EP4249572A1 - Thermolysereaktor für kunststoffabfälle - Google Patents
Thermolysereaktor für kunststoffabfälle Download PDFInfo
- Publication number
- EP4249572A1 EP4249572A1 EP22176380.8A EP22176380A EP4249572A1 EP 4249572 A1 EP4249572 A1 EP 4249572A1 EP 22176380 A EP22176380 A EP 22176380A EP 4249572 A1 EP4249572 A1 EP 4249572A1
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- EP
- European Patent Office
- Prior art keywords
- reactor
- helix
- plastic waste
- exhaust gases
- thermolysis
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000001149 thermolysis Methods 0.000 title claims abstract description 45
- 239000013502 plastic waste Substances 0.000 title claims abstract description 41
- 239000000463 material Substances 0.000 claims abstract description 24
- 238000006243 chemical reaction Methods 0.000 claims abstract description 18
- 238000012545 processing Methods 0.000 claims abstract description 5
- 239000007789 gas Substances 0.000 claims description 73
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 38
- 238000010438 heat treatment Methods 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 23
- 229910052799 carbon Inorganic materials 0.000 claims description 22
- 229920003023 plastic Polymers 0.000 claims description 16
- 239000004033 plastic Substances 0.000 claims description 16
- 230000001276 controlling effect Effects 0.000 claims description 7
- 230000001105 regulatory effect Effects 0.000 claims description 6
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 238000012546 transfer Methods 0.000 claims description 5
- 238000007599 discharging Methods 0.000 claims description 3
- 238000003860 storage Methods 0.000 claims description 3
- 238000003786 synthesis reaction Methods 0.000 claims description 3
- 239000002699 waste material Substances 0.000 claims description 2
- 238000003763 carbonization Methods 0.000 abstract description 2
- 239000000446 fuel Substances 0.000 description 12
- 230000008569 process Effects 0.000 description 10
- 239000000047 product Substances 0.000 description 7
- 239000007788 liquid Substances 0.000 description 6
- 150000002430 hydrocarbons Chemical class 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 229930195733 hydrocarbon Natural products 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 238000011084 recovery Methods 0.000 description 4
- 230000008929 regeneration Effects 0.000 description 4
- 238000011069 regeneration method Methods 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 3
- 239000004793 Polystyrene Substances 0.000 description 3
- 238000010521 absorption reaction Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
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- 239000000203 mixture Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 238000000197 pyrolysis Methods 0.000 description 3
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- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical group [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 2
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
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- 229920001903 high density polyethylene Polymers 0.000 description 2
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- 229920001684 low density polyethylene Polymers 0.000 description 2
- 239000004702 low-density polyethylene Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000003208 petroleum Substances 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 230000001172 regenerating effect Effects 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 239000011593 sulfur Substances 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
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- 239000003344 environmental pollutant Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 239000010763 heavy fuel oil Substances 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000012263 liquid product Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
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- 231100000719 pollutant Toxicity 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/05—Stirrers
- B01F27/11—Stirrers characterised by the configuration of the stirrers
- B01F27/114—Helically shaped stirrers, i.e. stirrers comprising a helically shaped band or helically shaped band sections
- B01F27/1145—Helically shaped stirrers, i.e. stirrers comprising a helically shaped band or helically shaped band sections ribbon shaped with an open space between the helical ribbon flight and the rotating axis
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/60—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis
- B01F27/72—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis with helices or sections of helices
- B01F27/721—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis with helices or sections of helices with two or more helices in the same receptacle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/90—Heating or cooling systems
- B01F35/95—Heating or cooling systems using heated or cooled stirrers
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B47/00—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion
- C10B47/28—Other processes
- C10B47/32—Other processes in ovens with mechanical conveying means
- C10B47/44—Other processes in ovens with mechanical conveying means with conveyor-screws
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
- C10B53/07—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of solid raw materials consisting of synthetic polymeric materials, e.g. tyres
Definitions
- the present disclosure provides a reactor for conducting plastic waste thermolysis with continuous feeding of plastic raw material and automatic removal of carbonization products and any other reaction residues.
