SYSTEMS AND METHODS FOR REMOVING CARBON FROM REACTION CHAMBERS IN PYROLYSIS REACTORS
20250129289 ยท 2025-04-24
Inventors
- Andrew James Ritchey (Bothell, WA, US)
- Scott Edward Hogan (Mukilteo, WA, US)
- Stephen I. Harris (Long Beach, CA, US)
- Mahdi Mahdi (Shoreline, WA, US)
- Max Nathan Mankin (Shoreline, WA, US)
Cpc classification
International classification
Abstract
Systems and methods for removing carbon from the pyrolysis reactor are disclosed herein. For example, a pyrolysis reactor according to the present technology can include a combustion component that is fluidly couplable to a combustion fuel supply, as well as a reaction chamber that is thermally coupled to an output of the combustion component. Further, the pyrolysis reactor can include a carbon removal component that is operably coupled to the reaction chamber. The carbon removal component can include an actuator, a rod coupled to the actuator, and a scraper head coupled to the rod and positioned within the reaction chamber. The actuator can drive movement of the rod within the reaction chamber, thereby driving movement of the scraper head. The scraper head can include a plurality of teeth that are positioned to scrape carbon deposits from an interior wall of the reaction chamber.
Claims
1. A pyrolysis reactor, comprising: a combustion component fluidly couplable to a combustion fuel supply; a reaction chamber thermally coupled to an output of the combustion component and fluidly couplable to a pyrolysis fuel supply, the reaction chamber configured to transfer heat from the combustion component to a flow of pyrolysis fuel from the pyrolysis fuel supply to generate an output flow comprising hydrogen gas and carbon particulates; and a carbon removal component operably coupled to the reaction chamber, the carbon removal component comprising: an actuator; a rod operably coupled to the actuator and positioned at least partially within the reaction chamber; a sealing device between the rod and the reaction chamber to allow movement of the rod along a longitudinal axis of the reaction chamber and restrict a flow of gas out of the reaction chamber; and a scraper head coupled to the rod, the scraper head having a plurality of teeth positioned to scrape carbon deposits from an interior wall of the reaction chamber during the movement of the rod along the longitudinal axis of the reaction chamber.
2. The pyrolysis reactor of claim 1, further comprising a combustion chamber fluidly coupled to the combustion component and positioned to receive a hot flue gas from the combustion component, wherein: the reaction chamber is positioned circumferentially around the combustion chamber; the scraper head is a ring-shaped component having an internal side facing the combustion chamber and an external side, wherein the plurality of teeth are positioned along at least one of the internal side or the external side; and the rod is one of a plurality of rods coupled to and distributed about a circumference of the ring-shaped component of the scraper head.
3. The pyrolysis reactor of claim 2 wherein: the scraper head includes a first housing and a second housing rotatably coupled to the first housing, wherein the second housing includes a gear track; a distal end region of each of the plurality of rods is fixedly coupled to the first housing; the distal end region of at least one of the plurality of rods includes a gear coupled to the gear track of the second housing; and in operation, driving the gear causes the second housing to rotate about the longitudinal axis with respect to the first housing.
4. The pyrolysis reactor of claim 2 wherein the scraper head includes a first tooth holder coupled to at least some of the plurality of teeth positioned along the internal side and a second tooth holder coupled to at least some of the plurality of teeth positioned along the external side.
5. The pyrolysis reactor of claim 1 wherein the combustion component is fluidly coupled to the reaction chamber to direct a hot flue gas through the reaction chamber to transfer the heat from the combustion component to the flow of pyrolysis fuel.
6. The pyrolysis reactor of claim 5 wherein: the scraper head includes a plurality of openings each sized to receive an individual tooth from the plurality of teeth; and the carbon removal component further comprises an end cap couplable to the scraper head to retain each individual tooth within a corresponding opening from the plurality of openings.
7. The pyrolysis reactor of claim 5 wherein: the rod comprises an internal drive shaft; and the scraper head comprises: a sun gear coupled to the internal drive shaft of the rod; a main body having a plurality of openings, each of the plurality of openings sized to receive an individual tooth from the plurality of teeth; a plurality of gears each coupled to the sun gear and a corresponding tooth from the plurality of teeth, wherein driving the internal drive shaft drives rotation of each of the plurality of gears via the sun gear; and an end cap couplable to the main body to retain each individual tooth within a corresponding opening from the plurality of openings.
8. The pyrolysis reactor of claim 1 wherein the reaction chamber is one of a plurality of reaction chambers, wherein the carbon removal component includes a plurality of rods and a plurality of scraper heads individually coupled to a corresponding rod from the plurality of rods, and wherein each of the plurality of scraper heads is positioned within a corresponding individual reaction chamber from the plurality of reaction chambers.
9. The pyrolysis reactor of claim 8 wherein individual ones of the plurality of teeth has a wedge-shaped profile oriented to at least partially drive a rotation of each of the plurality of scraper heads when the plurality of scraper heads move along the longitudinal axis of the corresponding individual reaction chamber.
10. The pyrolysis reactor of claim 1 wherein the sealing device comprises one or more expandable components each having an aperture sized to form a seal around the rod.
11. The pyrolysis reactor of claim 1 wherein the sealing device is fluidly coupled to a pressurized inert gas source.
12. The pyrolysis reactor of claim 1 wherein the sealing device comprises an elastic scraping component positioned at least partially within the reaction chamber to scrape carbon deposits from the rod during the movement of the rod along a longitudinal axis of the reaction chamber.
13. A solids-removal component for scraping solids from an internal wall of chamber of a reactor during operation of the reactor, the solids-removal component comprising: an actuator; a drive component operably coupled to the actuator and positioned at least partially within the chamber of the reactor; a sealing device coupled to the chamber of the reactor, wherein the sealing device is configured to allow the drive component to move within the chamber and obstruct a flow of gas out of the chamber; and an end effector coupled to the drive component, the end effector having a plurality of scraping components positioned to scrape deposits of the solids from the internal wall of the chamber during movement of the drive component.
14. The solids-removal component of claim 13 wherein the end effector has an annular shape, and wherein the plurality of scraping components comprise an inward-facing subset and an outward-facing subset.
15. The solids-removal component of claim 13 wherein the movement of the drive component comprises plunges along a longitudinal axis of the chamber of the reactor, and wherein the solids-removal component further comprises an indexing component configured to rotate the drive component about the longitudinal axis between the plunges along the longitudinal axis.
16. The solids-removal component of claim 13 wherein each of the plurality of scraping components comprises a slot cutter, and wherein two or more of the plurality of scraping components further comprises a wedge cutter coupled to a corresponding slot cutter.
17. The solids-removal component of claim 13 wherein the movement of the drive component comprises rotation about a longitudinal axis of the chamber of the reactor.
