Pyrolysis Reactor Filter Elements for Particle-Free Gas
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Solution Overview
Problem
Existing methods for producing particle-free pyrolysis and synthesis gases face challenges such as particle discharge hindering subsequent processes, catalytic effects from mineral components reducing storage stability, and clogging issues due to tar formation, particularly with cyclone separators and filter elements which are inefficient at high particle fineness and require frequent cleaning.
Innovation Solution
A pyrolysis reactor design with a divided reaction chamber, where filter elements are integrated directly into the gas outlet area, allowing hot pyrolysis vapors and gases to pass through without cooling, and are cleaned using countercurrent jet pulse technology with flushing gases, enabling effective removal of tar-like substances and maintaining high efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cyclone separators are used to separate particles from pyrolysis gas, then robust construction and insensitivity during operation are achieved, but separation efficiency rapidly decreases with particle sizes below 1 μm and at part load operation
Solution Approach 1:
The patent employs filter elements with porous structures (candle filters or bag filters) made of metallic or ceramic materials. These porous materials enable effective separation of fine particles below 1 μm through their pore structures, while the metallic or ceramic composition provides robustness and resistance to high temperatures and corrosive environments, thus resolving the contradiction between reliability and separation efficiency for fine particles.
2Manufacturing precision
If tubular or candle-shaped filter elements are used to separate small particles, then separation efficiency is maintained independently of flow rate, but filter surfaces quickly clog due to sticky particles and particle agglomerates
Solution Approach 1:
The patent implements periodic reverse flow pulses (back-pulsing) to clean the filter elements. This periodic action reverses the flow direction briefly to dislodge and remove accumulated particles and agglomerates from the filter surfaces, preventing clogging and extending the service life of the filter elements while maintaining their separation efficiency for small particles.
Solution Approach 2:
The patent employs a system that discards accumulated particles from the filter surfaces through reverse flow pulses and recovers the filtered gas for further processing or utilization. This approach prevents permanent clogging by periodically removing deposits while maintaining the filter's functionality and extending its operational life.
3Duration of action of stationary object
If filter elements are placed in the gas outlet of the pyrolysis furnace, then cleaning at elevated temperatures increases service life, but heterogeneous catalytic reactions still cause gradual clogging of filter surfaces
Solution Approach 1:
The patent positions the filter elements directly in the reaction chamber where they are exposed to high temperatures and undergo preliminary cleaning through thermal effects before particles can accumulate and cause clogging. This preliminary thermal action prevents tar formation and catalytic reactions from occurring on the filter surfaces, thereby extending service life while maintaining separation efficiency.
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 design ensures long service life and easy cleanability, preventing particle discharge and tar formation, thus maintaining the quality of pyrolysis and synthesis gases by effectively separating particles and reducing clogging, while utilizing pyrolysis gases for cleaning and process control.
Implementation Method 1
filter elements inserted directly into the reaction chamber... hot pyrolysis vapors and pyrolysis gases reach the filter elements directly
Implementation Method 2
The hot pyrolysis vapors and pyrolysis gases produced during pyrolysis rise from the process zone upwards into the extended reaction space arranged above and reach the filter elements in this area directly
Implementation Method 3
The filter elements are cleaned individually in series by pressure surges in the countercurrent direction with a flushing gas during ongoing operation
Implementation Method 4
The filter elements are cleaned individually in series by pressure surges in the countercurrent direction with a flushing gas during ongoing operation
Data Source
Figure 1
AI summary
Pyrolysis reactor for producing high-quality particle-free pyrolysis and synthesis gases, comprising a reaction chamber (1). The aim of the invention is to modify the pyrolysis reactor such that it has a long service life and that the used cleaning agents can be easily cleaned off. This aim is achieved by a reactor the reaction chamber of which comprises a process zone (2) in a lower section and a reaction chamber extended above the process zone and having filter elements (10) inserted therein towards a gas draw-off (11) as the upper section.