- thermolysis or pyrolysis
- a relatively large compound is broken down into molecules due to high temperatures.
- Such process for converting plastic waste into liquid fuels is generally acknowledged as a convenient way to handle plastic waste, since the cost is manageable, and the final product (liquid fuel) may have properties that are more or less like the common petroleum fuels.
- the products that are deriving from the thermolysis of plastic provide the advantage of not containing any sulfur, as the petroleum products do, thereby being more environmentally friendly, since sulfur is a known pollutant that also affects the health of the public.
- Conventional reactors however, that convert plastic waste to usable fuel do show some drawbacks, mainly related to the thermal efficiency of the overall process. Further, in conventional reactors, the process is not continuous, meaning that when a batch of raw material is process through a thermolysis reactor chamber, then the entire operation should stop to cool down the reactor and remove any carbon residues.
- thermolysis reactor for conducting plastic waste thermolysis is designed and based to continuous closed operation cycle in a way that is achieved maximum energy efficiency.
- a relatively compact/controllable size of the equipment is succeeded, thereby allowing the installation of such equipment in a quite fast and precise manner in any workplace.
- Such arrangement further allows for a continuous thermolysis reaction and a continuous extraction of syngas from the reactor, thus enhancing the efficiency of the overall process.
- thermolysis reactor for conducting plastic waste thermolysis comprising a reactor chamber comprising an input end for receiving plastic waste and an output end for discharging synthesis gas, at least one gas burner, an agitating device that is housed within the reactor chamber for processing plastic waste material, a carbon rejection device and an exhaust gases collector, wherein the agitating device comprises a rotating helix assembly with a first helix and a second helix wherein each of the first and second helices is hollow, thereby forming helical ducts for circulating exhaust gases to heat the plastic waste.
- the agitating device effectively uses the exhaust gases to heat the molten plastic waste within the reactor.
- the first helix is positioned coaxially relative to the second helix such that plastic waste material is moved by the first helix towards the output end of the reactor chamber.
- the direction of the second helix is opposite to the direction-of the first helix.
- the first helix encloses the second helix.
- the second helix comprises an inner diameter and an outer diameter and wherein the inner diameter of the first helix is bigger than the outer diameter of the second helix.
- the inner diameter of the first helix is of about 600 to 700 mm
- the outer diameter of the first helix is of about 900 to 1000 mm
- the outer diameter of the second helix is of about 500 mm and 600 mm
- the inner diameter of the second helix is of about 200 mm and 300 mm.
- the number of the turns of the first helix is greater than the number of turns of the second helix.
- the agitating device comprises an exhaust gas inlet and an exhaust gas outlet, wherein the exhaust outlet comprises a valve for regulating the flow of the exhaust gases.
- the reactor chamber is of semi-circular shape and wherein an outer surface of the reactor chamber comprises a plurality of heating jackets, configured to drive the exhaust gases towards the exhaust gas collector.
- each heating jacket comprises a control valve for controlling the flow of exhaust gases from each heating jacket.
- the reactor comprises at least one gear box that, when activated, is configured to initiate the rotation of the agitating device.
- the reactor comprises one or more load cells, wherein said load cells are removably attached on a bottom surface of the reactor and they are configured to monitor the supply of plastic waste material within the reactor.
- the carbon rejection device comprises a first valve for opening or closing a first port to the carbon rejection device, a residue chamber-for the storage of carbon residues, a helix that is mounted within the residue chamber and a second valve for opening or closing a second port of the residue chamber.
- the at least one of the first and second helices is surrounded by scraped segments that are designed such that they detach and transfer any residues to the carbon rejection device.
- the reactor chamber comprises electrical resistors, wherein said electrical resistors are removably connected to an upper surface of the reaction chamber.
- the agitating device defines a longitudinal axis X which is substantially parallel to a horizontal plane, wherein the pitch of the first helix is of about 200-250 mm and the pitch of the second helix is of about 400-500 mm.
- thermolysis comprising the steps of:
- the method comprises automatically rejecting the carbon residues that are produced during thermolysis via a carbon rejection device.
