Pyrolysis Reactor Sensor Feedback for Uniform Heating
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Solution Overview
Problem
Existing pyrolysis apparatuses face issues with uncontrolled combustion and uneven pyrolysis distribution within the pyrolysis chamber, leading to inefficiencies in the pyrolysis process.
Innovation Solution
A pyrolysis apparatus with controlled temperature, flowrate, pressure, and diffusion conditions is implemented, utilizing recirculated synthesis gas for heating and sensors to monitor and adjust combustion parameters, ensuring uniform pyrolysis across the material mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heating is applied directly by delivering heated gaseous mixture into the pyrolysis chamber, then heating efficiency is improved, but uncontrolled combustion of the material may occur
Solution Approach 1:
The patent introduces an inert gas (nitrogen or carbon dioxide) into the pyrolysis chamber to create an oxygen-deficient atmosphere. This prevents uncontrolled combustion while allowing controlled heating of the material. The inert gas displaces oxygen, ensuring that the heating process occurs without unwanted oxidation or combustion reactions.
Solution Approach 2:
The patent employs sensors to monitor temperature, gas composition, and flow rate within the pyrolysis chamber. This feedback system allows real-time adjustment of heating parameters and inert gas flow to maintain optimal pyrolysis conditions, preventing uncontrolled combustion while maximizing heating efficiency.
2Productivity
If heating is applied intensively to achieve high pyrolysis rates, then productivity is improved, but uneven pyrolysis distribution occurs within the material mass
Solution Approach 1:
The patent divides the heating function into multiple heating zones within the pyrolysis chamber, each equipped with independent heating elements and temperature control. This segmentation allows different regions of the material mass to be heated at optimal rates, ensuring uniform pyrolysis throughout while maintaining high overall productivity.
Solution Approach 2:
The patent implements localized heating control where each zone can be independently adjusted to provide the specific temperature and heating rate required for uniform pyrolysis. This local quality approach ensures that no region of the material is under-heated or over-heated, achieving consistent pyrolysis products throughout the entire mass.
3Power
If oxygen content is increased to support combustion heating, then heating power is improved, but uncontrolled combustion develops
Solution Approach 1:
The patent replaces oxygen with inert gases (nitrogen or carbon dioxide) to create an oxygen-deficient atmosphere in the pyrolysis chamber. This eliminates the risk of uncontrolled combustion while providing sufficient heating power through controlled heat transfer from the inert gas and heating elements.
Solution Approach 2:
The patent uses inert gas as an intermediary medium to transfer heat to the material without supporting combustion. The inert gas acts as a heat carrier that can be heated to high temperatures and then transfer that heat to the material through convection and conduction, providing high heating power without the harmful effects of oxygen presence.
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 achieves uniform pyrolysis without uncontrolled combustion, optimizing the pyrolysis process by reducing fuel consumption and enhancing heat distribution efficiency.
Implementation Method 1
The material loaded into the pyrolysis chamber is heated by at least one heating device (6), which includes a burner (7), supplied, for example, with a liquid, gaseous or solid fuel
Implementation Method 2
The fumes produced by the combustion of the fuel in the burner (7) are introduced into a first end (21) of a tubular conduit (8)
Implementation Method 3
The pyrolysis apparatus (1) can be equipped with recirculating means of the synthesis gas that comprises an outlet opening (16), made in an upper zone of the pyrolysis chamber (5)
Implementation Method 4
a second part of synthesis gas that entered the first conduit (17) enters the ejecting device (20), which conveys said second part of synthesis gas to the tubular conduit (8)
Implementation Method 5
The group S of sensors arranged in the tubular conduit (8) measures a plurality of parameters of said fumes in the tubular conduit (8)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A pyrolysis apparatus (1), for the pyrolysis of solid state materials, comprises a pyrolysis reactor (2), with a body (3) inside which a pyrolysis chamber (5) is defined, at least one heating device (6; 6a; 6b; 6c; 6'; 6") with a burner (7; 7a; 7b; 7c; 7'; 7") associated with a tubular conduit (8; 8a; 8b; 8c; 8'; 8") that leads inside the pyrolysis chamber (5), into which tubular conduit (8; 8a; 8b; 8c; 8'; 8") fumes are delivered that are produced by the combustion of a fuel delivered into the burner (7; 7a; 7b; 7c; 7'; 7"), said tubular conduit (8; 8a; 8b; 8c; 8'; 8") being operationally associated with a group of sensors (S; Sa; Sb; Sc; S'; S") that measure a plurality of parameters of said fumes in said tubular conduit (8; 8a; 8b; 8c; 8'; 8"), before the fumes are delivered to the pyrolysis chamber (5).