Rapid Thermal Processing Reactor Pressure Management
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Solution Overview
Problem
Current rapid thermal processing (RTP) systems for carbonaceous materials face challenges in handling higher feedstock rates without increasing the cost and complexity of equipment, as larger volumes of gaseous products and char require larger reactor and reheater sizes.
Innovation Solution
Operating the RTP arrangement at higher pressures (about 70 kPa gauge or greater) to compress gaseous products and flue gas, reducing the volumetric flow rates and maintaining equipment size, thus minimizing the cost and complexity of shipping, installation, and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the RTP arrangement operates at higher feedstock rates, then productivity increases, but the volume of gaseous products and flue gas increases requiring larger equipment size
Solution Approach 1:
The patent applies parameter changes by operating the RTP arrangement at elevated pressures (e.g., 5-50 bar gauge) to compress the gaseous products and flue gas. This pressure parameter change reduces the volumetric flow rates of gases, allowing higher feedstock rates to be processed without proportionally increasing equipment size. The compressed gas volume maintains acceptable volumetric flow rates within existing reactor and reheater dimensions.
2Volume of stationary object
If the RTP arrangement operates at higher pressures, then volumetric flow rates of gaseous products are reduced, but equipment design and operation become more complex
Solution Approach 1:
The patent utilizes pneumatic principles by implementing pressure management systems including pressure-resistant reactors, reheaters, and cyclones, along with compressors and pressure control mechanisms. These pneumatic components and control systems manage the elevated pressure operations, reducing gas volumes while maintaining operational control through specialized equipment designed for high-pressure rapid thermal processing.
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 approach allows for increased carbonaceous feedstock rates without the need for larger equipment, maintaining operational efficiency and reducing costs by keeping the reactor and reheater sizes consistent.
Implementation Method 1
The heated inorganic solid particulates transfer heat to pyrolyze the carbonaceous material forming char and gaseous products
Implementation Method 2
Fast pyrolysis is a generic term that encompasses various methods of rapidly imparting a relatively high temperature to feedstocks for a very short time
Implementation Method 3
The reheater is a vessel that burns the char into ash and reheats the inorganic solid particulates
Implementation Method 4
The cyclone separates the gaseous products and solids (e.g. inorganic solid particulates and char)
Implementation Method 5
The inorganic solid particulates and char are contained in the lower portion of the reheater and are fluidized by the air, forming a fluidized bubbling bed
Data Source
AI summary
Embodiments of methods and apparatuses for rapid thermal processing of carbonaceous material are provided herein. The method comprises the step of contacting a carbonaceous feedstock with heated inorganic heat carrier particles at reaction conditions effective to rapidly pyrolyze the carbonaceous feedstock to form a product stream comprising pygas, pyrolysis oil, and solids. The solids comprise char and cooled inorganic heat carrier particles. The reaction conditions include a reactor pressure of about 70 kPa gauge or greater.