Pyrolysis Plant Pneumatic Sealing and Continuous Char Removal
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Solution Overview
Problem
Current tire-to-fuel pyrolysis plants face issues with maintaining constant pressure in biomass feeder systems, sealing mechanisms in pyrolysis reactors, batch heating and cooling processes, inefficient char/ash/carbon removal, and the management of syngas and carbon contaminants in the fuel production process.
Innovation Solution
The implementation of an exhaust heated feeder system with a twin screw feeder, a continuous pyrolysis reactor design with double flight screws, a rotary screen cleaning tower, an exhaust heat fuel cleaner, and a carbon refiner, along with a safety burner, to ensure continuous operation, efficient heat exchange, and effective carbon particle removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch feeding with gates and valves is used to maintain seal, then oxygen leakage is prevented, but oxygen enters the hopper and reactor during cycling
Solution Approach 1:
The invention extracts the sealing function from mechanical gates/valves and replaces it with a pneumatic seal system. The seal is maintained continuously through pressure differential and pneumatic actuation rather than mechanical closure, eliminating the opening/closing cycles that allow oxygen contamination.
Solution Approach 2:
The invention replaces the mechanical gate/valve system with a pneumatic control system. The feed hopper uses pneumatic pressure to maintain the seal and control feeding, substituting mechanical movement with pneumatic pressure differential to prevent oxygen leakage while maintaining continuous operation.
2Device complexity
If rotating vessels with batch process are used, then sealing is simplified, but continuous filling and discharge is not achieved
Solution Approach 1:
The invention implements continuous operation by eliminating the batch cycle. The feed hopper continuously feeds material through pneumatic pressure, the reactor continuously processes material through conveyor mechanisms, and the char removal system continuously extracts processed material. This creates an uninterrupted flow through the entire system, maintaining productivity without compromising sealing simplicity.
3Ease of operation
If reactors are cooled down for cleaning and restart, then access doors can be opened, but start-up time is significantly prolonged
Solution Approach 1:
The invention segments the reactor into modular sections with independent access points. This allows cleaning to be performed on specific sections without cooling down the entire reactor. The modular design enables maintenance activities to be isolated to specific zones, reducing the time the entire system must be offline and minimizing start-up time requirements.
4Productivity
If manual cleaning of char/ash/carbon is used, then removal is achieved, but labor costs increase and employee safety is compromised
Solution Approach 1:
The invention implements self-service cleaning mechanisms where the system cleans itself. Conveyor mechanisms automatically transport char, ash, and carbon from the reactor to collection points. Pneumatic systems automatically clear blockages and maintain flow. This eliminates the need for manual cleaning operations, improving productivity while removing employees from hazardous environments.
Solution Approach 2:
The invention replaces manual cleaning operations with automated mechanical and pneumatic systems. Conveyors, pneumatic blowers, and automated removal mechanisms substitute human labor in the cleaning process, achieving continuous char/ash/carbon removal without exposing employees to airborne dust hazards.
5Temperature
If burners are positioned along the reactor length, then heat is provided for pyrolysis, but expansion requires special fittings
Solution Approach 1:
The invention applies local quality by concentrating the heating function at specific locations rather than distributing burners throughout the reactor length. Heating zones are positioned only where thermal processing is required, allowing other sections to be designed for thermal expansion without complex fittings. This localized approach maintains heating capability while simplifying the overall structural design.
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 configuration maintains constant pressure, reduces oxygen leakage, enables continuous material flow, enhances heat exchange efficiency, and effectively removes carbon contaminants, resulting in improved safety and reduced operational costs by minimizing energy consumption and manual labor.
Implementation Method 1
The vapours that condenses below 260°C (500°F) will condense and then re-boil into vapours leaving the heavier fuel behind.
Implementation Method 2
A veritable speed rotary screen can increase the travel distance of the vaporized gas by increasing the RPM of the turning paddles.
Implementation Method 3
Pyrolysis plants are known from US 2018/010048 A1, US 2018/010049 A1, US 9 663 662 B1, US 2017/361558 A1 and US 2017/362511 A1.
Data Source
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AI summary
The invention refers to a pyrolysis plant comprised inter alia by: a) an exhaust heated feeder comprised at least by: a receiver hopper (101); a drive (103); a photo eye sensor or paddle switch (104); a slide gate (106); a twin screws feeder (102); a pneumatic or a hydraulic power system (121); a heated collar (111); b) a reactor comprised at least by: an upper reactor tube (107a) and lower reactor screw (107b) with double flight screws; wrapped heater boxes (601) having one burner (108) per box; a tube steel frame (608) having flat bar landings (606) for the carts (605); c) a rotary screen cleaning tower comprised at least by: fan wheel (705); spinning paddles (704); screen plates (703); a cleaner tower housing (713); a main shaft (727); and an electric motor (714) with a gear box (706); d) an exhaust heat fuel cleaner comprised at least by: a main cleaner housing (1004); an inlet tube (1003); a split insulated metal enclosure (1005); duct connections (1008 and 1009); a discharge valve (1010); a discharge tank (1011); a pump (1001); a diverter valve (1027); a vent pipe (1013); a condenser (1015); an holding tank (1021); a actuator valve (1006); sensors (1016/1017); and a check valve (1028); e) a carbon refiner comprised at least by: a screw auger (107b); a gated airlock arrangement, an upper gate (1302); an ash discharge auger (1301); a first hopper (1303); a level indicator (1304); a drive (1305); a middle gate (1306); an hopper (1307); a lower gate (1308); a metering screw (1309) rotating in a housing (1310); matching air openings; a duct (1316); a burner blower (1311); a combustion chamber (1312); a pilot flame (1314); a discharge opening (1322); a motor drive (1317) invertor; an extended packing seal (1318); a burner blower (1311); a vent line (1319); a water bubbler (1320); a vacuum source (1321); a separator tank (1323); a level switch (1325); a vertical lift auger (1328); an opening (1329); openings (1330) in the lift tube (1331); an horizontal screw auger (1335); a pyrolysis burner box (601); a condenser inline (1334); an auger (1335); an airlock (1336); a cyclone (1338); an airlock (1339); a blower (1340); an exhaust (1346) into a bag filter (1341); and an airlock (1343); f) a safety burner tower comprised at least by: a control valve (1701); a pipe (1702) and a safety burner housing base (1703); a blower (1708); a venturi nozzle (1707); a pilot light (1714); a bubbler chamber (1719); having an insulated area (1711); a computer (1718); a stack (1709); a battery backup (1717); a level control (1705).