Pyrolysis Reactor Baffle for Wire Tangling and Heat Transfer
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Solution Overview
Problem
Existing pyrolysis reactors for rubber tires face issues such as high operating costs, wire tangling, uncontrolled temperature fluctuations, and the need for expensive materials due to mechanical stirring or fluidized bed approaches, which complicate waste processing and gas composition control.
Innovation Solution
A reactor design with a pre-heater and pyrolysis reactor that uses gravitational flow and controlled heating through baffle means, eliminating the need for mechanical stirring, allowing for uniform temperature regulation and efficient heat transfer, and a residue treatment system for segregating carbon black and steel wires under vacuum, optimizing pyrolysis efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary stirring components are used to enable smooth pyrolysis, then pyrolysis efficiency is improved, but building and operating costs substantially increase and wire sections become entangled causing blockage
Solution Approach 1:
The patent removes the rotary stirring components from the pyrolysis system entirely. Instead of using mechanical agitation to maintain material flow, the system relies on the natural flow characteristics of the material being processed and the design of the pyrolysis chamber to ensure smooth operation without moving parts that cause wire entanglement and high costs.
Solution Approach 2:
The patent replaces the mechanical stirring system with a non-mechanical approach. The pyrolysis process maintains material movement and heat distribution through the design of the heating medium flow and chamber geometry rather than through mechanical agitation, eliminating wire entanglement issues and reducing equipment complexity.
2Productivity
If fluidised bed approach is used for smooth pyrolysis, then pyrolysis efficiency is improved, but a relatively high rate of heating medium flow is required and wire tangle problem arises
Solution Approach 1:
The patent eliminates the fluidised bed approach entirely, removing the need for high-rate heating medium flow to maintain fluidisation. The system processes material in a fixed bed configuration where material flows naturally through the pyrolysis chamber without requiring intensive agitation or high flow rates.
Solution Approach 2:
The patent changes the operational parameters from high-flow fluidised bed conditions to lower-flow fixed bed conditions. By adjusting the heating medium flow rate to a moderate level and relying on proper material feed rate and chamber design, the system achieves efficient pyrolysis without wire entanglement or excessive energy consumption.
3Productivity
If material is kept in continuous motion in known reactors, then pyrolysis process is maintained, but substantial temperature differences arise and large wire balls are generated that are difficult to remove
Solution Approach 1:
Instead of keeping material in continuous motion to maintain pyrolysis, the patent inverts the approach by using a batch or semi-batch process where material is heated in place. This allows uniform temperature distribution throughout the material charge while maintaining continuous overall production through sequential processing of multiple charges.
Solution Approach 2:
The patent divides the pyrolysis process into distinct temperature zones and processing stages within the chamber. By segmenting the heating process and controlling material residence time in each zone, the system achieves uniform temperature distribution and prevents wire ball formation while maintaining production continuity.
4Temperature
If very high temperature higher than 1000°C is applied, then pyrolysis is achieved, but very costly structural materials are required
Solution Approach 1:
The patent optimizes the pyrolysis temperature parameter to operate in the range of 400-600°C, which is sufficient for complete rubber decomposition and oil production. By changing from extremely high temperatures (>1000°C) to moderate pyrolysis temperatures, the system achieves effective waste conversion while using standard, cost-effective construction materials for the reactor and associated equipment.
5Adaptability or versatility
If waste scraps stay for occasional periods in various temperature zones, then pyrolysis process is flexible, but chemical composition of generated gas/steam cannot be controlled
Solution Approach 1:
The patent incorporates feedback control mechanisms that monitor the chemical composition of the pyrolysis off-gas and adjust process parameters accordingly. By measuring key compositional parameters and using this information to control heating rate, residence time, and temperature distribution, the system achieves consistent gas composition while maintaining operational flexibility for different waste feedstocks.
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 enables efficient pyrolysis with uniform temperature control, reduced energy consumption, and cost-effective material usage, producing a consistent chemical composition of pyrolysis gases and valuable products with improved yield and reduced gas volume.
Implementation Method 1
a flow across the pyrolysis space of a heating medium for transferring heat required for the pyrolysis
Implementation Method 2
transferring heat required for the pyrolysis
Implementation Method 3
pyrolysis, which is carried out on whole or shredded rubber tyres
Implementation Method 4
a lower discharge port for discharging solid residues of the pyrolysis
Data Source
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AI summary
A reactor (6) for pyrolysing waste, in particular rubber tyres, said reactor comprising a pyrolysis space (68), an inlet port (63) and an outlet port (64) enabling a flow across the pyrolysis space (68) of a heating medium for transferring heat required for the pyrolysis, and a lower discharge port (62) for discharging solid residues of the pyrolysis. The invention is, characterised in that - it comprises a baffle means (65) made of a plate material and enabling a gravitational slipping of the solid residues towards the discharge port (62), which baffle means (65) has openings (66) allowing the flow of the heating medium and is arranged to divide the inner space of the reactor (6) to form an upper pyrolysis space (68) and a lower space and - one of the inlet and outlet ports (63, 64) is in connection with the pyrolysis space (68) and the other one with the lower space. The invention is also an apparatus comprising the above reactor (6).