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WO2024214093A1 - Réacteur annulaire avec un racleur de carbone cum agitateur et son procédé de pyrolyse - Google Patents

Réacteur annulaire avec un racleur de carbone cum agitateur et son procédé de pyrolyse Download PDF

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Publication number
WO2024214093A1
WO2024214093A1 PCT/IB2024/055263 IB2024055263W WO2024214093A1 WO 2024214093 A1 WO2024214093 A1 WO 2024214093A1 IB 2024055263 W IB2024055263 W IB 2024055263W WO 2024214093 A1 WO2024214093 A1 WO 2024214093A1
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WO
WIPO (PCT)
Prior art keywords
reactor
annular space
agitator
gear
cylinder
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Application number
PCT/IB2024/055263
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English (en)
Inventor
Mithilesh Madanlal GUPTA
Kritika Rakesh GUPTA
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Individual
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Individual
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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

Definitions

  • the present disclosure relates to the reactors designed for decomposition of materials using heat, steam, electricity or microwave energy. More particularly, the present disclosure relates to a simple, cost-effective, and efficient reactor with a carbon scrapper cum agitator, which facilitates thermal decomposition of input materials and efficiently scrapes and collects coke/carbon/char/biochar accumulated in the reactor.
  • the reactor is considered the heart of the pyrolysis process which is used to control/enhance the quality of heat transfer, mixing/agitation of feedstock, gas and liquid phase, residence times, and the flow of main products.
  • Several types of reactors design are available in the art for the pyrolysis process.
  • patent document number CN106701140 discloses a melting cracker for medical plastic waste, which comprises a cylindrical melting chamber and a cylindrical cracking chamber, both cemented in a horizontal layout and of low capacity.
  • the disclosed patent fails to provide an enhanced heat transfer that is required for effective thermal cracking.
  • there is no efficient and simple arrangement for enabling agitation of molten plastic which also enables scrapping and collection of by-products accumulated in the cracking chamber.
  • Another patent document number W02020212403A1 discloses a reactor for converting plastic to oil.
  • the disclosed reactor is a vertical cylindrical with an annular high- pressure inlet chamber which injects plastic melt feed at high pressure into the reactor chamber and the pressure turbulent mixing occurs in the cylindrical reactor.
  • the disclosed patent does not involve any agitator for the reactor, which is required for an efficient pyrolysis process. Besides, there is no arrangement for scrapping by-products accumulated in the reactor.
  • the present disclosure relates to a simple, cost-effective, and efficient reactor with a carbon scrapper cum agitator, which facilitates pyrolysis of plastic waste and efficiently scrapes and collects coke/carbon accumulated in the reactor.
  • the present invention discloses a unique annular reactor (FIG. 3) with agitator cum scrapper is used, which is implementable at an industrial scale while achieving better cost-effectiveness and thermal efficiency as compared to the existing reactors, while alleviating one or more shortcomings associated with the conventional processes.
  • the proposed cracker reactor receives filtered molten plastic mixture from a separate Melter or screw extruder or can even receive shredded plastic waste. After reactor rapidly heats the input plastic mixture up to pyrolysis temperature and maintains the temperature inside the reactor during residence time.
  • the reactor is an annular cylinder with a bevel gear arrangement in the annular space of the reactor for configuring the scraper cum agitator.
  • a burner is mounted inside an inner cylinder of the annular reactor with a flue gas jacket extending to envelop the outer cylinder of the annulus. The burner may be Deisel/Gas fired, which maintains the temperature required for cracking the molten mix in the annular space.
  • the accumulated carbon is scrapped by the agitator cum scrapper and is taken out with the help of a screw conveyor mounted at the bottom of the annular reactor. The screw conveyor then directs the carbon out of the vessel into the carbon slurry tank placed below the annular reactor. Both the scraper agitator and screw conveyor are designed to work in tandem for the desired function of efficient carbon removal.
  • the present invention discloses a A process for pyrolysis comprising the steps of: i. preheating the plastic waste stock in melting chamber followed by filtering by a surface type filtration system to provide the filtered molten plastic mixture; ii. introducing the filtered molten plastic mixture in the annular space (106) through the inlet (104-1) provided at the top end of the outer cylinder (104); iii. configuring the annular space (106) of the reactor (100) to facilitate cracking of the received input mixture at a predefined temperature and predefined pressure for a predefined time; iv.
