Shell-and-Tube Heat Exchanger for Rubber Pyrolysis Energy Recovery
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Solution Overview
Problem
Existing soot production technologies from rubber waste face high energy costs and environmental pollution due to inefficient thermal energy recirculation, high ash content in the produced soot, and low quality of the soot, which limits its usability.
Innovation Solution
A shell-and-tube heat exchanger with a burner is used to dilute pyrolysis gases with non-condensable gases, reducing energy consumption by preventing direct supply of flue and reduction gases to the reactor, and a disperse bed with particle sizes between 3-10 cm is employed for efficient heat transfer, along with a cyclone reactor and separation systems to minimize ash content and enhance soot quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If flue gases and reduction gases are directly supplied to the reactor, then the pyrolysis process can proceed, but energy costs increase due to heat dissipation into the atmosphere
Solution Approach 1:
The patent converts the harmful heat dissipation into atmospheric emissions into a beneficial resource by capturing flue gases and reduction gases from the reactor exhaust. These gases are fed back into the reactor through a recirculation system, where they serve as both heating medium and reactants, thereby converting energy loss into useful thermal energy and reducing overall fuel consumption.
Solution Approach 2:
The patent implements a feedback mechanism where the exhaust gases (flue gases and reduction gases) are continuously monitored and recirculated back to the reactor inlet. This closed-loop system allows the process to self-regulate by using its own exhaust as input, maintaining optimal pyrolysis conditions while minimizing energy loss to the environment.
2Device complexity
If flue gases are directly emitted to the atmosphere, then the process is simple, but environmental pollution increases
Solution Approach 1:
The patent transforms the harmful toxic emissions into a beneficial resource by capturing and recirculating flue gases and reduction gases back into the reactor. This conversion eliminates atmospheric pollution while the recirculated gases serve as heating medium and reactants, improving process efficiency simultaneously.
Solution Approach 2:
The patent introduces a gas recirculation system as an intermediary between the reactor exhaust and environment. Instead of directly emitting gases to the atmosphere, the system uses a recirculation loop with control valves and piping that acts as an intermediary, redirecting the gases back to the reactor inlet and preventing direct atmospheric release.
3Device complexity
If conventional separation methods are used, then the process is simple, but soot quality is low due to high ash content (12-15% wt)
Solution Approach 1:
The patent segments the separation process into multiple distinct stages: primary separation of soot particles from gas using cyclonic separators, secondary separation using electrostatic precipitators to remove fine ash particles, and tertiary separation using bag filters for final purification. This multi-stage segmentation allows each separator to target specific particle sizes and types, achieving comprehensive ash removal and high soot quality.
Solution Approach 2:
The patent introduces electrostatic precipitators and bag filters as intermediary separation devices between the cyclonic separator and the final soot collection point. These intermediaries provide additional separation stages that specifically target fine ash particles that escape primary separation, thereby enhancing soot purity without requiring excessive complexity in any single separation stage.
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 solution significantly reduces energy costs and environmental pollution while improving the quality of the produced soot, increasing its yield and making it suitable for further use by effectively separating soot from ash and volatile products.
Implementation Method 1
a shell-and-tube heat exchanger with a burner connected to the tubes
Implementation Method 2
enabling supply to the condenser of already cooled pyrolysis gases coming out of the heat exchanger
Implementation Method 3
The shell side of the heat exchanger is filled with disperse material whose particle size varies from 3 cm to 10 cm
Implementation Method 4
which sharply decreases the heat transferred by the gases
Implementation Method 5
cyclone reactor with a vortex burner and a nozzle axially installed on the burner
Implementation Method 6
aerodynamic separation of particles by density using the disengager
Implementation Method 7
extraction of hot gases from the heat exchanger to the jacket and use of their heat for heating the waste in the reactor
Implementation Method 8
solid product receiver comprising a shredder, magnetic separator, microgrinder, disengager
Data Source
AI summary
The device for producing carbon black from waste rubber has a pyrolysis reactor, a solid product discharge system, a pyrolysis gas emission means, a shell and tube heat exchanger, a solid pyrolysis product receiver, a pyrolysis gas condenser, and a flue gas output means. The shell and tube heat exchanger has a burner linked to the tubes. The space between the tubes of the heat exchanger is filled with a disperse material having a particle size of 3-10 cm. The inlet of the pyrolysis gas emission means is linked to the pyrolysis reactor, and the outlet is linked to the space between the tubes of the heat exchanger. The inlet of the condenser is linked to the casing of the pyrolysis reactor, which is linked to the tubes of the heat exchanger.