CONTINUOUS-FLOW PYROLYSIS REACTOR, POSITIVE-PRESSURE FEED HOPPER FOR PYROLYSIS REACTOR, KILN FOR PYROLYSIS REACTOR, AND PYROLYSIS SYSTEM
20240301291 ยท 2024-09-12
Inventors
Cpc classification
B29B17/04
PERFORMING OPERATIONS; TRANSPORTING
C10B53/07
CHEMISTRY; METALLURGY
B01J6/00
PERFORMING OPERATIONS; TRANSPORTING
B29C48/00
PERFORMING OPERATIONS; TRANSPORTING
F27B1/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
C10B53/07
CHEMISTRY; METALLURGY
B29B17/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A continuous flow pyrolytic reactor (200) equipped with one or more pyrolysis chamber assemblies (204) is disclosed. A positive pressure waste feeder hopper (100) for the pyrolytic reactor and its respective furnace, in addition to a pyrolysis system for the use of waste. The pyrolytic reactor (200) having a plurality of cylindrical pyrolysis chambers (201) provided, within it, with an endless screw conveyor (202) arranged longitudinally. The worm conveyor screw (202) is provided with a shaft (203), the shaft (203) being coupled to the bases of the pyrolysis chamber (201). The shaft (203) is further coupled to a rotation device that transfers torque to the shaft (203) by rotating the worm conveyor screw (202). The cylindrical pyrolysis chambers (201) are housed in an insulating housing (300) having within it two or more assemblies (204). The assemblies (204) are fed by a hopper (100) forming a pyrolysis system.
Claims
1. A continuous flow pyrolytic reactor (200) comprising: a plurality of cylindrical pyrolysis chambers (201) equipped inside with an endless helical conveyor thread (202) arranged longitudinally, the endless helical conveyor thread (202) being provided with a shaft (203), said shaft (203) being coupled to bases of the pyrolysis chamber (201); the shaft (203) is further coupled to a rotation device that transfers torque to said shaft (203) by rotating the endless conveyor helical conveyor thread (202) to rotate, the cylindrical pyrolysis chambers (201) are housed in an insulating housing (300) comprising within two or more sets (204) of cylindrical pyrolysis chambers (201); each one of the sets (204) including a plurality of chambers (201) of pyrolysis chamber (201), the cylindrical pyrolysis chamber (203) are arranged in an alternately offset direction thereof, an each one of the assemblies being arranged in the same direction.
2. (canceled)
3. The continuous flow pyrolytic reactor (200) according to claim 12, wherein the shaft (203) of a first internal cylindrical pyrolysis chamber (201i) is located below the shaft (203) of a first outer chamber (201e).
4. The continuous flow pyrolytic reactor (200) according to claim 3, wherein the collection of pyrolysis gases is carried out by at least one lower tube (2051) coupled to each of the inner cylindrical pyrolysis chambers (201i) of each of the sets (204), the lower tube (2051) being connected to an upper tube (2052) forming a unevenness; the upper tube (2052) then connects to a vertical tube (205) for collecting the pyrolysis gases.
5. The continuous flow pyrolytic reactor (200) according to claim 3, wherein a waste inlet is located above one of the ends of the first external cylindrical pyrolysis chamber (201e) of each of the sets and the coal outlet is located underneath one of the ends of the last inner cylindrical pyrolysis chamber (201i) of each of the assemblies (204).
6. The continuous flow pyrolytic reactor (200), according to claim 1, wherein the housing (300) has a parallelepipedal shape having the closure at the upper portion (301) in the shape a longitudinal cylindrical section, where the vertex of the upper portion (3011) is parallel to the longitudinal axis of the parallelepipedal portion of the housing (300).
7. The continuous flow pyrolytic reactor (200) according to claim 6, wherein the housing (300) is provided in a lower portion with a heat diffusing plate (303) in the shape of a cylindrical surface, its vertex positioned downwards, being arranged above one or more flutes (304).