18. A method for continuously operating a reactor, the method comprising: directing a flow of a hydrocarbon fuel into a chamber of the reactor; heating the hydrocarbon fuel within the chamber to cause a reaction that creates a product stream, wherein the product stream comprises hydrogen gas and solids, and wherein at least a portion of the solids precipitate onto an internal wall of the chamber to form a solids buildup; and while directing the flow of the hydrocarbon fuel into the chamber, actuating an end effector of a removal component within the chamber to scrape at least a portion of the solids buildup off of the internal wall.
19. The method of claim 18 wherein actuating the end effector comprises moving the end effector along a longitudinal axis of the chamber, and wherein the method further comprises indexing the end effector between subsequent actuations along the longitudinal axis of the chamber.
20. The method of claim 18 wherein the reactor is a pyrolysis reactor, wherein the solids comprise carbon, wherein the chamber is a reaction chamber at least partially surrounding a combustion chamber of the pyrolysis reactor, and wherein heating the hydrocarbon fuel within the reaction chamber comprises combusting a combustion fuel within the combustion chamber while directing the flow of the hydrocarbon fuel into the reaction chamber.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0025] The drawings have not necessarily been drawn to scale. Similarly, some components and/or operations can be separated into different blocks or combined into a single block for the purpose of discussion of some of the implementations of the present technology. Moreover, while the technology is amenable to various modifications and alternative forms, specific implementations have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the technology to the particular implementations described.
DETAILED DESCRIPTION
Overview
[0026] Pyrolysis reactors heat hydrocarbon reactants (e.g., methane, natural gas, ethane, propane, butane, pentane, gasoline, diesel, kerosene, and/or the like) to decompose them into hydrogen gas, solid carbon, and various products. For example, pyrolysis reactors can decompose the methane, ethane, propane, and other hydrocarbon components in natural gas to generate hydrogen gas. In the example of methane, the pyrolysis reaction is:
CH4(gas).fwdarw.C(solid)+2H2(gas).
The hydrogen gas can then be substituted as the combustion fuel anywhere the natural gas, or other hydrocarbons, would have been used. For example, the hydrogen gas can be consumed by various heating units (e.g., furnaces, water heaters, water boilers, steam boilers, and/or the like), combustion engines, fuel cells and/or power generators (e.g., in a backup power generator), combined heat and power systems, cooking units (e.g., gas stoves), and/or in various other suitable uses. Additionally, or alternatively, the hydrogen can be used in various industrial processes, such as producing various ammonia-based products (e.g., ammonia fertilizers), providing process heat, and/or other chemical processing industries and/or injected back into the natural gas pipeline to partially decarbonize the natural gas in the pipeline. Further, the solid carbon can be collected and used in various downstream applications. Purely by way of example, the solid carbon product can partially replace binders in asphalt products, thereby effectively sequestering the carbon from the hydrocarbon reactant.
[0027] The solid carbon, however, often collects on walls (and/or other surfaces) within the pyrolysis reactor. If nothing is done to remove the solid carbon buildup from the reaction chamber, it will have negative effects on the conversion of the hydrocarbon to hydrogen. Over time, the carbon buildup can eventually cause the reaction chamber to clog, thereby requiring the reaction chamber to be shut down, cleaned, and re-heated. For example, the carbon buildup (sometimes also referred to as coke and/or fouling) can be removed by oxidizing the carbon with O.sub.2 gas and/or air; spraying the carbon with a hot, pressurized water or steam jet; shoveling, brushing, scraping, or otherwise mechanically removing carbon. In another example, the pyrolysis reactor can incorporate a chemical vapor infiltration (CVI) process in which a template and/or scaffold of carbon (or another material) is inserted into the reactor. The scaffold then accumulates carbon produced from pyrolysis (e.g., in addition to or in place of the walls of the reactor). The pyrolysis reactor can then be cooled to remove the scaffold, allowing the carbon to be removed and disposed of. However, these processes can produce carbon dioxide and/or carbon monoxide emissions, thereby undermining one of the goals of the pyrolysis system. Further, the cleaning results in downtime where no hydrocarbon reactant is being converted into hydrogen and solid carbon. Still further, the cool-down and reheating process can undermine the overall efficiency of the pyrolysis reaction.
[0028] In some systems, the pyrolysis reactor can be designed to aid in capturing and removing the solid carbon. For example, the pyrolysis reactor can include a fluidized bed reactor. In the fluidized bed reactor, particles (sometimes catalysts) are fluidized on the reaction gas stream. As the carbon is formed, it can attach to the particles. As the carbon builds up on the particles, they become bigger and are either pushed out of the reactor or drop to the bottom for separation. In another example, the pyrolysis reactor can include molten salt or molten metal catalyst reactors. In this example, the carbon forms within the molten salt. Then, by nature of being less dense than the molten salt, the carbon floats to the top of the bed of molten salts, where it can be fluidized or skimmed off the surface. However, each of these design choices imposes other restrictions on the pyrolysis reactor (e.g., requiring the use of molten salts), which can undermine the efficiency of the pyrolysis reaction and/or be overly costly to implement.
[0029] Systems and methods for removing carbon from the pyrolysis reactor are disclosed herein. For example, as discussed in more detail below, a pyrolysis reactor according to the present technology can include a combustion component that is fluidly couplable to a combustion fuel supply (e.g., a supply of methane, natural gas, hydrogen gas, and/or the like), as well as a reaction chamber that is thermally coupled to an output of the combustion component. The reaction chamber is also fluidly couplable to a pyrolysis fuel supply (e.g., a supply of methane, natural gas, and/or the like). As a result, the reaction chamber can receive an incoming flow of the pyrolysis fuel and transfer heat from the combustion component to the pyrolysis fuel. As discussed above, the heat can drive a pyrolysis reaction, thereby generating an output flow that includes hydrogen gas and carbon particulates. Further, the pyrolysis reactor can include a carbon removal component that is operably coupled to the reaction chamber. For example, the carbon removal component can include an actuator, a rod coupled to the actuator, and a scraper head coupled to a distal end region of the rod and positioned within the reaction chamber. The actuator can drive movement of the rod (e.g., a push rod, rotatable rod, and/or the like) within the reaction chamber, thereby driving movement of the scraper head. The scraper head can include a plurality of teeth that are positioned to scrape carbon deposits from an interior wall of the reaction chamber as the actuator drives the movement.
[0030] The carbon removal component can also include a sealing device that is operably coupled between the rod and an end region of the reaction chamber. The sealing device allows movement of the rod (e.g., along a longitudinal axis of the reaction chamber, rotating about the longitudinal axis, and/or the like) while restricting (e.g., blocking and/or otherwise impeding) a flow of gas out of the end region of the reaction chamber. That is, the sealing device allows the rod to move while preventing any reaction gasses (e.g., pyrolysis fuel, hydrogen gas, and/or the like) from escaping from the reaction chamber.
[0031] In some embodiments, the pyrolysis system includes a plurality of reaction chambers. In such embodiments, the carbon removal component can include a plurality of rods and scraping heads corresponding to each of the plurality of reaction chambers. In some such embodiments, the rods can each be coupled to a strongback component that is coupled to the actuator, allowing each of the rods to be actuated together.
