Screw Conveyor Cooling Chamber for Char Removal

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for removing char particles from pyrolysis systems are inefficient and pose safety risks due to the risk of spontaneous ignition, requiring prolonged downtime and manual handling.

Innovation Solution

A screw conveyor system with a physically isolated cooling chamber allows for efficient heat exchange between a cooling fluid and char, reducing the time needed to cool char to a safe temperature for removal, while preventing contamination and ensuring continuous operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If char is stored in a pyrolysis chamber after processing, then char can be removed, but the system must wait approximately 70 hours to prevent spontaneous ignition, causing plant shutdown and time loss

Engineering Contradiction:

Improvesafety of char removalVSAvoiddowntime for char removal

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention extracts the cooling function from the pyrolysis chamber by introducing a separate cooling screw conveyor with a cooling chamber. This allows char to be cooled and removed continuously without requiring the entire pyrolysis system to shut down and wait 70 hours, thus resolving the contradiction between safety and time loss.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The cooling screw conveyor acts as an intermediary device between the pyrolysis chamber and the external environment. It provides a controlled cooling chamber where char can be safely cooled and transported without direct exposure to oxygen, enabling continuous operation while maintaining safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If a cooling screw conveyor is used to transport char, then char can be moved, but cooling fluid may contact and contaminate the dried char

Engineering Contradiction:

Improvecontinuous char removalVSAvoidpurity of dried char

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The screw conveyor is segmented into distinct functional zones: a cooling chamber where cooling fluid contacts the char, and a drying chamber where dried char is transported. This segmentation allows continuous removal while preventing contamination of the final dried char product.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The screw conveyor itself acts as an intermediary barrier that separates the cooling fluid from the dried char. The design ensures that cooling fluid and dried char never contact each other, enabling continuous operation while maintaining char purity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If manual handling of char is used, then char removal is simple, but spontaneous ignition risk increases and handling time is prolonged

Engineering Contradiction:

Improvesimplicity of char removalVSAvoidspontaneous ignition risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The invention replaces manual mechanical handling with an automated cooling screw conveyor system. This mechanical system continuously transports and cools char, eliminating the need for manual handling while reducing ignition risk through controlled cooling and oxygen exclusion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cooling chamber creates an inert environment by excluding oxygen from contact with hot char during the critical cooling period. This inert atmosphere prevents spontaneous ignition while the screw conveyor automates the removal process, resolving the contradiction between ease of operation and safety.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 system enables secure and efficient removal of char in under 2 hours, eliminating the risk of spontaneous ignition and allowing for continuous plant operation, thereby maximizing throughput and minimizing bottlenecks.

Implementation Method 1

The cooling chamber allows for a heat exchange between a cooling fluid and the char on the char contact surface of the screw conveyor in operation

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

Pyrolysis is a type of thermolysis, and is most commonly applied to organic materials exposed to high temperatures

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentEP3260519B1Removal of char in a process for conversion of waste hydrocarbon material into fuel

Publication Date: 2025.02.19 PLASTIC ENERGY LTD

Figure 1
Figure 2
Figure 3

AI summary

The invention discloses screw conveyor unit (10, 20, 30) for removing char (1) from a system for processing plastic waste, the screw conveyor unit (10, 20, 30) comprising - a screw conveyor (11,21,31), comprising a char contacting surface (12, 32) and - a cooling chamber (13, 23, 33) adapted to contain a cooling fluid (2), arranged such that - the cooling chamber (13, 23, 33) is physically isolated from the char contacting surface (12, 32) of the screw conveyor (11, 31) and - the screw conveyor (11, 31) and the cooling chamber (13, 23, 33) allow, in operation, a heat exchange between the cooling fluid (2) and the char (1) when the cooling chamber (13, 23, 33) contains a cooling fluid (2). The invention also concerns a system for treatment of waste plastics and a method for removing char from a system for treatment of waste plastics.