8. The continuous flow pyrolytic reactor (200) according to claim 7, wherein between the edges of the heat diffusing plate (303) and each of the larger inner sides (3053) of the housing (300) is arranged a horizontal sheet (312) of refractory material provided with a plurality of holes (3121).
9. The continuous flow pyrolytic reactor (200), according to claim 6, wherein the housing (300), in the lower portion of one of its smaller sides (3051), it is provided with one or more holes (306) for the passage of one or more of the flutes (304) that are coupled to one or more gas burners (309), the said smaller side (3051) also provided with one or more visors (307), immediately above one or more holes (306): said smaller side (3051) is further provided in a lower portion with an opening for collecting ash (308).
10. The continuous flow pyrolytic reactor (200) according to claim 6, wherein the upper face (301) comprises at least one outlet hole (310) for coupling a flue gas collection pipe (311)).
11. The continuous flow pyrolytic reactor (200) according to claim 10, wherein one or more flue collection ports (310) are sized in such that the volume of the inlet gas injected by one or more burners (309) is equal to the volume of the flue gases collected in one or more ports (310).
12. The continuous flow pyrolytic reactor (200) according to claim 6, wherein the lower portion (313) of the housing (300) is provided with a combustion drawer (314) having a prismatic trapezoidal shape, with a smaller base being positioned at the bottom of the housing and below the one or more flutes (304).
13. A feeder hopper (100) with positive pressure to the continuous flow pyrolylic reactor (200) provided with an enlarged upper portion (1010) where the waste is deposited; the upper portion (1010) is passed longitudinally by a helical thread (102) endless presser in the vertical position, the helical thread (102) and further fixed to a rotating shaft (105) that couples to a rotating device (106), the hopper (100) comprises a tubular medial portion (1011), narrower than the upper portion (1010), and the tubular medial portion (1011) is passed longitudinally the helical thread (102); the rotating shaft (105) is coupled by a bearing in a bifurcation pipe (103) at the beginning of a moe portion (1012) of the hopper; the bifurcation (103) originates from pipes (104).
14. The feeder hopper (100) according to claim 13, wherein the connectors (107a, 107b) for feeding the continuous flow pyrolytic reactor (200) have a reduction in a diameter of 5 to 30% in relation to a diameter of the waste conduction tubes (104a, 104b).
15. The feeder hopper (100) according to claim 13, wherein the screw thread (102) is provided with a plurality of holes (108).
16. The feeder hopper (100) according to claim 13, wherein helical of the screw thread (102) have a larger diameter in the an upper portion (1010) in relation to a diameter of the helical thread (102) of a medial portion (1011) of the hopper, wherein said diameter is gradually reduced to the beginning of the medial portion (1011).
17. The feeder hopper (100) according to claim 13, wherein the helical screw (102) has a decrease in pitch and diameter from a lower second half of the medial portion (1011).
18. A pyrolytic reactor furnace provided with an insulating housing (300) with a parallel shape, wherein a closure in an upper portion (301) is shaped longitudinal as a cylindrical section, where a vertex of an upper face (3011) is parallel to a longitudinal axis of the parallelepipedal portion of the housing (300), a lower portion being provided with a heat diffusing plate (303) in the form of a cylindrical surface, a vertex being positioned downwards; the heat diffuser plate (303) is further arranged above one or more flutes (304).
19. The pyrolytic reactor furnace, according to claim 18, wherein between the edges of the heat diffuser plate (303) and each of the larger inner sides (3053) of the housing (300) is arranged a horizontal plate (312) made of a refractory material provided with a plurality of holes (3121).
20. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The present invention will hereafter be more fully described based on an example embodiment depicted in the drawings.
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DETAILED DESCRIPTION OF THE INVENTION
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[0068] The function of the hopper (100) is to capture the residues that are inserted into its upper portion (1010). The hopper is pierced longitudinally by a worm thread (102) endless presser in the vertical position. This helical thread (102) is further fixed on a rotating shaft (105) that couples to a rotating means (106), such as a motor.