- the method comprises the step of controlling the flow of the exhaust gases that are guided to the at least one heating jacket and to the agitating device.
- thermolysis reactor An embodiment of the thermolysis reactor according to aspects of the disclosure will now be described with reference to Figures 1-7 .
- the reactor is described with reference to specific examples, it should be understood that modifications and changes may be made to these examples without going beyond the general scope as defined by the claims.
- individual characteristics of the various embodiments shown and/or mentioned herein may be combined in additional embodiments. Consequently, the description and the drawings should be considered in a sense that is illustrative rather than restrictive.
- first the terms “first,” “second,” etc. may be used herein to describe various elements, components, regions, layers, sections, and/or parameters, these elements, components, regions, layers, sections, and/or parameters should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed herein could be termed a second element, component, region, layer, or section without departing from the teachings of the present disclosure.
- FIG. 1 illustrates the various components that, when assembled, form a thermolysis reactor (100) for conducting plastic waste pyrolysis.
- the reactor (100) comprises a reactor chamber (110) where the thermolysis reaction takes place, the reactor chamber comprising an input end for receiving plastic waste and an output end for discharging synthesis gas, at least one gas burner (150) for creating the necessary temperature for the heating distributors, an agitating device (130) that is housed within the reactor chamber (110) for processing plastic waste material with the usage of exhaust gases, thereby heating the plastic waste within the reactor, a carbon rejection device (140), and an exhaust gas collector (120)
- the agitating device (130) comprises a rotating helix assembly comprising a first helix (131) and a second helix (132) wherein each of the first and second helix is hollow, thereby forming helical ducts for circulating exhaust gases to heat the plastic waste. Further, such configuration of the rotating helix assembly results in the formation of a single screw system that comprises the first and the second
- the reactor chamber (110) and the helix assembly may be made by stainless steel which is known for its long-term value and the corrosion resistance that it provides.
- the reactor chamber (110) may have a semicircular shape and may be arranged horizontally relative to a horizontal plane.
- the reactor chamber (110) may be divided in two compartments which may be called in the herein disclosure as lower and upper part of the reaction chamber.
- the lower and the upper part may be separate components, so as to facilitate the installation of other components within the reactor and may be assembled together through suitable attaching means such as screws.
- the outer surface of the lower part of the reactor chamber (110) comprises a plurality of heating jackets (111), which in the described embodiment are limited to three, configured to drive the exhaust gases towards the exhaust gas collector (120).
- the exhaust gas collector (120) may comprise a chamber with nozzles that are connected with the helix assembly of the agitating device (130) of the reactor.
- the nozzles may be connected with flow regulating valves, and in particular proportional exhaust flow regulating valves, for controlling the exhaust gas flow.
- the exhaust gas collector (120) may further comprise a compartment where a screw (not shown) allows the insertion of the plastic waste into the reactor, in liquid state.
- an internal surface of the upper part of the reactor chamber (110) may comprise electrical resistors that are removably connected to that upper surface of the reaction chamber.
- the usage of electrical resistors ensures that when the the syngas that is resulting from the thermolysis reaction passes from these sections that contain the resistors, the temperature at these points is at the desired level to achieve gasification and any small particles that have resulted from the thermolysis reaction but have not yet been gasified.
- At least one gas burner (150) is provided for the diffusion of the exhaust gases.
- two gas burners (150) are used to create the required temperature for the heating distributors, to achieve the optimal diffusion of the exhaust gases.
- the gas burners (150) may be mounted on one side of the reactor chamber (110) and direct the exhaust gases through specific paths within the reactor (100) where the thermolysis reaction of the plastic takes place.
- the power of the gas burners is proportional to a wide range and a closed loop air / fuel ratio control is performed, to achieve maximum efficiency and low NOx levels.
- An important aspect of these gas burners is their multifunction .
- natural gas or liquefied petroleum gas (LPG) or any other gas or liquid or any other kind of energy can be used as the main fuel and non-condensable gases as supplementary fuel, where depending on the stock, the filling rate of the fuel mixture is automatically calculated.
