Solid Inert Residue Dryer and Extraction System
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Solution Overview
Problem
The challenge lies in effectively removing volatile organic materials from solid inert residues (SIR) emitted from pyrolytic reactors to meet environmental regulations, as existing methods often result in residues being deposited in landfills or used as fillers without adequate treatment.
Innovation Solution
A system comprising heated dryers and a collection area with compression systems, utilizing inert sweep gases and multiple plungers or augers to volatilize and compact SIR, ensuring minimal volatile organic material remains, thereby preventing air or vapor escape and facilitating safe disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If heated dryers are used to remove volatile organic material from SIR, then environmental compliance is improved, but energy consumption increases
Solution Approach 1:
The system performs preliminary drying of SIR in heated dryers before collection and compression. By removing volatile organic materials in advance through controlled heating, the system ensures environmental compliance is achieved before disposal, preventing harmful emissions during subsequent handling and landfill operations.
Solution Approach 2:
The system controls and adjusts temperature parameters in the heated dryers to optimize the removal of volatile organic materials. By carefully managing heating parameters and residence time, the system achieves effective volatilization while minimizing excessive energy consumption.
2Volume of moving object
If collection area with compression system is used to compact SIR, then disposal space efficiency is improved, but device complexity increases
Solution Approach 1:
The collection area is divided into multiple chambers or zones, each equipped with its own compression mechanism. This segmentation allows independent operation of each compression unit, simplifying control and maintenance while achieving high overall compaction efficiency for the SIR material.
Solution Approach 2:
The system employs mechanical compression mechanisms within the collection area to compact SIR material. By using straightforward mechanical press systems rather than complex chemical or thermal treatment methods, the system achieves volume reduction with relatively simple and reliable equipment.
3Productivity
If multiple plungers and augers are used to convey SIR, then transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The conveyance system is divided into multiple independent plunger and auger units that operate in sequence or parallel. Each unit handles a portion of the SIR material flow, enabling high overall transfer rates while keeping individual component designs simple and manageable.
Solution Approach 2:
The system combines plunger mechanisms for pushing material with auger mechanisms for conveying and mixing. By merging these different conveyance methods into an integrated system, the patent achieves high transfer efficiency through complementary actions that compensate for each other's limitations.
4Object-affected harmful factors
If seals are installed to prevent vapor escape, then environmental safety is improved, but manufacturing complexity increases
Solution Approach 1:
The system uses flexible sealing elements and thin film barriers at critical interfaces in the collection and conveyance areas. These simple-to-install sealing components effectively prevent flammable and harmful vapors from escaping without requiring complex mechanical sealing systems.
Solution Approach 2:
The system creates an inert atmosphere within the collection area by filling it with inert gas. This approach prevents vapor escape and combustion risks without requiring complex mechanical seals, as the inert environment inherently prevents harmful interactions and simplifies sealing requirements.
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 efficiently removes volatile organic materials from SIR, allowing for the safe compaction and disposal of residues, meeting environmental standards and preventing flammable vapor escape, thus ensuring environmental compliance and safe handling.
Implementation Method 1
A heated dryer for treating the emitted SIR comprises heating said residues to substantially remove the volatile organic material therein
Implementation Method 2
Preferably a sweep gas comprising an inert, non-condensable gas is also utilized to liberate the volatile organic material from the SIR
Implementation Method 3
the residues are transferred to a collection area that compresses (compacts) the residues into a mass of material
Implementation Method 4
various seals prevent flammable and/or harmful vapors from escaping conveyance system
Data Source
AI summary
Plastic conversion vessels such as pyrolytic reactors convert plastic waste materials such as polymers, or hydrocarboneous material, or both, via in situ chemical reactions comprising cracking, recombination, reforming, recracking, and the like, to usable chemical compounds such as naphtha, diesel fuel, heavy oil, wax, and the like. Inherent within the polymers and/or carbonaceous material are generally solid, inert residues such as various fillers, pigments, flame retardants, silica, aluminum, talc, glass, clay, and so forth. Such solid inert residues (SIR) must be treated to remove residual volatile organic material therefrom in order to meet acceptable environmental standards and/or limits. A heated dryer for treating the SIR comprises heating units to remove excessive volatile organic material therefrom as when moved along a conveyor that transfers said material to a collection area. The collection area comprises one or more pistons that are capable of compacting and discharging said SIR material. Another collection area embodiment comprises a plurality of plungers that transfer the SIR material from said collection area to a plunger collection area, and subsequently to a collection container.