Integrated Pyrolysis Reactor Combustion Boiler Heat Recovery
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Solution Overview
Problem
Existing pyrolysis processes face inefficiencies due to the need for additional fuel, water vaporization issues leading to environmental nuisances, and inadequate utilization of side and waste flows, with known devices not allowing for flexible process flows or efficient handling of intermediate/products.
Innovation Solution
An integrated apparatus comprising a pyrolysis reactor, condensing device, combustion boiler, and separating device that circulates heat transfer material and side/waste flows to the combustion boiler for energy recovery, allowing for efficient pyrolysis product formation and energy production without additional fuel, while managing water vaporization and odorous gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional pyrolysis process is used with separate dryer and pyrolyzer, then the pyrolysis liquid can be produced, but additional fuel is required for drying and pyrolysis operations
Solution Approach 1:
The patent combines the dryer and pyrolyzer into a single integrated device where the combustion chamber serves dual purposes: drying the biomass material and providing heat for pyrolysis. This eliminates the need for separate fuel supplies for drying and pyrolysis operations, as the same combustion process fulfills both functions sequentially.
Solution Approach 2:
The combustion chamber is designed to perform multiple functions: it acts as a dryer during the drying phase and as a pyrolysis heater during the pyrolysis phase. The system universally handles both drying and pyrolysis operations within a single device, eliminating redundant equipment and fuel consumption.
2Loss of substance
If biomass is dried using conventional drum or flash dryers, then water content is reduced, but organic compounds may escape causing environmental nuisances
Solution Approach 1:
The patent converts the potentially harmful organic compounds that would normally escape during drying into useful pyrolysis products. By immediately subjecting the dried material to pyrolysis in the same device, the organic compounds are transformed into pyrolysis oil and gas rather than being released into the environment.
Solution Approach 2:
The system maintains continuous operation where drying is immediately followed by pyrolysis without interruption or material removal. This continuous process ensures that organic compounds are continuously converted into useful products rather than being emitted, eliminating environmental nuisances while maintaining efficient water removal.
3Quantity of substance
If fast pyrolysis is performed with short contact time, then pyrolysis liquid yield increases, but efficient utilization of side flows and waste materials is limited
Solution Approach 1:
The integrated device universally handles multiple material streams: it can process biomass for pyrolysis, burn produced gas for energy, and handle various waste materials. The system is adaptable to different feedstocks and can utilize side flows and waste materials as additional fuel sources for the combustion chamber, enhancing versatility while maintaining high pyrolysis liquid yield.
4Ease of operation
If separate drying and pyrolysis equipment is used, then process control is simplified, but device complexity and space requirements increase
Solution Approach 1:
The patent merges the dryer and pyrolyzer into a single integrated device with a unified combustion chamber, reducing the number of separate equipment pieces. This integration simplifies the overall system while maintaining distinct operational phases, as the same chamber sequentially performs drying and pyrolysis functions.
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 apparatus enhances pyrolysis product yield and energy efficiency by utilizing side and waste flows for heat and steam production, reducing environmental impact and eliminating the need for additional fuel, with improved product quality and process safety.
Implementation Method 1
a pyrolysis reactor for forming pyrolysis product fractions from raw material by fast pyrolysis
Implementation Method 2
a condensing device for condensing gaseous pyrolysis product fractions to mainly liquid pyrolysis product fractions
Implementation Method 3
a combustion boiler for forming energy fractions
Implementation Method 4
heat transfer material which is heated in the combustion boiler and is used for transferring the energy fractions
Data Source
Figure 1
AI summary
The invention relates to an apparatus for producing a pyrolysis product, the apparatus comprising a pyrolysis reactor (2) for forming pyrolysis product fractions from raw material by fast pyrolysis, a condensing device (3) for condensing gaseous pyrolysis product fractions to mainly liquid pyrolysis product fractions, a combustion boiler (1) arranged in conjunction with the pyrolysis reactor for forming energy fractions, and feeding devices (5, 6, 22) for feeding raw materials to the pyrolysis reactor and the combustion boiler. According to the invention, the apparatus comprises a separating device (4) arranged substantially in conjunction with the pyrolysis reactor for separating other fractions (13) from the gaseous pyrolysis product fractions after the pyrolysis and means (13) for conducting other fractions than the gaseous pyrolysis product fractions from the separator (4) to the combustion boiler (1).