- LPG liquefied petroleum gas
- the agitating device (130) comprises an exhaust gas inlet and an exhaust gas outlet, wherein the exhaust gas outlet comprises a valve (123), in examples a proportional valve, for regulating the flow of the exhaust gases.
- the exhaust gas outlet comprises a valve (123), in examples a proportional valve, for regulating the flow of the exhaust gases.
- the plastic waste enters the thermolysis reactor (100) at a temperature of 220°C, in molten state. Its temperature begins to rise, using the heat of the exhaust gases which are led to the thermolysis reactor (100).
- the exhaust gases are led to the external surface of the reactor (100), and more specifically to the exhaust gas collector (120), through specially designed ducts that form a plurality of heating jackets (111), which in the described example are three.
- each heating jacket there is a proportional flow control valve (124) at the exhaust outlet, for regulating the flow of the exhaust gases.
- the first helix (131) is positioned coaxially relative to the second helix such that plastic waste material is moved by the first helix (131) towards the output end of the reactor chamber (110).
- the exhaust gases are led inside the thermolysis reactor (100) through the helical paths.
- each of the first helix (131) and the second helix (132) comprises an inner diameter and an outer diameter wherein the inner diameter of the first helix (131) is bigger than the outer diameter of the second helix (132) thereby creating an arrangement where the first helix encloses the second helix, or to further simplify, the second helix (132) is inside the first helix (131).
- the inner diameter (d1) of the first helix (131) is of about 600-700mm
- the outer diameter (d2) of the first helix is of about 900 to 1000 mm
- the outer diameter (d3) of the second helix (132) is of about 500 mm and 600 mm
- the inner diameter (d4) of the second helix is of about 200mm and 300mm.
- the thickness of the helices (131, 132) may be between 3-10mm and in particular 5mm.
- the two helixes are connected through connecting means, in such a way that they rotate synchronously through the same rotating means. In one embodiment both helixes (131, 132) rotate clockwise.
- the direction of the second helix (132) is opposite to the direction of the first helix (131). More specifically, the helix direction of the first helix can be clockwise, or right-handed and the direction of the second helix counterclockwise or left-handed. The opposite combination is also possible, without departing from the teaching of the present disclosure.
- the first helix (131) that has the bigger diameter pushes the material to always move in the opposite direction from the inner second helix (132). In this way two flow streams of the material are formed, where with the repeated circulation of the flow, the heat is transferred directly and evenly throughout the material, making it completely homogenized.
- the number of the turns of the first helix (131) is greater than the number of the turns of the second helix.
- the turns of the first helix (131) may be between nine to twelve (9-12) and in particular eleven (11) and the turns of the second helix (132) may be between five to eight (5-8) and in particular six (6).
- the agitating device (130) defines a longitudinal axis X which is substantially parallel to a horizontal plane, wherein the pitch (h1) of the first helix (131) is of about 200-250mm and in particular 225 mm and the pitch (h2) of the second helix is of about 400-500mm and in particular 450 mm.
- the pitch of a helix as the height of one complete helix turn, measured parallel to the axis of the helix, as it can be seen in figure 7 .
- Such arrangement is beneficiary since the size of the overall equipment is relatively small, thereby facilitating its installation to any suitable location.
- such configuration provides the advantage of having agitation and homogenization of the plastic material with continuous flow while heating with direct and uniform transfer of heat to the material from the reactor core, where the residence time of the raw material in the reactor is reduced to the minimum.
- the temperature inside the reactor (100) may reach 370°C to 425°C. At this temperature, the plastic becomes gaseous. The reaction of the plastic at this temperature causes the plastic carbon chain lengths to randomly break into various lengths. The pressure inside the reactor (100) may rise to 3 bar. The syngas resulting from the thermolysis reaction pass through the upper surface of the reactor chamber (110) that comprises the electrical resistors. As previously described, in this way the temperature at these points is at the desired level to achieve gasification and any small particles that have resulted from the thermolysis reaction but have not yet been gasified.
- the reactor (100) comprises at least one gear box (170) that, when activated, is configured to initiate the rotation of the agitating device (130).
