastics are converted into pyrolysis oil, pyrolysis gas, and solid residue, thereby expanding the processing range to include all types of plastic waste regardless of their separability
Solution Approach 2:
The patent utilizes phase transitions during pyrolysis to separate and recover different components. Plastic waste undergoes thermal decomposition transitioning from solid to liquid (pyrolysis oil) and gas (pyrolysis gas) phases. The condensed pyrolysis fluid is then separated into different fractions based on their boiling points, enabling comprehensive recovery of non-separable plastic waste that mechanical methods cannot handle
2Productivity
If pyrolysis is used to convert plastic waste to petroleum products, then recycling efficiency is improved, but energy consumption increases
Solution Approach 1:
The patent implements preliminary drying of plastic waste before pyrolysis to remove moisture content. This preliminary action prevents energy waste during the pyrolysis process itself, as moisture would otherwise require additional energy to evaporate. By pre-drying the feedstock, the system optimizes energy utilization and improves overall recycling efficiency
Solution Approach 2:
The patent employs a feedback mechanism where condensed pyrolysis fluid is separated into different fractions and the lighter oil fraction is recycled back into the pyrolysis reactor as feedstock. This feedback loop reduces the need for external energy input and raw material supply, thereby improving energy efficiency and productivity of the recycling process
3Productivity
If continuous pyrolysis operation is implemented, then productivity increases, but system complexity increases
Solution Approach 1:
The patent segments the pyrolysis system into distinct functional units: feedstock preparation unit, pyrolysis reactor, condensation unit, separation unit, and recycling unit. Each unit performs a specific function and can be independently controlled and maintained. This segmentation enables continuous operation while managing system complexity through modular design, where each module can be optimized separately
Solution Approach 2:
The patent implements continuous pyrolysis operation where plastic waste is continuously fed into the reactor, pyrolysis products are continuously condensed and separated, and recycled oil is continuously returned to the reactor. This continuous operation maximizes productivity by eliminating idle time between batches, while the modular segmented design keeps system complexity manageable through standardized continuous processing equipment
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
Enables efficient conversion of polymeric materials into petroleum products with reduced energy consumption, supports mobile operations, and reduces environmental impact by recycling plastic waste into valuable fuels and gases, while minimizing atmospheric emissions.
Implementation Method 1
a pyrolysis chamber pipe (33) enveloping a paddle conveyor auger (32), arranged for conveying and pyrolyzing feed of said compacted oil-wet particulate polymeric materials, from said third inlet (30) connected from said pyrolysis injector (1), into said pyrolysis fluids (41a, 41b, 41c)
Implementation Method 2
a first condenser (50) for condensing a first pyrolysis fluid (41c) of said pyrolysis fluids (41a, 41b, 41c)
Implementation Method 3
one or more first heating elements (15) arranged for heating said reservoir (13) with said oil-wet particulate polymeric material (and oil) present therein
Data Source
AI summary
A pyrolysis injector includes a feeder unit with a first inlet for particulate polymeric material and a second inlet for oil, wherein said first inlet and said second inlet lead to a reservoir arranged for mixing said particulate polymeric material and oil into oil-wet particulate polymeric material, and with one or more feeding auger arranged in a feeder gutter portion of said reservoir, the feeder gutter portion leading to a narrowing pipe portion about an end portion of the one or more feeder auger arranged for compacting the oil-wet particulate polymeric material for form a compacted oil-wet particulate polymeric material, the narrowing pipe portion leading to a compacting pipe which is arranged for feeding the compacted oil-wet particulate polymeric material to a third inlet of a pyrolysis reactor, the pyrolysis reactor provided with at least one first outlet for pyrolysis fluids in gaseous form, one or more first heating elements arranged for heating the reservoir with the oil-wet particulate polymeric material (and oil) present therein, and for boiling off water and/or chemicals, one or more second heating elements arranged on the compacting pipe with the compacted oil-wet particulate polymeric material and arranged for pre-heating the compacted oil-wet particulate polymeric material before injection to the third inlet of the pyrolysis reactor, and wherein the second inlet for oil is arranged for receiving a part of an intermediary pyrolysis fluid of the pyrolysis fluids in a condensed liquid state back to the reservoir.