[0032] For ease of reference, the pyrolysis systems, and the components thereof, are sometimes described herein with reference to top and bottom, upper and lower, proximal and distal, upwards and downwards, and/or horizontal plane, x-y plane, vertical, or z-direction relative to the spatial orientation of the embodiments shown in the figures. It is to be understood, however, that the pyrolysis systems, and the components thereof, can be moved to, and used in, different spatial orientations without changing the structure and/or function of the disclosed embodiments of the present technology.
[0033] Further, although primarily discussed herein in the context of removing carbon from a hydrocarbon pyrolysis system, one of skill in the art will understand that the scope of the technology disclosed herein is not so limited. For example, the carbon removal systems can be implemented in various other chemical processing applications and/or reactor systems to address various other solid buildups and/or to reduce fouling in the other systems. That is, the embodiments of the present technology introduced above can allow continuous removal of solids built up in any chemical reactor, solids precipitator, cryogenic condenser, or other system where solids build up during operation of the system. In a specific, non-limiting example, the product stream from a pyrolysis reactor can be sent to a condensing component to be cooled to a low temperature to solidify and collect organic compound byproducts from the product stream. The organic compound byproducts can then be removed mechanically from the condensing component using trimmer systems of the type disclosed herein without pausing the operation of the pyrolysis system. Accordingly, the scope of the invention is not confined to any subset of embodiments, and is confined only by the limitations set out in the appended claims.
[0034] The embodiments of the present technology introduced above provide systems and methods for removing the solid carbon deposit (and/or other solid deposits) from a pyrolysis reactor in situ, without the need to stop or otherwise interrupt the pyrolysis reaction, and without directly generating CO or CO2. As a result, embodiments of the present technology can allow a pyrolysis reactor (and/or other processes that need to mitigate coke and/or fouling) to run continuously (or generally continuously) without needing to switch to a backup reactor and/or without needing to factor in downtime. As used herein, continuous operation can refer to generally continuous operation of the pyrolysis system, which can include operating the pyrolysis system without needing to pause to clean or otherwise empty the reaction chamber for periods of at least 3 hours, 6 hours, 12 hours, 24 hours, 48 hours, 72 hours, 1 week, 1 month, 6 months, and/or longer periods. Continuous operation can include operation of the pyrolysis system that periodically pauses, e.g., when demand for hydrogen gas goes down (or goes to zero), and/or pauses to allow components of the pyrolysis reactor to be serviced (e.g., for maintenance), and/or pauses when particular reaction conditions need to be met (e.g. microwave heating can shut off when actuation of the trimmer occurs so as to not have the end effector interfere with the electromagnetic heating).
[0035] The continuous operation without downtime and/or thermal cycling (e.g., switching to the backup reactor) can help reduce costs associated with the pyrolysis reactors because the continuous pyrolysis system does not require multiple pyrolysis reactors to allow one pyrolysis reactor to be reset while another reactor is operating. Additionally, or alternatively, continuous operation can lower operating expenses associated with a pyrolysis system because the capital expense has a high utilization fraction. Additionally, or alternatively, continuous operation can allow the continuous pyrolysis system to fit into a smaller footprint (e.g., because the system does not require thermal cycling to remove carbon).
[0036] Further, the embodiments of the present technology introduced above can allow a pyrolysis system to operate without catalyst entrapment, consumables, and/or catalyst post-processing. The omission of these components can help reduce the operating costs and footprint of the pyrolysis reactor and its associated balance of plant. Still further, the embodiments of the present technology introduced above can allow a pyrolysis system to operate without requiring onsite utilities like high-pressure or high-temperature water or steam. In turn, the non-requirement for high pressure or temperature water or steam enables the continuous pyrolysis system to be operational at non-industrial sites, such as within or located at a single-family household, within or located at an apartment building, within or located at a commercial building (e.g., an office building, a retail store, restaurant, and/or the like), at an industrial site without high-pressure steam or water, and/or the like. Additionally, the non-requirement for high-pressure or temperature water or steam can reduce the operational costs, capital costs, and/or footprint associated with the continuous pyrolysis system.
[0037] Additionally, or alternatively, the embodiments of the present technology introduced above can allow a pyrolysis system to operate without requiring a consumable carbon scaffold, without the direct formation of CO or CO2 (thereby enabling the production of low (or negative) carbon intensity (CI) hydrogen), and/or operate at higher thermal efficiencies than reactor systems that require downtime. Still further, the embodiments of the present technology introduced above can allow a pyrolysis system to be amenable to a range of pyrolysis geometries, such as pyrolysis contained in individual tubes that are heated externally, annular pyrolysis zones that are heated internally, and/or a system that has parallel combustion tubes with the pyrolysis zone between these tubes.
[0038] Additional details on various aspects of the pyrolysis system, and components thereof, are set out below with respect to
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[0040] The combustion component 114 can provide the heat for the pyrolysis reaction to occur. In some embodiments, the combustion component 114 includes one or more burners that receive and combust a combustion fuel. As illustrated in
[0041] The combustion component 114 is thermally coupled to the reaction chamber 112 to receive heat along a third path (C). In some embodiments, the pyrolysis reactor is a combined combustion and pyrolysis reactor (CCP reactor) that provides continuous combustion and pyrolysis for any suitable amount of time. For example, the combustion component 114 can include one or more burners and a combustion chamber. Further, the reaction chamber 112 can be coupled to the combustion component 114 through a heat exchanger, a shared wall between the reaction chamber 112 and the combustion chamber, a flow of flue gas from the combustion component 114 in contact with a wall of the reaction chamber 112, and/or any other suitable mechanism. In another example, the combustion component is integrated with the reaction chamber 112. For example, the combustion component 114 can include a burner positioned to combust the combustion fuel and direct the flue gas directly through the reaction chamber 112. In such embodiments, the combustion component 114 (and/or any other suitable component of the pyrolysis reactor) can control the amount of oxygen available in the reaction chamber such that all (or almost all) of the available oxygen is consumed combusting the combustion fuel supply. That is, the combustion component 114 (and/or another suitable component) can help make sure no oxygen is present to disrupt the pyrolysis reaction. Additional details on examples of suitable pyrolysis reactors, and the thermal coupling between the reaction chamber 112 and the combustion component 114, are set out in U.S. Patent Publication No. 2021/0380407 to Ashton et. al, U.S. Patent Publication No. 2022/0315424 to Ashton et. al, and U.S. Patent Publication No. 2022/0120217 to Ashton et. al, and U.S. Patent Publication No. 2022/0387952 to Groenewald et al., each of which is incorporated herein by reference in their entireties.
