Waste Sludge Incinerator with Pyrolysis and Gasification
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Solution Overview
Problem
Current technologies for treating waste products from refineries and petrochemical plants with high calorific value are inefficient, generating excessive inert waste, requiring high investment and maintenance costs, and failing to achieve significant energy recovery due to complex processes and heterogeneous waste characteristics.
Innovation Solution
A reaction equipment system comprising a rotating drying and pyrolysis device, a rotating gasification device, and a combustion device, physically separated and positioned on different levels, with indirect heat-exchange systems to produce syngas with high calorific value, reducing final solid residues by 70%, and allowing self-sustenance and energy recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical treatment, chemical treatment, or biological treatment is used to treat organic waste, then the waste can be stabilized or processed, but the quantity of final inert waste increases and treatment costs become extremely expensive (at least 500 euro/t)
Solution Approach 1:
The patent applies thermal treatment parameters (temperature, heating rate) to fundamentally change the waste processing approach. By using controlled combustion and pyrolysis at specific temperature ranges, the system transforms organic waste into energy and reduced volume residues, achieving both effective treatment and waste minimization simultaneously
Solution Approach 2:
The patent converts the harmful aspect of waste (organic material that requires disposal) into a beneficial resource (energy). By exploiting the calorific value of organic waste through controlled thermal processes, the system generates energy while minimizing final residue, turning a disposal problem into an energy recovery opportunity
2Loss of substance
If co-combustion is used to reduce waste quantity, then the waste volume decreases significantly, but the plant requires significant treatment capacity (hundreds of thousands of t/y) to be economically viable
Solution Approach 1:
The patent segments the treatment process into distinct stages (drying, pyrolysis, combustion) that can be optimized for smaller scale operations. This segmentation allows the system to handle smaller waste quantities efficiently without requiring the massive throughput of traditional co-combustion plants, making the technology economically viable at smaller treatment capacities
Solution Approach 2:
The patent implements self-sustaining thermal processes where the waste itself provides the energy needed for treatment. The organic waste's calorific value is exploited to maintain combustion temperatures and drive the pyrolysis process, eliminating or reducing the need for external energy inputs and making smaller-scale operations economically viable
3Temperature
If incineration plants with flameless oxyfuel burners are used to treat dangerous waste, then high temperatures (above 2,000°C) can be reached, but the technology has not been developed on an industrial scale and requires significant investment
Solution Approach 1:
The patent applies partial combustion and pyrolysis actions rather than complete combustion at extreme temperatures. By using controlled oxygen supply and staged heating, the system achieves effective waste treatment at more moderate temperatures, reducing the complexity and investment required compared to high-temperature flameless oxyfuel technologies
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 effectively reduces final solid residues by 70%, produces syngas with a high calorific value for self-sustenance and additional uses, and operates efficiently with low maintenance and investment, suitable for small to medium-sized plants, achieving high energy recovery and waste minimization.
Implementation Method 1
a drying and pyrolysis device (4) which rotates around its longitudinal, tilted rotation axis (A)... said equipment being characterized in that: said combustion device (14), drying and pyrolysis device (4), gasification device (6) are physically separated and positioned on three different levels... the longitudinal rotation axis (A) of the drying and pyrolysis device (4) is tilted with respect to both the longitudinal rotation axis (B) of the gasification device (6) and also with respect to the longitudinal axis (C) of the combustion device (14)... it comprises a second heat-exchange device (12) in fluid communication with the first indirect heat-exchange device (3) and the combustion device (14)
Implementation Method 2
a drying and pyrolysis device (4) which rotates around its longitudinal, tilted rotation axis (A)... Gasification of the dried sludge at a temperature ranging from 750 to 950° C. for an overall period ranging from 30 to 60 minutes... forming syngas and solid residue
Implementation Method 3
a gasification device (6) which rotates around its longitudinal, horizontal rotation axis (B)... Gasification of the dried sludge at a temperature ranging from 750 to 950° C. for an overall period ranging from 30 to 60 minutes... forming syngas and solid residue
Implementation Method 4
a combustion device (14) comprising a burner (13) having a longitudinal horizontal axis (C)... combustion of the syngas at a temperature ranging from 850 to 1200° C. and recycling of the combustion products for the drying and gasification phases
Data Source
AI summary
The present invention relates to reaction equipment for the treatment of organic and/or inorganic waste of refineries or petrochemical plants comprising: •—a drying and pyrolysis device (4) which rotates around its longitudinal, tilted rotation axis (A), •—a gasification device (6) which rotates around its longitudinal, horizontal rotation axis (B), •—a combustion device (14) comprising a burner (13) having a longitudinal horizontal axis (C), •—at least one settling chamber (15) for the collection of intermediate solid residues and the accumulation of intermediate gaseous reaction products, •—at least one outlet duct of the gaseous end-products (16), at least one outlet duct of the solid end-products (7), and at least one inlet duct of the feedstock (2) •—said combustion device (14), drying and pyrolysis device (4), gasification device (6) are physically separated and positioned on three different levels, •—the longitudinal rotation axis (A) of the drying and pyrolysis device (4) is tilted with respect to both the longitudinal rotation axis (B) of the gasification device (6) and also with respect to the longitudinal axis (C) of the combustion device (14), •—the longitudinal rotation axis (B) of the gasification device (6) is parallel to the longitudinal axis (C) of the combustion device (14), •—the combustion device (14) is in fluid communication with the drying and pyrolysis device (4), •—the drying and pyrolysis device (4) comprises, in its interior, a first indirect heat exchange device (3) in which the combustion fumes coming from the combustion device (14) flow, •—at least one settling chamber (15) in fluid communication with said drying and pyrolysis device (4) and with said gasification device (6) and with said combustion device (14), •—conveying means (5) are positioned in the settling chamber (15) and put the drying and pyrolysis device (4) in fluid communication with the gasification device, •—it comprises a second heat exchange device (12) in fluid communication with the first indirect heat exchange device (3) and the combustion device (14), •—it comprises means for the suction of the intermediate gaseous reaction products, said means being positioned in the settling chamber (15).