  • bottoms stream includes carbon/coke that is separated and accumulated on the inner surfaces of the annular space (106) of the reactor (100); v. installing a burner in the inner cylinder (102) and the outer cylinder (104) enclosed by a flue gas jacket such that a heating area is created in the annular space (106) to obtain the thermally stable reactor (100) vi. configuring agitator-scrapper (108) to the mixture obtained from step (v) and facilitating the scraping of carbon deposited on the outer surface of the inner cylinder (102) and the inner surface of the outer cylinder (104) upon cracking of the mixture; vii.
  • the proposed reactor overcomes the drawback, limitations associated with the existing reactors, by providing a simple, cost-effective, and efficient reactor with a carbon scrapper cum agitator, which facilitates dry pyrolysis of plastic waste and efficiently scrapes and collects coke/carbon accumulated in the reactor.
  • the present invention employs a separate Melter, which helps overcome shortcomings such as restrictions as to the usage of the plastic waste, requirement of costly catalysts, restrictions on temperature range, scalability issues, and the like.
  • the proposed reactor allows a user to easily control the plastic pyrolysis process, pyrolysis product molecular distribution such as the composition of the feedstock, cracking temperature, heating rate, operation pressure, residence time, and application of catalyst. Further, the proposed reactor also enhances the plastic depolymerization process and pyrolysis product molecular distribution, thereby improving the quality and yield of the byproducts and making the overall process continuous.
  • FIG. 1 illustrates an exemplary longitudinal cross-sectional view of the proposed reactor with agitator cum scrapper, in accordance with an embodiment of the present disclosure.
  • FIG. 2A illustrates an exemplary cross-section of the reactor of FIG. 2A along the A-A’ axis.
  • FIG. 2B illustrates an exemplary view of the gear supporting plate of the proposed reactor, in accordance with an embodiment of the present disclosure
  • FIG. 3 illustrates the annular reactor with the outer jacket and the burner mount
  • plastic waste denotes the waste material from domestic or commercial source, such as plastic waste materials from residential sites, plastic waste materials from industrial sites, and plastic waste materials from land-fill sites, virgin plastic and virgin plastic materials such as scrap generated either during synthesis of the plastics materials or during processing of the plastics materials into the desired article.
  • the plastic waste may include single family plastic waste, for example, polyethyelene (PE), polypropylene (PP) or may include combination/mixture of several plastic wastes such as a combination of any of: polyethylene (PE), polypropylene (PP), polystyrene (PS), polyethylene terephthalate (PET), polychloroprene, nylon, polyvinyl chloride (PVC), polyacrylonitrile (PAN), and polyurethane (PU), but not limited thereto.
  • the plastic waste may also include one or more halogen containing plastic materials such as polyvinyl chloride (PVC), poly chloroprene and the likes.
  • the process of the present disclosure is amenable to wide variety of plastic wastes without any significant restrictions as to the type or characteristics of the plastic waste that may subjected to the instant process.
  • the plastic waste may have 20-50% of Polyethylene (PE), 20-50% of polypropylene (PP), 5- 30% of polyvinyl chloride (PVC) and the rest being other types of plastics that are typically used for common household purposes.
  • PE Polyethylene
  • PP polypropylene
  • PVC polyvinyl chloride
  • Embodiments of the present disclosure relate to a simple, cost-effective, and efficient reactor with a carbon scrapper cum agitator, which facilitates dry pyrolysis of plastic waste and efficiently scrapes and collects coke/carbon accumulated in the reactor.
  • the present disclosure elaborates upon an annular reactor with a carbon scrapper cum agitator.
  • the reactor can include an inner cylinder concentrically enclosed by an outer cylinder such that an annular space is created therebetween.
  • the annular space can be configured to receive and facilitate the cracking of the input feed material at predefined temperature and predefined pressure for a predefined time.
  • an agitator-scrapper can be movably configured in the annular space, which can be operable to mix the received mixture and facilitate scraping of carbon deposited on an outer surface of the inner cylinder and an inner surface of the outer cylinder upon cracking of the mixture.
  • a burner can be installed such that the flue gas is circulated in the inner cylinder and the outer cylinder is enclosed by a flue gas jacket.
  • the arrangement is such that a both inner cylinder and outer cylinder walls serve as heating area for the material in the annular space, which can facilitate cracking of the received input mixture, resulting in the generation of by-products comprising carbon that is deposited on the outer surface of the inner cylinder and the inner surface of the outer cylinder, and flue gas.
  • the inner cylinder can include a top cylinder configured coaxially over a bottom cylinder, where the diameter of the top cylinder is less than the diameter of the bottom cylinder such that a ledge portion is created for installation of the gear arrangement.
  • the agitator is supported and moves along with the gear arrangement which is driven by meshing gear on the rotor shaft driven by gear-box/motor.
  • the reactor can include a gear supporting plate (FIG. 2A and 2B) movably configured on a thrust ball bearing resting on top of the ledge portion.
