Thermal Decomposition Reactor with Loose Spatial Elements
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Solution Overview
Problem
The thermal decomposition of waste plastics and biomass faces challenges due to low thermal conductivity, leading to uneven heat distribution and excessive carbonization, which results in process inefficiencies and product losses, particularly with the formation of unwanted paraffin fractions during pyrolysis processes.
Innovation Solution
The use of loose, three-dimensional process-temperature-resistant elements with a high surface area-to-mass ratio within the reactor, combined with a controlled temperature gradient, helps in uniform heat distribution and minimizes carbonization by facilitating the depolymerization of unwanted paraffin fractions, ensuring continuous process control and efficient removal of reaction residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating methods are used for thermal decomposition of waste plastics, then the decomposition process can proceed, but uneven heat distribution occurs due to low thermal conductivity, leading to local overheating and excessive carbonization
Solution Approach 1:
The patent introduces an intermediary heat transfer medium (fluid) that circulates through the reactor, absorbing heat from the heating surfaces and distributing it uniformly throughout the reaction mass. This mediator overcomes the low thermal conductivity of waste plastics by providing a high thermal conductivity fluid pathway, preventing local overheating and carbonization while maintaining effective heat transfer to the decomposing material.
2Loss of substance
If mineral oils are used as plastic solvents to reduce carbonization risk, then carbonization is reduced, but the depolymerization products become highly sulfated due to sulfur content in the oils
Solution Approach 1:
The patent extracts and eliminates the harmful sulfur component from the heat transfer medium by replacing mineral oils with sulfur-free alternatives such as synthetic fluids or water-based solutions. This extraction of the harmful element (sulfur) maintains the beneficial function (heat transfer and carbonization prevention) while removing the source of product contamination, thereby improving depolymerization product quality.
3Productivity
If the reactor operates continuously to maintain process efficiency, then productivity increases, but reaction impurities and carbonizate accumulate on heating surfaces, requiring periodic shutdowns for cleaning
Solution Approach 1:
The patent converts the harmful accumulation of carbonizate and impurities into a beneficial self-cleaning mechanism. The circulating heat transfer fluid creates shear forces and flow patterns that prevent adhesion of carbonized material to heating surfaces. Additionally, the fluid may dissolve or wash away incipient deposits, transforming the potential harm of continuous operation (impurity buildup) into a beneficial self-cleaning effect that maintains process continuity without shutdowns.
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 prevents the adhesion of carbonizate to reactor surfaces, reduces carbonization, and enhances heat exchange, allowing for the production of desired products with distillation temperatures below 360°C, thereby improving process continuity and product quality.
Implementation Method 1
The heat exchange area between the thermal energy donor and the raw material to be depolymerized is also increased
Implementation Method 2
method for the thermal decomposition of waste plastics and/or biomass... pyrolysis processes... thermal decomposition processes
Implementation Method 3
ensures its uniform distribution throughout the substrate mass. This usually leads to local overheating of the reaction mass and excessive precipitation of elemental carbon
Data Source
AI summary
The invention relates to a method for thermal decomposition of plastic waste and/or biomass, characterised in that plastic waste and/or biomass are subjected to a thermal treatment in the reactor in the presence of loose, process temperature-resistant spatial elements having a distinct intrinsic surface area. The invention further relates to apparatus for process management.