Waste Conversion via Microwave Pyrolysis and Metal Wall Reactor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current waste processing methods, such as high temperature incineration and pyrolysis, generate pollutants and produce residues that are difficult to manage, and existing technologies for converting solid waste into useful products are inefficient and environmentally harmful.
Innovation Solution
A method involving low-frequency microwave irradiation of waste materials in a double metal wall reaction vessel, producing coal, asphalt, liquid hydrocarbons, organic acids, methane, and hydrogen, with specific conditions of temperature and pressure, and optional physicochemical reactions to enhance product yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high temperature incineration is used to convert waste to energy, then electric energy is generated, but high polluting emissions and difficult-to-manage ashes are produced
Solution Approach 1:
The patent changes the temperature parameter from high temperature incineration (typically above 800°C) to low temperature pyrolysis (200-500°C), and modifies the atmospheric conditions from oxidative to inert/anaerobic. This parameter transformation allows energy recovery while avoiding the formation of harmful emissions and difficult-to-manage ash residues that characterize high temperature incineration processes.
Solution Approach 2:
The patent utilizes phase transition of waste materials from solid to gas phase through pyrolysis, where organic matter decomposes into syngas (CO, H2, CH4) and biochar. This phase transition enables energy recovery in gaseous form while leaving behind stable solid residues that are easier to manage compared to incineration ashes, thereby resolving the contradiction between energy generation and harmful byproduct formation.
2Use of energy by moving object
If gasification or anaerobic digestion technologies are used for energetic recovery, then steam or electricity is obtained, but large amounts of residual waste materials remain
Solution Approach 1:
The patent optimizes temperature and pressure parameters within specific ranges (200-500°C, 1-20 bar) to maximize conversion efficiency. By controlling these parameters, the system achieves higher conversion of waste to useful products (syngas and biochar) compared to conventional gasification or anaerobic digestion, thereby reducing residual waste while maintaining energy production efficiency.
Solution Approach 2:
Instead of discarding residual materials as waste, the patent recovers them as valuable products. The solid residue (biochar) is recovered as a useful product with potential applications in agriculture or as fuel, and the gaseous products are recovered as syngas for energy generation. This recovery approach transforms what would be discarded residues into valuable resources, resolving the contradiction between energy recovery and waste reduction.
3Object-affected harmful factors
If microwave irradiation is used for disinfection and volume reduction, then the organic waste is disinfected and volume is reduced, but the treated material still needs to be deposited in landfills
Solution Approach 1:
The patent utilizes phase transition from solid to gas phase through controlled pyrolysis, converting organic waste into syngas and biochar. This phase transition achieves volume reduction and disinfection while simultaneously creating valuable products that eliminate the need for landfill deposition, thereby resolving the contradiction between waste treatment effectiveness and landfill requirement.
Solution Approach 2:
The patent recovers the treated material as valuable products (syngas for energy and biochar for various applications) rather than discarding it as treated waste. This recovery approach eliminates the need for landfill deposition while maintaining the disinfection and volume reduction benefits, thus resolving the technical contradiction.
4Manufacturing precision
If traditional pyrolysis with thermal energy from burners is used, then decomposition is achieved, but gases are released into the environment and energy efficiency is reduced
Solution Approach 1:
The patent replaces the mechanical/chemical combustion system (burners) with an electromagnetic radiation system (microwave irradiation). This substitution allows for more precise control of the decomposition process, reduces energy losses associated with heat transfer, and minimizes harmful gas emissions by operating in an inert/anaerobic environment, thereby resolving the contradiction between decomposition control and environmental harm.
Solution Approach 2:
The patent changes the energy input method from external thermal energy (burners) to internal electromagnetic energy (microwaves), and controls temperature within a specific range (200-500°C). This parameter transformation enables precise decomposition control while reducing energy inefficiency and harmful emissions, as microwaves provide direct heating with minimal heat loss and allow operation without atmospheric oxygen.
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 method effectively converts waste into valuable products while minimizing pollution and residue generation, achieving efficient energy use and environmental sustainability.
Implementation Method 1
said outer wall blocks the transfer of thermal energy by conduction and convection, whereby said outer metal wall is a secondary source of radiation for said material contained within said inner metal wall and whereby photon radiation from said outer wall passes through said inner wall of said reaction vessel
Implementation Method 2
The outer wall blocks the transfer of thermal energy by conduction and convection, whereby the outer metal wall is a secondary source of radiation
Implementation Method 3
subjecting the waste material to irradiation with low frequency macro waves, with a wavelength of between 700 nm and 1 mm
Implementation Method 4
Microwave irradiation of organic waste is used for processes of disinfection by internal heating of the organic waste, caused by internal friction as a result of the application of microwaves
Implementation Method 5
Other approaches are different methods of pyrolysis in which the decomposition is performed with application of thermal energy to the material to be pyrolyzed
Implementation Method 6
The outer wall blocks the transfer of thermal energy by conduction and convection
Implementation Method 7
The outer wall blocks the transfer of thermal energy by conduction and convection, whereby the outer metal wall is a secondary source of radiation
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for producing coal, asphalt, liquid hydrocarbon, organic acids, methane gas and/or hydrogen from a waste material comprising: a) providing a waste material; b) subjecting the waste material to irradiation with low frequency macro waves, with a wavelength of between 700 nm and 1 mm, whereby the temperature is between 2050C and 9000C and the pressure is between 1.0 bar and 19.0 bar, thereby producing coal; c) optionally subjecting the residual materials in gaseous state from step b) to a physicochemical reaction in the presence of a solid metal identified as DPP B102, whereby the temperature is between 1800C and 5000C and the pressure is between 0.98 bar and 5.5 bar, thereby producing asphalt; d) optionally subjecting the residual materials in gaseous state from step b) or c) to a physicochemical reaction and/or condensation, whereby the temperature is between 1500C and 7500C and the pressure is between 0.96 bar and 200 bar, thereby producing liquid hydrocarbon; e) optionally subjecting the residual materials in gaseous state from step b), c) or d) to a physicochemical reaction in the presence of a solid metal identified as DPP D 102, whereby the temperature is between 500C and 1500C and the pressure is between 0.95 bar and 1.5 bar, thereby producing organic acids; f) optionally subjecting the residual materials in gaseous state from step b), c) d) or e) to an absorbent wash and cooling at room temperature, thereby producing methane gas and hydrogen, wherein said waste material has a composition with a carbon content of 9-85%, a hydrogen content of 1-15% and an oxygen content of 0-65% based on dry weight of the material. The invention further relates to products obtainable by such methods and an apparatus for performing such methods.