- the electric gearbox (170) enables the helix assembly to rotate, meaning that the rotation of each of the first and second helices (131, 132) may be activated by a single electric gear box.
- a pair of electric gearboxes is provided, as shown in figure 3 , as a precaution to avoid any distortions across the length of the rotating helix assembly.
- a pair of electric gearboxes (170) may also be provided for activating the rotation of the first and second helices (131, 132).
- the rotation of the first and second helix will be independent from each other since each helix will have assigned its own electric gear box for initiating the relevant helix rotation.
- the reactor (100) comprises one or more load cells, wherein said load cells are removably attached on a bottom surface of the reactor (100) and they are configured to monitor the supply of plastic waste material within the reactor (100). In that way, the reactor (100) is automatically checked for its continuous feeding with plastic material, while the completeness of the plastic waste within the reactor is successfully maintained.
- the carbon rejection device (140) comprises a first valve (141) for opening or closing a first port to the carbon rejection device (140) , a residue chamber (142) for the storage of carbon residues, a helix that is mounted within the residue chamber (142) and a second valve (143) for opening or closing a second port to the residue chamber (142).
- Any suitable valve should be foreseen for carrying out the described operation.
- the first and second valves may be, but not limited to, proportional. With the usage of specific software, the degree of performance of the reactor (100) is calculated and when it drops below a certain threshold, the regeneration process begins.
- the carbon rejection device (140) is activated, for example, through specially designed software means, and the residues generated by the thermolysis process are discarded from the reactor (100).
- the first valve (141) is activated, and the first port of the carbon rejection device (140) opens. Meanwhile, the port at the bottom of the residue chamber (142) is closed.
- the helix (144) of the carbon rejection device (140) starts moving to enter the reactor (100). Through the helix, the carbon residues that have accumulated for example above the port of the first valve (141) are discarded in the residue chamber (142) and the helix (144) is moved to its initial position.
- At least one of the first and second helices (131, 132) is surrounded by scraped segments that are designed such that they detach and transfer any residues to the carbon rejection device (140).
- the first valve (141) is closed and the agitating device (130) rotates to bring carbon residue above the port of the first valve (141) and subsequently the agitating devices stops its rotation.
- the first valve (141) opens, and the helix (144) of the carbon rejection device (140) is activated and at the same time it moves to enter the reactor (100).
- the carbon residues that have accumulated above the port of the first valve (141) are discarded in the residue chamber (142).
- the helix (144) is moved to its initial position and the first valve (141) closes.
- the agitating device (130) rotates again with a specific step to bring carbon residue above the port of the first valve (141).
- the agitating device (130) stops rotating and the first valve (141) opens.
- the helix (144) of the carbon rejection device (140) is activated and at the same time it moves to enter the reactor (100) to discard the accumulated residues in the residue chamber (142).
- a valve (143), in examples a proportional valve (143) is actuated and the port that is located at a bottom surface of the residue chamber (142) opens, thereby disposing the residues, for example in an external container for further processing or final disposal.
- the above procedure is repeated and lasts until all the amount of carbon residue present in the reactor (100) is discarded.
- all parts of the unit are automatically put into production process mode.
- the regeneration process does not require the reduction of the reactor temperature, so the accumulated energy in the reactor mass remains and thus the recovery of its energy is not required to continue the production process. In this way the regeneration time of the reactor is limited only to the disposal of carbon residues without the loss of its thermal energy.
- the plastic materials that are suitable for the conversion according to the present disclosure may be, but not limited to, PE (polyethylene), PET (polyethylene terephthalate), HDPE (high density polyethylene), LDPE (low density polyethylene), PP (polypropylene), PS (polystyrene), ABS (acrylonitrile-butadiene-styrene copolymer).
- the plastic material may preferably be in cylindrical shaped particles ('spheres') with a maximum diameter of 10mm.
- the most preferred feedstock from the above list of materials for the production of liquid hydrocarbons are the PE, PP and PS thermoplastics.