[0042] Further, it will be understood that while specific examples of the pyrolysis reactor 110 have been discussed herein, the technology is not so limited. For example, in some embodiments, the reaction in the reaction chamber 112 can be driven by a thermal coupling to another suitable component (e.g., a home heating device, such as a furnace, water boiler, steam boiler, plasma device, and/or the like) coupled to the hydrocarbon reactant (e.g., in and/or upstream of the reaction chamber 112); a catalytic heater coupled to the hydrocarbon reactant; an electrical heating component coupled to the hydrocarbon reactant; a microwave component operably coupled to the hydrocarbon reactant (e.g., to microwave gas in the reaction chamber 112); and/or any other suitable component. In a specific, non-limiting example, the reaction chamber 112 can include molten salt that is heated by electrical heaters and/or hot gas from another suitable component and/or a fluidized bed reactor with or without a catalyst. In this example, the molten salt can heat the incoming hydrocarbon reactant to cause the pyrolysis reaction.
[0043] As further illustrated in
[0044] As further illustrated in
[0045] The hydrogen consumption component 20 can include (or be coupled to) a variety of end locations. For example, the hydrogen consumption component 20 can include (or be coupled to) a hydrogen storage (or local consumption point, such as the combustion component 114, a heating unit coupled to the pyrolysis system 100, a power generation component coupled to the pyrolysis system 100, and/or the like). The hydrogen storage can allow the hydrogen gas to be consumed locally as needed (e.g., during peak demand for power, to augment and/or replace a hydrocarbon gas to drive the combustion component 114, and/or the like). As used herein, local consumption can mean within the same building as the pyrolysis system 100, within the same property as the pyrolysis system 100, within a half mile of the pyrolysis system 100, within about 5 miles of the pyrolysis system 100, within an endpoint for public utilities (e.g., the consumption does not require any public utility line or public transportation means between the pyrolysis system 100 and the point of consumption), and/or the like. In another example, the hydrogen consumption component 20 can include (or be coupled to) a hydrogen grid (e.g., a public utility grid, such as a dedicated hydrogen grid) and/or into the natural gas grid. In some embodiments, the hydrogen consumption component 20 can provide hydrogen gas to the combustion component 114 to supplement, augment, and/or replace other combustion fuels (e.g., to replace, fully or in part, natural gas as the combustion fuel). In embodiments where the hydrogen gas is directed into the natural gas grid, a volume of the hydrogen directed into the natural gas grid can be controlled such that the hydrogen gas is less than about 20% of the gas, by volume, in the natural gas pipeline. Limiting the amount of hydrogen gas in the natural gas pipeline can limit risks associated with the hydrogen gas in the natural gas grid, while also helping to partially decarbonize the natural gas grid. In another example, the hydrogen consumption component 20 can include (or be coupled to) a supply grid for hydrogen-powered electronics, vehicles, machines, and/or the like. For example, the supply grid can provide the hydrogen gas to fuel cell electric vehicles (FCEVs), H2 internal combustion engines (H2 ICE) powered vehicles, and/or the like. In yet another example, the hydrogen consumption component 20 can include (or be coupled to) a combined heat and power device (e.g., rather than to the hydrogen storage) to be consumed. Examples of suitable combined heat and power devices are disclosed in U.S. Patent Publication No. 2022/0387952 to Groenewald et. al, and U.S. Patent Publication No. 2022/0120217 to Ashton et. al, each of which is incorporated herein by reference. Additionally, or alternatively, the hydrogen consumption component 20 can include (or be coupled to) a power generation device (e.g., a combustion engine, thermionic converter, linear generator, fuel cell, and/or other suitable power generator). In yet another example, the hydrogen consumption component 20 can include (or be coupled to) a chemical processing component that uses the hydrogen gas for various other chemical processing operations.
[0046] Similarly, the product stream processing component 120 can direct the carbon removed from the product stream along a sixth flow path (F) toward a carbon consumption component 30 (or carbon processing component). The carbon consumption component can use or store the carbon to help ensure that the carbon is not eventually released as carbon dioxide. That is, the carbon consumption component 30 can help finalize the carbon capture from the pyrolysis fuel. In various embodiments, the carbon consumption component 30 can include a collection bin, a processing component that prepares the carbon to be used (or uses the carbon) in various applications. Purely by way of example, the carbon consumption component 30 can prepare the carbon to be used as a binder replacement and/or supplement for asphalt products.
[0047] In some embodiments, the product stream processing component 120 includes one or more heat exchangers and/or recuperators to absorb heat from the product stream. For example, the product stream processing component 120 can absorb heat from the product stream and transfer the heat to incoming pyrolysis fuel in the first flow path (A) and/or incoming combustion fuel in the second flow path (B) to preheat the incoming gasses. The preheating process can help increase an efficiency of the pyrolysis reactor 110 and/or a completeness of the pyrolysis reaction within the reaction chamber 112. Additional details on examples of suitable recuperators are disclosed in U.S. Patent Publication No. 2022/0315424 to Ashton et. Al and U.S. Patent Publication No. 2022/0120217 to Ashton et. Al, each of which is incorporated herein by reference. Additionally, or alternatively, the heat can be directed to one or more heating units (e.g., an HVAC unit, water heater, steam boiler, and/or the like), a power generation device (e.g., the combined heat and power component 44, a thermionic device, thermoelectric device, fuel cell, thermoacoustic device, and/or any other suitable power generator), and/or the like.
[0048] As further illustrated in
[0049] In various embodiments, the pyrolysis system 100 can omit one or more of the components discussed above and/or include one or more additional components. For example, in embodiments where the combustion component 114 includes a burner positioned to direct the flue gas directly through the reaction chamber 112, the flue gas is mixed with the product stream. Accordingly, in this example, the pyrolysis system 100 can omit the separate flue gas processing component 130 and instead integrate any needed functionality into the product stream processing component 120 (e.g., adding a water vapor condenser and/or a carbon dioxide absorber to the product stream processing component 120 to separate components of the flue gas from the product stream). In another example, the pyrolysis system 100 can include a variety of additional processing components downstream from the pyrolysis reactor 110 to help separate and/or process the product stream (e.g., to help separate byproducts from the pyrolysis reaction, to further condition the hydrogen gas for consumption at an endpoint, and/or the like). In yet another example, although not illustrated in
Examples of Suitable Carbon Removal Components in Accordance with Embodiments of the Present Technology
[0050]
[0051] In various embodiments, the sealing device 232 can include a wiper, scraper, and/or other similar features for removing fluidized carbon from the surface of the rod 234 (e.g., a push rod, rotatable rod, and/or the like). In some embodiments, the sealing device 232 includes a set of seals for creating a pressure plenum. The pressure plenum can be controlled to a pressure that is higher than a pressure inside the pyrolysis reactor 200 (e.g., inside the CCP chamber 210). As a result, if the sealing device 232 leaks, the leak directs gas into the CCP chamber 210 and helps prevent product gasses from leaking outside the CCP chamber 210. In some embodiments, the pressure plenum is held at a gauge pressure of at least 1 pound per square inch (psi), at least 5 psi, at least 18 psi, or least 25 psi, at least 100 psi, at least 1000 psi, or at least 10000 psi. In various embodiments, the pressure plenum can include an inert gas (e.g., Argon, Nitrogen, or other noble gas, and/or another suitable inert gas); a hydrocarbon-based lubricant (e.g., mineral oil, motor oil, and/or other suitable lubricant); a sealing material capable of withstanding relatively high transient temperatures (e.g., transient temperature of at least 100 C., at least 200 C. or at least 300 C.). This relatively high heat resistance can help avoid deleterious effects when the rod 234 increases in temperature from heat within the CCP chamber 210. In some embodiments, a flushing fluid is pumped through the pressure plenum periodically to remove solid deposits (e.g., carbon deposits) that have built up, without pausing or otherwise interrupting the pyrolysis reactor 200.