[0069] The hopper (100) waste feeder has at least two tubes (104a) and (104b) pressed waste conductors already devoid of air (which is unwanted in the pyrolysis process). Thus, each tube (104a) and (104b) feeds a set (204) of pyrolysis chambers that are disposed within an insulating housing (300).
[0070] The flow-through pyrolysis system of the present invention has much higher energy efficiency than prior art pyrolysis systems. Energy efficiency is understood here not only by the economy achieved for the operation of the system as a whole, but mainly by the ability to convert waste into energy or products, in this case, coal, oil and gas. That is, the total energy balance is significantly improved. The gas has a higher calorific value of 42.98 (MJ/kg) at 20? C. The carbon is also of great quality, being with very low ash index, with very low humidity, with a very fine and loose granulometry and the main one is the amount of fixed carbon of 82% of the mass, being endowed, therefore, with high commercial value.
[0071] One of the reasons for the energy efficiency is that the pyrolysis process occurs simultaneously in two sets (204) of pyrolysis chambers (201), however, within the same housing (300).
[0072] The multiple pyrolysis chambers (201) are heated uniformly and therefore there is no temperature variation in the process. The form of circulation of the hot air obtained by the configuration of the furnace ensures the uniformity of the heat distribution and the efficiency of its transmission to the pyrolysis chambers (201).
[0073] The arrangement of the chambers (201) also helps in the distribution and use of heat and, as a consequence, in energy efficiency.
[0074] In the present invention, preferably there is a column with four external pyrolysis chambers (201e) and another column with four internal pyrolysis chambers (201i) forming a set (204) of pyrolysis chambers, as shown in
[0075] The pyrolytic reactor (200) of the present invention is of truly continuous flow. This capacity of the invention is provided by the constant feed of oxygen-free residues provided by the hopper (100), installed above the pyrolysis reactor (200), as shown in
[0076] In addition, hopper (100) is able to provide a greater amount of oxygen-free pressed tailings to simultaneously feed two sets (204) of pyrolysis chambers.
[0077] The cylindrical pyrolysis chambers (201) are provided, inside, with an endless screw conveyor (202) arranged longitudinally and preferably in a horizontal position, as shown in
[0078] The worm conveyor screw (202) is provided with a shaft (203), said shaft (203) being coupled to the base of the pyrolysis chamber (201) by means preferably of bearings.
[0079] The shaft (203) is further coupled to a rotational means, preferably a motor or reducing motor (not shown).
[0080] The motor may be unique for each of the assemblies (204) being the torque transferred to the shaft (203) of the pyrolysis chambers (201) by means of pulleys and belts, being the belts preferably steel.
[0081] The torque transferred to said shaft (203) rotates the helical threads (202) endless conveyors causing the residue that is undergoing the pyrolysis reaction to circulate through the pyrolytic reactor (200).
[0082] The cylindrical pyrolysis chambers (201) are housed in an insulating housing (300) comprising within it two or more sets (204) of cylindrical pyrolysis chambers (201).
[0083] The assemblies (204) allow simultaneous pyrolysis within the same housing (300). In addition, the arrangement of the pyrolysis chambers (201) alternately and spaced apart creates two columns of pyrolysis chambers on each side of the pyrolytic reactor (200), favoring the distribution of heat.
