Pyrolysis Reactor Scraper for In-Situ Carbon Fouling Removal
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Solution Overview
Problem
The accumulation of solid carbon on the walls of pyrolysis reactors leads to fouling, requiring reactor shutdowns and inefficient cleaning processes that generate CO and CO2 emissions, undermining the environmental benefits of hydrocarbon pyrolysis systems.
Innovation Solution
A carbon removal component with a scraper head and sealing device is integrated into the pyrolysis reactor, allowing continuous operation by mechanically removing carbon deposits without generating CO or CO2, using a combustion component to provide heat and a rod with scraping teeth to clean the reactor walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pyrolysis reactor operates continuously without cleaning, then productivity is maintained, but carbon accumulation on reactor walls increases causing fouling and eventual shutdown
Solution Approach 1:
The scraper head is actuated periodically to remove carbon deposits before they accumulate to levels that would cause reactor shutdown. This preliminary cleaning action prevents fouling from reaching critical levels, maintaining continuous operation without interruption.
Solution Approach 2:
The reactor system includes an integrated carbon removal mechanism that automatically scrapes carbon deposits from the reactor walls during operation. This self-service capability allows the system to maintain itself without external intervention or shutdown, continuously removing harmful carbon accumulation.
2Object-affected harmful factors
If the reactor is shut down for cleaning, then carbon fouling is removed, but productivity is reduced and greenhouse gas emissions may occur during cleaning
Solution Approach 1:
The carbon removal mechanism operates during the pyrolysis reaction without interrupting the process. The scraper head can be actuated while the reactor continues to produce hydrogen, ensuring continuous useful action without shutdown-related productivity loss or emissions from cleaning operations.
Solution Approach 2:
Instead of using traditional mechanical cleaning methods that require shutdown (such as manual scraping or high-pressure washing), the patent employs an integrated scraping mechanism that operates in-situ during normal reactor operation, replacing the need for disruptive cleaning procedures.
3Object-affected harmful factors
If a carbon removal component is added to the reactor, then carbon fouling is prevented, but device complexity increases
Solution Approach 1:
The rod serving as a sealing device also functions as an actuator for the scraper head. This multi-functionality reduces the number of separate components needed, minimizing the increase in device complexity while still achieving effective carbon removal and sealing functions.
Solution Approach 2:
The sealing device uses a relatively simple rod structure with sealing elements rather than complex mechanical assemblies. This approach maintains simplicity in the carbon removal component design, limiting the increase in overall system complexity.
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 continuous operation of pyrolysis reactors without downtime, reducing costs and emissions, and maintaining high thermal efficiency by continuously removing carbon without catalysts or consumables, suitable for various reactor geometries and locations.
Implementation Method 1
a scraper head with teeth that can be actuated to remove carbon deposits from the reactor walls
Implementation Method 2
a sealing device to prevent gas escape during scraping
Implementation Method 3
pyrolysis reactors function by heating a hydrocarbon input in an oxygen-free environment to an enthalpy point (or above) for a pyrolysis reaction, then continue to add heat to encourage the reaction to fully take place. In the pyrolysis reaction, the hydrocarbon splits into various constituents, resulting in an output flow that includes solid carbon and hydrogen gas
Data Source
AI summary
Systems and methods for removing carbon from the pyrolysis reactor are disclosed herein. For example, a pyrolysis reactor according to the present technology can include a combustion component that is fluidly couplable to a combustion fuel supply, as well as a reaction chamber that is thermally coupled to an output of the combustion component. Further, the pyrolysis reactor can include a carbon removal component that is operably coupled to the reaction chamber. The carbon removal component can include an actuator, a rod coupled to the actuator, and a scraper head coupled to the rod and positioned within the reaction chamber. The actuator can drive movement of the rod within the reaction chamber, thereby driving movement of the scraper head. The scraper head can include a plurality of teeth that are positioned to scrape carbon deposits from an interior wall of the reaction chamber.