[0052] Further, as illustrated in
[0053] As further illustrated in
[0054] In some embodiments, the rod 234 has a surface that is relatively smooth (e.g., with a surface roughness (measured in Ra) that is less than about 32 pin, or less than about 16 in). Rougher surfaces undermine the ability of the sealing device 232 to provide an adequate seal and/or cause premature degradation of the sealing device 232. In some embodiments, the rod 234 has a thermal diffusivity that is greater than about 1 square millimeter per second (mm.sup.2/s). In some embodiments, the thermal diffusivity is greater than about 3 mm.sup.2/s. In some embodiments, the hardness of the surface of the rod 234 is greater than about Rockwell C50. In some embodiments, the hardness of the surface of the rod is greater than about Rockwell C60.
[0055] In various embodiments, the scraping components 238 can include tungsten, molybdenum, cubic boron nitride (CBN), cobalt, polycrystalline diamond (PCD), diamond-like carbon, high-speed steel, tungsten carbide, micrograin tungsten carbide, silicon nitride, silicon carbide, tantalum carbide, various ceramics and/or ceramets, cemented carbides, superalloys, steel, titanium carbide, and/or other suitable materials. In general, the scraping components 238 can last longer and/or more effectively remove carbon (and other materials collecting on the internal wall 214) when the hardness of the scraping components 238 is matched or greater than the hardness of the materials being removed. In some embodiments, the scraping components 238 can include a coating to help increase the hardness of the scraping components 238, such as TIN, TiC, Ti(C)N, TiAIN, cubic-BN, polycrystalline diamond, diamond-like carbon, SiC, and/or other suitable materials. In a specific, non-limiting example, the scraping components 238 are a carbide with a TiN, cubic-BN, and/or polycrystalline diamond coating.
[0056] In some embodiments, a geometry of the scraping components 238 is generally matched to the length scale of the deposit being removed. For example, at steady-state operation, the carbon deposits will grow at a constant (or generally constant) rate. The height of the scraping components 238 (e.g., measured as a distance from the scraping head 236) must be generally equal to or greater than the thickness of the carbon that is deposited between actuations to prevent the scraping head 236 from hitting the carbon. If the scraping head 236 hits the carbon, then the required actuation force dramatically increases, increasing the risk of damage to the caron removal component 230 and/or the pyrolysis reactor 200 overall. In some embodiments, the pyrolysis reactor 200 continuously actuates the rod 234 during operation, allowing the scraping head 236 to continuously clean the internal wall 214. In some embodiments, the pyrolysis reactor 200 periodically actuates the rod 234 during operation (e.g., after a predetermined time period, in response to a detection of pressure buildup in the CCP chamber 210 indicating carbon buildup, and/or the like).
[0057] As best illustrated in
[0058]
[0059] Similar to the carbon removal component discussed above, the carbon removal component 330 of
[0060] Additionally, as discussed in more detail below, the actuator can provide inputs to actuate individual components of the scraper head 336 (e.g., to rotate the teeth 338 individually, to rotate portions of the scraper head 336, and/or the like). The actuator sled 342 can help translate inputs from the actuator 340 to the rod 334 and/or the scraper head 336.
[0061] In the illustrated embodiment, the carbon removal component 330 also includes an indexing mechanism 344 and a gearbox 346. The indexing mechanism 344 can include a motor or other suitable component that translates an input with motion in a first direction (e.g., rotational motion) to an output applied to the rod 334 with motion in a second direction (e.g., linear motion). Additionally, or alternatively, the indexing mechanism 344 (sometimes also referred to herein as a clocking mechanism) can rotate (e.g., index) the rod 334 a fixed angle prior to the start of each actuation and/or at the start of any suitable number of actuations (e.g., every one, two, three, five, ten, or other suitable number of actuations). In some embodiments, the indexing mechanism 344 can rotate the rod 334 a fixed amount partway through each actuation. The amount of rotation can be preselected such that a complete rotation of the rod 334 is achieved in a predetermined number of actuations. In some embodiments, the amount of rotation is selected such that consecutive passes of the cutting features do not fall in the same groove. In some embodiments, the number of actuations is selected such that the deposition rate of the carbon deposit does not outpace the rate of carbon removal. In various embodiments, the indexing mechanism 344 can include a pneumatic indexer, a servo motor, a belt drive system, a passive spring-loaded system, and/or any other suitable mechanism. In some embodiments, the actuator 340 and the actuator sled 342 output motion in the necessary directions, allowing the rod 334 to be coupled directly to the actuator sled 342.
[0062] Similarly, the gearbox 346 can translate a magnitude and/or torque of an input from the actuator 340 as suitable for the rod 334. As a result, for example, the gearbox 346 can help increase a force applied to the rod 334 by the actuator 340 to help ensure the rod 334 has sufficient force to scrape hard carbon deposits off the internal wall 324. In some embodiments, however, the carbon removal component omits the gearbox 346 (e.g., in applications where the magnitude of the force needed to scrape the carbon is relatively small).
[0063] In some embodiments, the pyrolysis system 300 is at least partially controlled by a controller (not shown) implementing a control algorithm. For example, the control algorithm can help determine an appropriate number of actuations per minute, speed of actuations, rotations of the rod 334, force to apply to the rod 334, and/or the like to remove carbon from the CCP chamber 320 while reducing (or minimizing) maintenance required for the pyrolysis system 300 and/or power requirements for the pyrolysis system 300. In various embodiments, the control algorithm can: model the growth of the carbon deposition using an approach such as a constant rate of mass gain, a constant rate of linear thickness gain, computational fluid dynamics with empirical correlation, and/or direct numerical simulation of the reaction pathways; record the growth rate of the carbon deposit based on a sensor within or coupled to the CCP chamber 320; calculate the growth rate of the carbon deposit based on flow rates and/or pressures of input and/or output flows to the CCP chamber 320; model the rotation of the end effector between actuations; model the time between actuations; and/or combine any of the models, measurements, and/or calculations discussed above to predict the force required to remove carbon deposits with a selected scraper head 336 geometry. In some embodiments, the force prediction can be based on tool area overlap with the measured cutting pressure, an overlap of the tool perimeter with the buildup length and shear strength of the carbon, and/or empirically correlated cutting force with a selected end effector geometry.