[0084] Thus, the assemblies (204) are provided with a plurality of cylindrical pyrolysis chambers (201), the axes (203) of the pyrolysis chambers (201) of each of the assemblies being arranged on top of each other forming a pair of columns in each of the assemblies (204). The columns are shifted vertically so that pyrolysis chambers (201) are shifted alternately. Preferably, the distance of the axes of the chambers (201) is the same for the uniform distribution of heat, as shown in
[0085] Preferably, the shaft (203) of the first inner cylindrical pyrolysis chamber (201i) is arranged below the shaft (203) of the first outer cylindrical pyrolysis chamber (201e), as shown in
[0086] Thus, the collection of the pyrolysis gases is carried out by means of at least one lower tube (2051) coupled to each of the inner cylindrical pyrolysis chambers (201i) of each of the assemblies (204), the lower tube (2051) being connected to an upper tube (2052) by means of knees and which in turn connects to a vertical tube (205) for collecting the pyrolysis gases, as shown in
[0087] This configuration allows pyrolysis gases to be collected in the internal pyrolysis chamber (201i), which decreases oil condensation within the pipes due to the high temperature provided by the flow of hot air in the central portion of the pyrolysis reactor (200).
[0088] In addition, the unevenness caused by the horizontal lower pyrolysis gas collection tube (2051) and the upper tube (2052) prevents the oil, perhaps condensed, from being conducted together with the pyrolysis gas. The unevenness between the pipes causes the condensed oil not to enter the vertical tube (205) for collecting the gases, preventing it from leaving disadvantageously with the gas. Heating also contributes to preventing condensation and facilitates the return of oil to the pyrolysis chambers (201). The unevenness may be accomplished by other means such as, for example, an upward angle in the tube that connects to the internal pyrolysis chamber (201i). Therefore, the embodiment of the present invention is not to be interpreted in a limiting manner.
[0089] These vapors (liquid effluents) collected by one or more pipes (2051) are sent to a condenser (not shown) that will condense the hydrocarbons (oils) and the non-condensable hydrocarbons exit the condenser in the form of pyrolytic gases that are stored to be consumed as gaseous fuel. Therefore, we have two products resulting from these vapors captured in pyrolysis (oil and gas). And a third is the coal (carbon black) that comes out from underneath, in the last cylinders of the chamber (201i) of the pyrolysis reactor (200). Coal also needs to be cooled before it can be stored.
[0090] The pyrolytic reactor waste inlet (200) is located at one end of the first outer cylindrical pyrolysis chamber (201e) of each of the assemblies and the coal outlet is located at one end of the last inner cylindrical pyrolysis chamber (201i) of each of the assemblies (204).
[0091] The housing (300) has substantially parallelepipedal shape having the closure in the upper portion (301) in substantially the shape of a longitudinal cylindrical section, where the vertex of the upper face (3011) is parallel to the longitudinal axis of the parallelepipedal portion of the housing (300), as shown in
[0092] The housing (300) is further provided in its lower portion with a diffuser plate (303) of heat in the shape of a cylindrical surface, its vertex being positioned downwards, being arranged above one or more flutes (304), as shown in
[0093] The convex diffuser plate (303) assists in distributing heat evenly within the face (300), as shown in
[0094] Between the edges of the heat diffuser plate (303) and each of the larger inner sides (3053) of the housing (300) is arranged a horizontal plate (312) of refractory material provided with a plurality of holes (3121), as shown in
[0095] Through the holes (3121) of the horizontal plate (312) of refractory material, there is a circulation of hot air inside the housing (300), as shown in
[0096] Air circulation is important, since it distributes heat homogeneously between the two assemblies (204) and through the pyrolysis chambers (201) inside the housing (300).
[0097] Hot air rises between the larger inner sides (3053) of the housing (300) and the outer pyrolysis chambers (201e) of both assemblies (204). Upon reaching the upper portion (301), the cylindrical shape promotes the conduction of hot air to the center of the housing (300). Then, the hot air currents coming from the sides meet in the upper longitudinal portion of the housing (300). This air, with a slightly lower temperature, descends through the central part of the housing (300) and encounters the heat radiated by the plate (303), which due to its cylindrical surface shape, promotes the heating of the air on a longitudinal axis. This causes hot air to spread inside the housing (300) by means of thermal convection, distributing heat homogeneously through the pyrolysis chambers (201).