  • the agitator-scrapper can extend from the bottom of the gear supporting plate to the bottom of the annular space.
  • the reactor can include a bevel gear/spur gear/miter gear arrangement comprising a driven gear and a driver gear with a predefined gear ratio, movably configured with the gear supporting plate.
  • the driver gear can mesh with the driven gear and the driven gear can engage with the gear supporting plate such that actuation of the driver gear by a motor can enable the driven gear to rotate the gear supporting plate over the ledge portion.
  • the rotation of the gear supporting plate over the ledge portion can move the agitator-scrapper in the annular space such that the agitator-scrapper slides/rolls on the outer surface of the inner cylinder and the inner surface of the outer cylinder, which can result in scraping of the deposited carbon from the outer surface of the inner cylinder and the inner surface of the outer cylinder.
  • the scraper blade arrangement on the agitator can be made suitably to give 100% scraping coverage to the inner cylinder and outer cylinder walls.
  • the driver gear can be configured in the annular space through a nozzle flange provided at an upper portion of the outer cylinder with a mechanical seal mounted on the nozzle flange for the driver gear.
  • the reactor can include a set of roller bearings mounted at predefined intervals along a length of the agitator-scrapper to support the agitator-scrapper and facilitate smooth sliding/rolling of the agitator-scrapper on the outer surface of the inner cylinder and the inner surface of the outer cylinder.
  • the reactor can include a screw conveyor positioned at the bottom of the annular space, which can be configured to move in tandem with the agitatorscrapper to collect and move the scrapped carbon to a carbon slurry tank.
  • the ledge portion can be supported by a set of gusset members being configured around the comer circumference of the ledge portion and the bottom cylinder.
  • the present invention discloses a A process for pyrolysis comprising the steps of: i. preheating the plastic waste stock in melting chamber followed by filtering by a surface type filtration system to provide the filtered molten plastic mixture; ii. introducing the filtered molten plastic mixture in the annular space (106) through the inlet (104-1) provided at the top end of the outer cylinder (104); iii. configuring the annular space (106) of the reactor (100) to facilitate cracking of the received input mixture at a predefined temperature and predefined pressure for a predefined time; iv.
  • bottoms stream includes carbon/coke that is separated and accumulated on the inner surfaces of the annular space (106) of the reactor (100); v. installing a burner in the inner cylinder (102) and the outer cylinder (104) enclosed by a flue gas jacket such that a heating area is created in the annular space (106) to obtain the thermally stable reactor (100) vi. configuring agitator-scrapper (108) to the mixture obtained from step (v) and facilitating the scraping of carbon deposited on the outer surface of the inner cylinder (102) and the inner surface of the outer cylinder (104) upon cracking of the mixture; vii.
  • the thermal cracking is achieved in the annular space 106 of the reactor 100 at a temperature ranging from 350°C to 650°C and at a pressure ranging from 150 to 300 mBar.
  • the thermal cracking is achieved at a temperature ranging from 350°C to 650°C and at a pressure ranging from 0 to 5 Bar Gauge.
  • the overhead stream from the thermal cracking is subjected to flashing using a flashing unit (flasher).
  • flashing unit flasher
  • the step of introducing feedstock into the reaction chamber is performed continuously to enable a continuous pyrolysis process.
  • the proposed annular reactor (FIG. 3) 100 (referred to as reactor 100, hereafter) with an agitator cum scrapper 108 (also referred to as agitator-scrapper 108, herein) is disclosed.
  • the reactor 100 can include an inner cylinder 102 including a top cylinder 102-1 configured coaxially over a bottom cylinder 102-2 having a diameter less than that of the top cylinder 102-1, such that a ledge portion 102-3 is created at connecting ends of the top cylinder 102-1 and bottom cylinder 102-2.
  • the reactor 100 can further include an outer cylinder 104 concentrically enclosing the inner cylinder 102 such that an annular space 106 is created therebetween.
  • the outer cylinder 104 can include an inlet 104-1 and an outlet 104-2 at the top end of the reactor 100.
  • the reactor 100 can include the agitator-scrapper 108 movably configured in the annular space 106.
  • a gear supporting plate 110 can be movably configured on a thrust ball bearing 112 resting on top of the ledge portion 102-3 and the agitator-scrapper 108 can extend from the bottom of the gear supporting plate 110 to the bottom of the annular space 106.
  • a set of roller bearings 124 can be mounted at predefined intervals along the length of the agitator-scrapper 108 to support the agitator-scrapper 108 and facilitate smooth sliding/rolling of the agitator-scrapper 108 on the outer surface of the inner cylinder 102 and the inner surface of the outer cylinder 104.