[0064] As discussed above, the control algorithm can be used to find a balance between a clocking angle (e.g., where, up to symmetric positions, larger angles are less likely to fall into old cuts while smaller angles wear the seals less), a time between actuations (e.g., where less time between actuations reduces the removal force and more time reduces the wear on the seals), and a number of cutting features (e.g., where fewer cutting features require less force per actuation while more cutting features requires less frequent actuations). As a result, the control algorithm can help minimize the cutting force required to be applied to (and by) the rod 334 while maximizing the time between required actuations (e.g., to provide an open flow path for the pyrolysis reaction). In some embodiments, the control algorithm is executed during a design phase to help determine elements of the design (e.g., the number of scraping components, an actuation period, an indexing angle, and/or an end effector geometry).
[0065]
[0066] As further illustrated in
[0067] In the embodiments illustrated in
[0068]
[0069] In the illustrated embodiment, however, the carbon removal component 500 is configured to allow each of the teeth to be individually rotated without detaching the end cap 522 from the scraper head 504. For example, the carbon removal component 500 can include a rotatable-insert holder 506 that includes a plurality of openings 508 (three illustrated in
[0070] As further illustrated in
[0071] As a result, the teeth 514 can be rotated without deconstructing the carbon removal component 500. That is, for example, as one edge of the teeth wears down from scraping solid carbon off the walls of a reaction chamber (e.g., the internal wall 324 of
[0072]
[0073] The illustrated annular arrangement positions the reaction chamber 620 entirely around the combustion chamber 610. As a result, heat can only be transferred out of the combustion chamber 610 along the fourth path P.sub.4 into the reaction chamber 620 or along the combustion flow path 612. That is, all of the heat that is not carried out of the combustion chamber 610 by the flue gas is communicated into the reaction chamber 620 to heat the pyrolysis fuel. It will be understood, however, that the technology disclosed herein is not limited to the arrangement illustrated in
[0074] As the heat travels from the combustion chamber 610 to the reaction chamber 620, the heat is also transferred to the pyrolysis fuel in the reaction flow path 622 to drive a pyrolysis reaction. As discussed above, the pyrolysis reaction can generate a product stream that includes hydrogen gas and solid carbon (and/or various other byproducts and/or coproducts). As also discussed above, a portion of the solid carbon can precipitate onto and/or otherwise collect on internal walls 624 of the reaction chamber 620. If not addressed, the carbon builds up and clogs/fouls the reaction chamber 620.
[0075] As further illustrated in
[0076] The sealing device 632 is positioned at a first end of the pyrolysis reactor adjacent to the combustion component 614. The sealing device 632 can allow a pyrolysis reaction fuel to flow into (and through) the reaction chamber 620 while preventing gasses (e.g., the pyrolysis fuel, pyrolysis reaction products, byproduct gasses, and/or the like) from escaping the reaction chamber 620. Further, the sealing device 632 can allow the one or more rods 634 to actuate within the reaction chamber 620. For example, the one or more rods 634 can move along a third path P.sub.3 generally parallel to a longitudinal axis of the reaction chamber 620 (e.g., along the reaction flow path 622), thereby also driving motion of the scraping head 636. During the actuation, scraping components 638 carried by the scraping head 636 can scrape against carbon deposited on the internal walls 624. The scraping can help dislodge the carbon to keep the internal walls 624 clean and/or maintain available flow paths for the pyrolysis reaction fuel and the product stream through the reaction chamber 620.
[0077] As best illustrated in
[0078]
[0079] As best illustrated in
[0080] As further illustrated in
[0081] In the illustrated embodiments, the rotation of the second housing portion 720b can be driven and/or controlled by the one or more rods 710 (one shown in the cross-section in
[0082] As further illustrated in
[0083]
[0084] As best illustrated in
[0085]
[0086] In the illustrated embodiment, the scraping inserts 924 have a square-scraping profile. However, it will be understood that the technology is not so limited. Purely by way of example, the scraping inserts 924 can have a wedged profile that can help reduce the force on a leading edge of the scraping inserts 924 to reduce the chance that the scraping inserts 924 break during a plunge. In some embodiments, the scraping inserts 924 include a tungsten carbide material with a relatively high melting point (e.g., to help ensure that the scraping inserts 924 do not warp at the relatively high temperatures within a reaction chamber). Additionally, or alternatively, the scraping inserts 924 can include tungsten, molybdenum, cubic boron nitride (CBN), cobalt, polycrystalline diamond (PCD), diamond-like carbon, high-speed steel, micrograin tungsten carbide, silicon nitride, silicon carbide, tantalum carbide, various ceramics and/or ceramets, cemented carbides, superalloys, steel, titanium carbide, and/or other suitable materials
[0087] In some embodiments, the rod 910 can rotate the main body 920 at a speed between about 400 rotations per minute (RPM) and about 4000 RPM, at a speed of about 500 RPM, at a speed of about 1800 RPM, and/or at a speed of about 3600 RPM. The higher rotational speeds can increase the force delivered by the scraping inserts 924 to dislodge carbon from the reaction chamber. The slower rotational speeds can decrease a chance that the scraping inserts 924 break during a plunge. In some embodiments, the end effector 900 can continuously plunge into (and out of) the reaction chamber. In some embodiments, the end effector 900 can plunge periodically into (and out of) the reaction chamber (e.g., every 1-5 minutes). In some embodiments, the end effector 900 changes the direction of the rotation along the rotational motion path R.sub.1 during and/or between plunges. The change in direction can help ensure that the scraping inserts wear more evenly over time and/or help disrupt the formation of grooves in carbon deposits that can prevent complete scraping of the walls of the reaction chamber.
[0088]
[0089]
[0090]
[0091] In the illustrated embodiment, however, the carbon removal component 1230 includes a support component 1232 a plunging tube 1234 positioned to move along a motion path P.sub.5, with support from the support component 1232 (e.g., a second strongback), into and out of the reaction chamber 1220. The plunging tube 1234 can include one or more scraping components (e.g., teeth) positioned along a length of the plunging tube 1234 and/or at a distal end of the plunging tube 1234. As a result, the plunging tube 1234 can avoid having any moving parts on the scraping system, which can help simplify the operation of the carbon removal component 1230 and/or increase the lifespan of the carbon removal component 1230 by reducing possible sources of error.
[0092] Further, in some embodiments, the plunging tube 1234 can rotate about a rotational axis R.sub.1 while moving along the motion path P.sub.5 into and out of the reaction chamber 1220. For example, as discussed in more detail below with reference to
Examples of Suitable Multi-Chamber Reactor Systems in Accordance with Embodiments of the Present Technology
[0093] In some embodiments, a pyrolysis system can include an array of adjacent, nested, and/or combined reaction and combustion chambers that provide additional passageways for a pyrolysis reaction to occur. In various such embodiments, the pyrolysis reactor includes alternating pyrolysis and combustion tubes in any number of geometries, unit cell arrangements, and/or unit cell configurations provided that enough heat is transferred from combustion to pyrolysis.