[0098] The housing (300), in its lower portion of one of its smaller sides (3051), provided with one or more holes (306) for the passage of one or more flutes (304) that couple to one or more gas burners (309), preferably electronic. Said minor side (3051) is further provided with one or more displays (307), immediately above one or more holes (306).
[0099] The displays have the function of inspecting the flute flames (304), since it is common to clog one or more flame holes.
[0100] Said minor side (3051) is further provided at its lower portion with an opening for collecting ash (308). Due to the work in continuous flow for prolonged periods there is production of a small amount of ash due to the burning of the gas in the flute (304). These ashes fall into the combustion drawer (314) and due to their inverted trapezoidal prismatic shape are routed to the smaller base and accumulate there. Through the opening for the collection of ashes (308) they are from time to time removed.
[0101] The upper face (301) of the housing (300) further comprises at least one outlet port (310) for coupling one or more flue gas collection tubes (311), as shown in
[0102] The combustion gases are then treated by means of a cyclone (318) for the removal of any particulate that may have exited through the pipes (311), as shown in
[0103] The lower portion (313) of the housing (300) is provided with a combustion drawer (314) in substantially prismatic trapezoidal shape, the smaller base of the trapezoidal prism being positioned at the bottom of the housing (300) and below one or more flutes (304), as shown in
[0104] The housing (300) is integrally equipped with double coating, that is, double sheet (317) of metal with thermal insulation (316) inside, as shown in
[0105] The present invention also discloses a positive pressure waste feeder hopper (100) that is disposed above the continuous flow pyrolytic reactor (200).
[0106] The hopper (100) can be better understood by dividing it into three parts, as shown in
[0107] The upper portion (1010) is passed longitudinally by a worm thread (102) endless presser in the vertical position, the worm thread (102) being further fixed on a rotating shaft (105) that couples to a rotating means (106), preferably a motor. The upper portion (1010) is limited to the beginning of the vertical tubular portion where the edge of the helical thread (102) is very close to the vertical pipe walls. At the angle formed between the upper portion (1010) and the vertical tubular portion begins the tubular medial portion (1011).
[0108] The hopper (100) then comprises a tubular medial portion (1011), narrower than the upper portion (1010), the tubular medial portion (1011) being longitudinally traversed by the worm thread (102). The rotating shaft (105) is coupled by means of a bearing at a fork (103) at the beginning of a lower portion (1012) of the hopper.
[0109] At the beginning of the lower portion (1012), that is, at the bifurcation (103) two or more conductive tubes (104a, 104b) of pressed waste that couple to each of the assemblies (204) of the pyrolytic reactor (200) of continuous flow originate.
[0110] The bifurcation (103) helps to make a certain retention in the waste, helping in the compaction of the waste and removal of the air.
[0111] In the first half of the medial portion (1011) the distance between the edge of the helical pressing thread (102) and the tube should be as small as possible, such as for example 1 to 4 mm, preferably 2 mm. This distance avoids the jamming of waste and promotes the exit of air from them.
[0112] At the end of the lower portion are the connectors (107a, 107b) for feeding the continuous flow pyrolytic reactor (200). The connectors (107a, 107b) have a reduction in their diameter of 5 to 30% relative to the diameter of the conductive tubes (104a, 104b) of waste, preferably the reduction is 10 to 15%. This reduction in diameter produces a reduction in the inlet flow of waste in the reactor (200), important for the compaction thereof and the advantageous removal of air.
[0113] Thus, the waste enters the reactor very compressed without air and in continuous flow feeding at least two sets (204) of pyrolysis chambers (201).
[0114] In order to perform the air withdrawal, the helical thread (102) is provided with a plurality of holes (108). When pressing the material the air is expelled through the holes (108), as shown in
[0115] The helical thread (102) has a larger diameter in the upper portion (1010) relative to the diameter of the helical thread (102) of the medial portion (1011) of the hopper. That is, the first blade has a larger diameter that gradually reduces in the upper portion (1010) of the hopper (100), as shown in
[0116] This arrangement provides the ability of the hopper (100) of the present invention to be able to process in continuous flow the lighter materials, such as grass and cardboard for example. These lighter materials have difficulty being driven by gravity. Thus, the arrangements of the helical thread blades (102) force the entry of waste into the medial portion (1011) of the hopper even for the lightest materials, which present difficulties in the solutions of the state of the art.