- thermosetting plastics, wood, and paper results to the formation of carbonous substances and lowers the rate and yield of liquid products.
- thermolysis products are directly related to the chemical composition and chemical structure of the plastics, since the chemical composition of the feedstock affects the thermolysis process.
- the plastic feedstock contains PVC
- the resulting products may contain HCI that is found to be hazardous for the fuels.
- the plant should also comprise a re-treatment system to remove Hcl from the resulting pyrolysis products.
- the thermolysis products may be grouped as petroleum gases, petrol, kerosene, diesel and WAX (>Cso).
- the above-mentioned fuels may contain hydrocarbon group with different carbon chain lengths as given in below Table1. However, it has to be contemplated that there are also other ways to describe the hydrocarbons such as boiling range, phase of products at room temperature etc. Table 1. Hydrocarbon range in commercial fuels Fuels LPG Petrol Kerosene Diesel Heavy Fuel oil Hydrocarbons C 1 to C 4 C 5 to C 10 C 10 to C 16 C 14 to C 20 C 20 to C 70
- a method for plastic waste thermolysis comprises the steps of continuously providing plastic waste to a thermolysis reactor (100) at a temperature between 180 - 240 °C, producing exhaust gases via at least one gas burner (150), guiding the exhaust gases on an outer surface of the thermolysis reactor (100) via at least one heating jacket (111) , guiding the exhaust gases in the helical ducts of at least one of the first and second helices of the agitating device (130), rotating the agitating device (130), heating the plastic waste to a temperature between 370 - 430 °C, thereby converting the waste plastic to gaseous form.
- the method may further comprise the step of automatically rejecting the carbon residues that are produced during thermolysis via a carbon rejection device (140).
- the method may further comprise the control of the flow of the exhaust gases that are guided to the at least one heating jacket (111) and to the agitating device (130).
- Such method enhances the overall thermal efficiency, since the temperature difference between the liquid plastic material that enters the reactor ( ⁇ 220°C) and the temperature at which the heat treatment reaction takes place (370°C - 425°C) is relatively low, while it ensures an uninterrupted continuous thermolysis reaction with continuous extraction of syngas from the reactor and rejection of any carbon residues.
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PCT/EP2023/055798 WO2023232301A1 (en) | 2022-05-31 | 2023-03-07 | Plastic waste thermolysis reactor |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080128259A1 (en) * | 2006-11-06 | 2008-06-05 | Stanislaw Kostek | Methods and apparatus for pyrolyzing material |
US20130240343A1 (en) * | 2006-12-26 | 2013-09-19 | Nucor Corporation | Pyrolyzer furnace apparatus and method for operation thereof |
CN108840538A (zh) * | 2018-06-25 | 2018-11-20 | 南京中电环保固废资源有限公司 | 一种燃气间接式加热回转内螺旋碳化炉 |
CN110090576A (zh) * | 2019-06-06 | 2019-08-06 | 江西中医药大学 | 固液混合与加热装置 |
US20190264109A1 (en) * | 2016-11-28 | 2019-08-29 | OOO "Nauchno-Proizvodstvennoe Obedinenie Innovatekh" | Device for Processing Scrap Rubber |
-
2022
- 2022-05-31 EP EP22176380.8A patent/EP4249572A1/de active Pending
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080128259A1 (en) * | 2006-11-06 | 2008-06-05 | Stanislaw Kostek | Methods and apparatus for pyrolyzing material |
US20130240343A1 (en) * | 2006-12-26 | 2013-09-19 | Nucor Corporation | Pyrolyzer furnace apparatus and method for operation thereof |
US20190264109A1 (en) * | 2016-11-28 | 2019-08-29 | OOO "Nauchno-Proizvodstvennoe Obedinenie Innovatekh" | Device for Processing Scrap Rubber |
CN108840538A (zh) * | 2018-06-25 | 2018-11-20 | 南京中电环保固废资源有限公司 | 一种燃气间接式加热回转内螺旋碳化炉 |
CN110090576A (zh) * | 2019-06-06 | 2019-08-06 | 江西中医药大学 | 固液混合与加热装置 |
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