[0094] For example, in the embodiments illustrated in
[0095] In the embodiments illustrated in
[0096] In the embodiments illustrated in
[0097] In any of the embodiments of
[0098] In another example, the carbon removal component can include one or more actuators coupled to a strongback component. The strongback can be a stiff piece of metal or other suitable component that links the motion of multiple rods together. Each of the one or more rods coupled to the strongback then follows the vertical (or other) motion of the strongback. As they move, each rod can drive the actuation of a corresponding end effector within a corresponding reaction chamber to scrape or otherwise dislodge carbon from the reaction chamber.
[0099] In the illustrated embodiments, the pyrolysis reactor 1600 is generally similar to the pyrolysis reactor 1300 discussed above with reference to
[0100] As further illustrated in
[0101]
[0102] As further illustrated in
[0103] As best illustrated in
[0104] As best illustrated in
[0105] As further illustrated in
[0106] It will be understood that while a particular embodiment of the end effectors 1738 is illustrated and discussed with reference to
[0107]
Examples of Suitable Sealing Devices for Reactor Systems in Accordance with Embodiments of the Present Technology
[0108]
[0109] The sealing device 1900 also includes a scraping component 1916 and a retaining component 1918 each carried by the first end region 1912. The scraping component 1916 can scrape carbon and/or other buildup off of a rod (e.g., any of the rods discussed above) and/or another suitable component moving through an opening 1930 at the first end region 1912. As a result, the scraping component 1916 can help prevent carbon (or other particulates) from entering the sealing device 1900, where they could undermine the quality of the sealing device 1900 (e.g., causing leaks and/or requiring maintenance). The retaining component 1918 can help retain the scraping component 1916 at the first end region 1912 while allowing the scraping component 1916 to be periodically replaced to service the sealing device 1900. The sealing device 1900 also includes a retaining component 1920 with an opening 1922 at the second end region 1914. The retaining component 1920 can help retain each of the components of the sealing device 1900 together and/or attach the sealing device to an end region of a corresponding reaction chamber. The opening 1922 provides room for a rod and/or other suitable component to move through the sealing device 1900.
[0110] As further illustrated in
[0111]
[0112] As further illustrated in
[0113]
[0114] In the embodiments illustrated in
[0115] In the embodiments illustrated in
[0116] In the embodiments illustrated in
[0117] In the embodiments illustrated in
[0118] In the embodiments illustrated in
[0119]
[0120] In some embodiments, the full-metal sealing system has all-metal contacts between the seal and pushrod. Additionally, or alternatively, the full-metal sealing system can include a scraper at the lower entrance of the seal housing. As a result, the metallic sealing systems can (1) have potentially greater longevity than polymer seals due to lower temperature sensitivity as a result of not having polymers in contact with the rod; (2) reduce the chance that oil leaks out of the sealing system, thereby reducing the chance that oil either contributes to a fire and/or fouls the end effector because oil can be fed in much smaller quantities than with polymer and/or rubber seals; (3) reduce the chance of leaks in the event of a delayed end effector retraction (and therefore a hotter-than-normal rod interacting with the sealing system) since the full-metal seal can resist the heat; and/or (4) help prevent abrasive material from entering the seal housing to reduce or mitigate deleterious effects associated with the wear of the sealing surfaces (e.g., eventually leading to leakage).
[0121] In each of the embodiments illustrated in
[0122] In the embodiments illustrated in
[0123] In the embodiments illustrated in
[0124] As further illustrated in
[0125] In the embodiments illustrated in
[0126]
[0127]
[0128] In the illustrated embodiment, the tool-scraping component 3100 includes two rings. However, it will be understood that tool-scraping component 3100 can include any other suitable number of rings (e.g., one ring, three rings, five rings, and/or any other suitable number). Further, each of the rings can include features to help prevent rotation of the tool-scraping component 3100. For example, each of the rings can include a tab that can mesh with an insert in the sealing device to help prevent the rings from rotating as the rod is actuated. As further illustrated in
EXAMPLES
[0129] The present technology is illustrated, for example, according to various aspects described below. Various examples of aspects of the present technology are described as numbered examples (1, 2, 3, etc.) for convenience. These are provided as examples and do not limit the present technology. It is noted that any of the dependent examples can be combined in any suitable manner, and placed into a respective independent example. The other examples can be presented in a similar manner.
[0130] 1. A pyrolysis reactor, comprising: [0131] a combustion component fluidly couplable to a combustion fuel supply; [0132] a reaction chamber thermally coupled to an output of the combustion component and fluidly couplable to a pyrolysis fuel supply, the reaction chamber configured to transfer heat from the combustion component to a flow of pyrolysis fuel from the pyrolysis fuel supply to generate an output flow comprising hydrogen gas and carbon particulates; and [0133] a carbon removal component operably coupled to the reaction chamber, the carbon removal component comprising: [0134] an actuator; [0135] a rod operably coupled to the actuator and positioned at least partially within the reaction chamber; [0136] a sealing device between the rod and the reaction chamber to allow movement of the rod along a longitudinal axis of the reaction chamber and restrict a flow of gas out of the reaction chamber; and a scraper head coupled to the rod, the scraper head having a plurality of teeth positioned to scrape carbon deposits from an interior wall of the reaction chamber during the movement of the rod along the longitudinal axis of the reaction chamber. [0137] 2. The pyrolysis reactor of example 1, further comprising a combustion chamber fluidly coupled to the combustion component and positioned to receive a hot flue gas from the combustion component, wherein: [0138] the reaction chamber is positioned circumferentially around the combustion chamber; [0139] the scraper head is a ring-shaped component having an internal side facing the combustion chamber and an external side, wherein the plurality of teeth are positioned along at least one of the internal side or the external side; and [0140] the rod is one of a plurality of rods coupled to and distributed about a circumference of the ring-shaped component of the scraper head.
[0141] 3. The pyrolysis reactor of example 2 wherein: [0142] the scraper head includes a first housing and a second housing rotatably coupled to the first housing, wherein the second housing includes a gear track; [0143] a distal end region of each of the plurality of rods is fixedly coupled to the first housing; [0144] the distal end region of at least one of the plurality of rods includes a gear coupled to the gear track of the second housing; and [0145] in operation, driving the gear causes the second housing to rotate about the longitudinal axis with respect to the first housing.
[0146] 4. The pyrolysis reactor of any of examples 2 and 3 wherein the scraper head includes a first tooth holder coupled to at least some of the plurality of teeth positioned along the internal side and a second tooth holder coupled to at least some of the plurality of teeth positioned along the external side.
[0147] 5. The pyrolysis reactor of example 1 wherein the combustion component is fluidly coupled to the reaction chamber to direct a hot flue gas through the reaction chamber to transfer the heat from the combustion component to the flow of pyrolysis fuel.
[0148] 6. The pyrolysis reactor of example 5 wherein: [0149] the scraper head includes a plurality of openings each sized to receive an individual tooth from the plurality of teeth; and [0150] the carbon removal component further comprises an end cap couplable to the scraper head to retain each individual tooth within a corresponding opening from the plurality of openings.
