A continuous reflux reactor and controlled condenser system for thermochemical treatment of plastic and/or elastomeric waste has five zones with different complements. The zones comprises the bottom zone, pyrolysis zone, meeting zone, reflux zone and extraction zone. The reactor uses a reflux zone to increase the production of a light oil in the process. The reflux zone is equipped with some studded tubes that enhances the contact area. Cold molten salt is used as the cooling element of this step. The pyrolysis zone, where the material will be pyrolyzed, has the differential of being equipped with molten salt coils using hot molten salt as the heating element. After the material passes to all zones, the material goes to a cyclone that will condense heavier hydrocarbons present in this step and send the light hydrocarbons to the condensers.

A high-temperature plastic pyrolysis process that can produce high yields of ethylene, propylene and other light olefins from waste plastics is disclosed. The plastic feed is pyrolyzed at a high temperature of about 600 to about 900° C. directly to monomers, such as ethylene and propylene. During pyrolysis, the plastic feed is contacted with a diluent gas stream at a mole ratio of carbon feed to diluent gas of 0.6 to 20.

A plastic pyrolysis process produces light olefin product and heavier products. The light olefin products are separated in a recovery process while the heavier product can be sent to a cracking unit to be further cracked to desired products. The cracked effluent stream may be subjected to the recovery process along with the light olefin product.

Disclosed is a method for reducing the tar content in pyrolysis gas generated in a pyrolysis reactor (1). The method comprises the steps of: guiding the pyrolysis gas through a filter (2) to remove at least 90% of all the particles in the pyrolysis gas having a particle size down to 7μ and preferably down to 4μ from the pyrolysis gas, partially oxidizing the pyrolysis gas in a partial oxidation reactor (3) to remove tar from the pyrolysis gas, and guiding the pyrolysis gas through a coke bed (4) to further remove tar from the pyrolysis gas. Furthermore, a two-stage gasifier (6) is disclosed.

A system and method for making syngas using carbonaceous feedstock, including organic material and/or polymeric material such as ground tire, wood, coal, and the like.

An apparatus is provided for processing reusable fuel comprising: a continuous material supply assembly; a heated airlock feeder configured to continuously receive and process the material supply received therein; a reactor configured to receive the processed material from the heated airlock feeder; and a vapor refining system configured to process vapor supplied by the reactor. The apparatus may comprise a char disposal system configured to eliminate char from the reactor. The apparatus may also comprise a thermal expansion system configured to allow thermal expansion of the reactor. A cooling system may be configured to receive processed fuel from the reactor.

An apparatus is provided for processing reusable fuel comprising: a continuous material supply assembly; a heated airlock feeder configured to continuously receive and process the material supply received therein; a reactor configured to receive the processed material from the heated airlock feeder; and a vapor refining system configured to process vapor supplied by the reactor. The apparatus may comprise a char disposal system configured to eliminate char from the reactor. The apparatus may also comprise a thermal expansion system configured to allow thermal expansion of the reactor. A cooling system may be configured to receive processed fuel from the reactor.

Provided are separation systems and related methods for use in processing organic polymeric feed materials—such as plastics—to form pyrolysis oil. The disclosed systems can be operated in a continuous manner and utilize novel liquid-solid separation techniques integrated with a novel condensing approach so as to operate in a product-efficient and an energy-efficient manner.

An operations unit, comprising: a first chamber; a second chamber; a conduit extending through the first chamber and into the second chamber, the conduit being at least partially enclosed by a conduit jacket that defines an outer diameter, the conduit placing the second chamber into fluid communication with an environment exterior to the chamber, the second chamber comprising a wall facing the conduit jacket, and the second chamber being rotatable relative to the first chamber; a seal defining a boundary between the first chamber and the second chamber, the seal extending radially from the wall of the second chamber toward the conduit j acket, the seal comprising a flange, the flange defining an inner diameter, (a) the seal comprising a layered portion that comprises a plurality of ring-shaped portions, or (b) the seal comprising a brush that rotatably abuts the conduit jacket.

This disclosure provides a method of making a high-fixed-carbon material comprising pyrolyzing biomass to generate intermediate solids and a pyrolysis vapor; condensing the pyrolysis vapor to generate pyrolysis liquid; blending the pyrolysis liquid with the intermediate solids, to generate a mixture; and further pyrolyzing the mixture to generate a high-fixed-carbon material. A process can comprise: pyrolyzing a biomass-comprising feedstock in a first pyrolysis reactor to generate a first biogenic reagent and a first pyrolysis vapor; introducing the first pyrolysis vapor to a condensing system to generate a condenser liquid; contacting the first biogenic reagent with the condenser liquid, thereby generating an intermediate material; further pyrolyzing the intermediate material in a second pyrolysis reactor to generate a second biogenic reagent and a second pyrolysis vapor; and recovering the second biogenic reagent as a high-yield biocarbon composition. The process can further comprise pelletizing the intermediate material. Many process and system configurations are disclosed.