[0117] The helical thread (102) has a decrease in pitch and diameter from the lower second half of the medial portion (1011). This arrangement increases compression and decreases the chances of waste jamming.
[0118] The present invention further discloses a pyrolytic reactor furnace provided with an insulating housing (300) having substantially parallelepipedal shape. The closure on the upper portion (301) of the furnace is shaped substantially from a longitudinal cylindrical section, where the vertex of the upper face (3011) is parallel to the longitudinal axis of the parallelepipedal portion of the housing (300).
[0119] The lower portion of the oven is further provided with a diffuser plate (303) of heat in the shape of a cylindrical surface, its apex being positioned downwards. The heat diffuser plate (303) is further disposed above one or more flutes (304), as shown in
[0120] Between the edges of the heat diffuser plate (303) and each of the larger inner sides (3053) of the housing (300) is arranged a horizontal plate (312) of refractory material provided with a plurality of holes (3121), as shown in
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[0122] The present invention further discloses a pyrolysis system comprising a hopper (100) positive pressure waste feeder for the continuous flow pyrolytic reactor (200) passed longitudinally by a worm thread (102) endless presser in the vertical position. Said helical thread (102) is further fixed on a rotating shaft (105) that couples to a motor (106).
[0123] The hopper outlet (100) has at least two tubes (104a and 104b) pressed waste conductors (without air or with very little air). Each tube (104a and 104b) of the hopper (100) feeds a set (204) of pyrolysis chambers that are disposed within the insulator housing (300).
[0124] In order to facilitate the identification of the elements of the present invention, below is the list of numerical references: [0125] 100hopper; [0126] 1010upper portion of the hopper; [0127] 1011tubular medial portion of the hopper; [0128] 1012lower portion of hopper; [0129] 102worm presser helical thread; [0130] 103bifurcation; [0131] 104a and 104bwaste conductor tubes; [0132] 105rotating shaft of the helical thread; [0133] 106rotation means helical thread of the hopper; [0134] 107a and 107bconnectors with the pyrolytic reactor; [0135] 108holes of the worm screw conveyor; [0136] 200pyrolytic reactor; [0137] 201pyrolysis chambers; [0138] 201iinternal cylindrical pyrolysis chamber; [0139] 201eexternal cylindrical pyrolysis chamber; [0140] 202endless screw conveyor; [0141] 203worm conveyor helical thread shaft; [0142] 204pyrolysis chamber assemblies; [0143] 205vertical tube for collecting pyrolysis gases; [0144] 2051horizontal tube for collecting lower pyrolysis gases; [0145] 2052horizontal tube for collecting the upper pyrolysis gases; [0146] 206orifice for the passage of the pyrolysis gas collection piping; [0147] 300carcass; [0148] 301upper portion of the shaped housing; substantially of a longitudinal cylindrical section; [0149] 3011upper face; [0150] 302lower face (portion) of the carcass; [0151] 303heat diffuser plate; [0152] 304gas flute burner; [0153] 3051smaller sides; [0154] 3052larger sides; [0155] 3053larger internal sides; [0156] 306orifice for passing the flute; [0157] 307display; [0158] 308opening for ash collection; [0159] 309gas burner; [0160] 310port for connecting the flue gas collection piping; [0161] 311flue gas collection piping; [0162] 312horizontal plate of refractory material; [0163] 3121horizontal plate holes; [0164] 313lower portion of the bowl; [0165] 314combustion drawer; [0166] 315orifice for the passage of the vertical piping for collecting pyrolysis gases; [0167] 316thermal insulation; [0168] 317double plate for the entire coating of the carcass; [0169] 318cyclone.