[0151] 7. The pyrolysis reactor of any of examples 5 and 6 wherein: [0152] the rod comprises an internal drive shaft; and the scraper head comprises: [0153] a sun gear coupled to the internal drive shaft of the rod; [0154] a main body having a plurality of openings, each of the plurality of openings sized to receive an individual tooth from the plurality of teeth; [0155] a plurality of gears each coupled to the sun gear and a corresponding tooth from the plurality of teeth, wherein driving the internal drive shaft drives rotation of each of the plurality of gears via the sun gear; and [0156] an end cap couplable to the main body to retain each individual tooth within a corresponding opening from the plurality of openings.
[0157] 8. The pyrolysis reactor of any of examples 1-7 wherein the reaction chamber is one of a plurality of reaction chambers, wherein the carbon removal component includes a plurality of rods and a plurality of scraper heads individually coupled to a corresponding rod from the plurality of rods, and wherein each of the plurality of scraper heads is positioned within a corresponding individual reaction chamber from the plurality of reaction chambers.
[0158] 9. The pyrolysis reactor of example 8 wherein individual ones of the plurality of teeth has a wedge-shaped profile oriented to at least partially drive a rotation of each of the plurality of scraper heads when the plurality of scraper heads move along the longitudinal axis of the corresponding individual reaction chamber.
[0159] 10. The pyrolysis reactor of any of examples 1-9 wherein the sealing device comprises one or more expandable components each having an aperture sized to form a seal around the rod.
[0160] 11. The pyrolysis reactor of any of examples 1-10 wherein the sealing device is fluidly coupled to a pressurized inert gas source.
[0161] 12. The pyrolysis reactor of any of examples 1-11 wherein the sealing device comprises an elastic scraping component positioned at least partially within the reaction chamber to scrape carbon deposits from the rod during the movement of the rod along a longitudinal axis of the reaction chamber.
[0162] 13. A solids-removal component for scraping solids (e.g., carbon) from an internal wall of chamber of a reactor (or other system requiring solids removal) during operation of the reactor, the solids-removal component comprising: [0163] an actuator; [0164] a drive component operably coupled to the actuator and positioned at least partially within the chamber of the reactor; [0165] a sealing device coupled to the chamber of the reactor, wherein the sealing device is configured to allow the drive component to move within the chamber and obstruct a flow of gas out of the chamber; and [0166] an end effector coupled to the drive component, the end effector having a plurality of scraping components positioned to scrape deposits of the solids from the internal wall of the chamber during movement of the drive component.
[0167] 14. The solids-removal component of example 13 wherein the chamber is a first chamber of a plurality of chambers in the reactor, wherein the drive component is a first drive component of a plurality of drive components, wherein the end effector is a first end effector of a plurality of end effectors, and wherein the carbon removal component further comprises a strongback coupled between the actuator and the plurality of drive components, the strongback configured to translate motion from the actuator to movement in of each of the plurality of drive components.
[0168] 15. The solids-removal component of any of examples 13 and 14 wherein the end effector has an annular shape, and wherein the plurality of scraping components comprise an inward-facing subset and an outward-facing subset.
[0169] 16. The solids-removal component of any of examples 13-15 wherein the movement of the drive component comprises plunges along a longitudinal axis of the chamber of the reactor, and wherein the solids-removal component further comprises an indexing component configured to rotate the drive component about the longitudinal axis between the plunges along the longitudinal axis.
[0170] 17. The solids-removal component of any of examples 13-16 wherein each of the plurality of scraping components comprises a slot cutter, and wherein two or more of the plurality of scraping components further comprises a wedge cutter coupled to a corresponding slot cutter.
[0171] 18. The solids-removal component of any of examples 13-17 wherein the movement of the drive component comprises plunges rotation about a longitudinal axis of the chamber of the reactor.
[0172] 19. A method for continuously operating a reactor (e.g., a pyrolysis reactor), the method comprising: [0173] directing a flow of a hydrocarbon fuel into a chamber of the reactor; [0174] heating the hydrocarbon pyrolysis fuel within the chamber to cause a reaction that creates a product stream, wherein the product stream comprises hydrogen gas and solids (e.g., carbon and/or other solids), and wherein at least a portion of the solids precipitates onto an internal wall of the chamber to form a buildup; and [0175] while directing the flow of the hydrocarbon pyrolysis fuel into the chamber, actuating an end effector of a carbon removal component within the chamber to scrape at least a portion of the buildup off of the internal wall.
[0176] 20 The method of example 19 wherein actuating the end effector comprises moving the end effector along a longitudinal axis of the chamber.
[0177] 21. The method of example 20, further comprising indexing the end effector between subsequent actuations along the longitudinal axis of the chamber.
[0178] 22 The method of any of examples 19-21 wherein actuating the end effector comprises rotating the end effector about a longitudinal axis of the chamber.
[0179] 23 The method of any of examples 19-22 wherein heating the hydrocarbon fuel within the chamber comprises combusting a combustion fuel within the chamber while directing the flow of the hydrocarbon fuel into the chamber.
[0180] 24. The method any of examples 19-22 wherein the reactor is a pyrolysis reactor, wherein the solid is carbon, wherein the chamber is a reaction chamber at least partially surrounding a combustion chamber of the reactor, and wherein heating the hydrocarbon fuel within the reaction chamber comprises combusting a combustion fuel within the combustion chamber while directing the flow of the hydrocarbon fuel into the reaction chamber.
CONCLUSION
[0181] From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the technology. To the extent any material incorporated herein by reference conflicts with the present disclosure, the present disclosure controls. Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word or is expressly limited to mean only a single item exclusive from the other items in reference to a list of two or more items, then the use of or in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of the items in the list. Furthermore, as used herein, the phrase and/or as in A and/or B refers to A alone, B alone, and both A and B. Additionally, the terms comprising, including, having, and with are used throughout to mean including at least the recited feature(s) such that any greater number of the same features and/or additional types of other features are not precluded. Further, the terms generally, approximately, and about are used herein to mean within at least within 10% of a given value or limit. Purely by way of example, an approximate ratio means within 10% of the given ratio.
[0182] Several implementations of the disclosed technology are described above in reference to the figures. The computing devices on which the described technology may be implemented can include one or more central processing units, memory, input devices (e.g., keyboard and pointing devices), output devices (e.g., display devices), storage devices (e.g., disk drives), and network devices (e.g., network interfaces). The memory and storage devices are computer-readable storage media that can store instructions that implement at least portions of the described technology. In addition, the data structures and message structures can be stored or transmitted via a data transmission medium, such as a signal on a communications link. Various communications links can be used, such as the Internet, a local area network, a wide area network, or a point-to-point dial-up connection. Thus, computer-readable media can comprise computer-readable storage media (e.g., non-transitory media) and computer-readable transmission media.
[0183] From the foregoing, it will also be appreciated that various modifications may be made without deviating from the disclosure or the technology. For example, one of ordinary skill in the art will understand that various components of the technology can be further divided into subcomponents, or that various components and functions of the technology may be combined and integrated. In addition, certain aspects of the technology described in the context of particular embodiments may also be combined or eliminated in other embodiments.
[0184] Furthermore, although advantages associated with certain embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.