Rotatable Pyrolysis Reactor with Sweep Fluid Injection
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Solution Overview
Problem
Current methods for treating polymer waste are inefficient in reducing environmental impact and maximizing hydrocarbon recovery, as they often result in blowback of pyrolyzed gases and require complex water management due to high water content.
Innovation Solution
A system comprising a hollow chamber with rotatable spaces and a heating system that allows for differential temperature control and the injection of sweep fluids like steam or condensable gases to enhance fluid flow and separate pyrolysis products, preventing gas blowback and simplifying water management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymer waste is treated by pyrolysis using a conventional reactor with carrier gas flow, then thermal decomposition occurs to produce pyrolyzed gas, but gas blowback occurs and water management becomes complex
Solution Approach 1:
The reactor is divided into multiple zones (heating zone and pyrolysis zone) separated by a partition wall, allowing independent control of temperature and gas flow in each zone. This segmentation prevents gas blowback by controlling the flow direction through sweep gas injection in the heating zone while maintaining efficient pyrolysis in the pyrolysis zone.
Solution Approach 2:
Sweep gas is introduced as an intermediary substance in the heating zone to control gas flow direction and prevent blowback. The sweep gas acts as a mediator that directs the flow of pyrolyzed gas through the system without allowing reverse flow, thereby solving the gas blowback problem while maintaining pyrolysis efficiency.
2Productivity
If polymer waste is treated by pyrolysis with high water content, then complete decomposition occurs, but complex water management systems are required
Solution Approach 1:
Water is extracted and removed from the pyrolysis process by introducing sweep gas that carries water vapor away from the reaction zone. The sweep gas flow extracts water products from the decomposition process and transports them to condensation systems, simplifying water management while ensuring complete decomposition of polymer waste.
Solution Approach 2:
Gas flow dynamics are utilized to manage water removal. Sweep gas is introduced to create a controlled flow that carries water vapor through the system, using pneumatic principles to transport and remove water products without requiring complex mechanical water management systems.
3Ease of manufacture
If uniform temperature is applied throughout the reactor, then heating is simplified, but hydrocarbon recovery efficiency decreases
Solution Approach 1:
Different temperature conditions are applied to different zones of the reactor. The heating zone receives higher temperatures to ensure complete decomposition, while the pyrolysis zone maintains optimal temperature for hydrocarbon recovery. This local differentiation of temperature quality maximizes both decomposition completeness and hydrocarbon recovery efficiency.
Solution Approach 2:
The reactor is segmented into zones with different temperature requirements. The partition wall allows independent temperature control in each zone, enabling the heating zone to operate at higher temperatures for complete decomposition while the pyrolysis zone maintains conditions optimal for hydrocarbon recovery, thereby resolving the contradiction between heating simplicity and recovery 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 approach effectively collects a product comprising sweep fluid and pyrolyzed gas, reduces water content, and enhances hydrocarbon recovery, improving the techno-economic performance and sustainability of polymer waste pyrolysis processes.
Implementation Method 1
polymer waste material can be treated by pyrolysis, i.e. by thermal decomposition of the polymer waste material at elevated temperatures in an inert atmosphere
Implementation Method 2
at least one sweep fluid injector capable of injecting at least one sweep fluid into the first space or into the first space and into the second space in order to form a fluid flow towards at least one gas outlet
Implementation Method 3
the heating system comprises a first heating space configured to receive a first heating gas having a first temperature and a second heating space configured to receive a second heating gas having a second temperature
Data Source
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AI summary
According to an example aspect of the present invention, there is provided a system (1) comprising a hollow chamber (2) comprising a first chamber (3) and a second chamber (4), wherein the second chamber (4) is rotatable or the first chamber (3) and the second chamber (4) are rotatable, a heating system (19) configured to heat the second chamber (4) or to individually heat the first chamber (3) and the second chamber (4), a lance (5) having at least one feed outlet (6), wherein the lance (5) extends within the hollow chamber (2) at least through the first chamber (3), and wherein the system (1) is configured to feed polymer waste (7) into the second chamber (4) via the at least one feed outlet (6), at least one injector (21) capable of injecting at least one sweep fluid into the first chamber (3) or into the first chamber (3) and into the second chamber (4) in order to form a fluid flow towards at least one gas outlet (20) for collecting a product (13) comprising the at least one sweep fluid and a gas (22) from at least partially pyrolyzed polymer waste .