  • the scraper blade arrangement on the agitator can be made suitably to give 100% scraping coverage to the inner cylinder and outer cylinder walls.
  • the reactor 100 can further include a bevel gear/spur gear/miter gear arrangement comprising a driven gear 116 and a driver gear 118 with a predefined gear ratio, movably configured with the gear supporting plate 110, such that the driver gear 118 meshes with the driven gear 116 and the driven gear 116 engages with the gear supporting plate 110.
  • the driver gear 118 can be configured in the annular space 106 through a nozzle flange 120 provided at an upper portion of the outer cylinder 104/top head of the reactor with a mechanical seal mounted on the nozzle flange 120 for the driver gear 118.
  • actuation of the driver gear 118 by a motor enables the driven gear 116 to rotate the gear supporting plate 110 over the ledge portion 102-3.
  • the rotation of the gear supporting plate 110 over the ledge portion 102-3 can move the agitatorscrapper 108 in the annular space 106 such that the agitator-scrapper 108 slides/rolls on the outer surface of the inner cylinder 102 and the inner surface of the outer cylinder 104.
  • the entire assembly of gear arrangement and motor can be flexibly supported so as to operate during cold as well as elevated temperature conditions.
  • the annular space 106 of the reactor 100 can be configured to receive a filtered molten plastic mixture.
  • the plastic waste is pre-heated in a separate melting chamber and filtered by a surface type filtration system to provide the filtered molten plastic mixture, which can be then fed into the annular space 106 through the inlet 104-1 provided at the top end of the outer cylinder 104.
  • the annular space 106 of the reactor 100 can be configured to facilitate cracking of the received input mixture at a predefined temperature and predefined pressure for a predefined time.
  • the thermal cracking of the molten plastic mixture takes place in the annular space 106 of the reactor 100, resulting in an overhead stream and a bottom stream.
  • Bottoms stream can include carbon/coke that is separated and accumulated on the inner surfaces of the annular space 106 of the reactor 100.
  • a burner can be installed in the inner cylinder 102 and the outer cylinder 104 can be enclosed by a flue gas jacket such that a heating area is created in the annular space 106. This makes the reactor 100 thermally stable and efficient and also increases the operating life of the reactor 100.
  • the heating area in the annular space 106 can facilitate cracking of the received filtered molten plastic mixture, which can result in the generation of by-products including the carbon/coke in the annular space 106.
  • the agitator-scrapper 108 can be configured to mix the received mixture and facilitate the scraping of carbon deposited on the outer surface of the inner cylinder 102 and the inner surface of the outer cylinder 104 upon cracking of the mixture.
  • the reactor 100 can include a screw conveyor 122 positioned at the bottom of the annular space 106, which can be configured to move in tandem with the agitator-scrapper 108 to collect and move the scrapped carbon to a carbon slurry tank.
  • thermal cracking can be achieved in the annular space 106 of the reactor 100 at a temperature ranging from 350°C to 650°C and at a pressure ranging from 150 to 300 mBar.
  • the step of thermal cracking can be achieved at a temperature ranging from 350°C to 650°C and at a pressure ranging from 0 to 5 Bar Gauge.
  • the thermal cracking of the molten plastic mixture can take place in the annular space 106 of the reactor 100, resulting in carbon/coke that can be separated and accumulated on the inner surfaces of the annular space 106 of the reactor 100, which can be scrapped by the novel agitator-scrapper 108.
  • the scrapped carbon can then be collected by the screw conveyor 122 at the bottom and transported to a carbon slurry tank for further processing or usage. Further, the overhead stream from the thermal cracking is subjected to flashing using a flashing unit (flasher).
  • the proposed reactor 100 overcomes the above drawback, limitations, and shortcomings associated with the existing reactors, by providing a simple, cost-effective, and efficient reactor 100 with a carbon scrapper cum agitator 108 having a separate Melter and cracker, which facilitates dry pyrolysis of plastic waste and efficiently scrapes and collects coke/carbon accumulated in the reactor 100.
  • a separate Melter and cracker reactor 100 this helps overcome shortcomings such as restrictions as to the usage of the plastic waste, requirement of costly catalysts, restrictions on temperature range, scalability issues, and the like, associated with existing reactor 100s.
  • the proposed reactor 100 allows a user to enhance the heat transfer with ease in control of the plastic pyrolysis process and pyrolysis product molecular distribution by changing parameters such as the composition of the feedstock, cracking temperature, heating rate, operation pressure, residence time, speed of agitation and application of catalyst. Further, the proposed reactor 100 also enhances the plastic pyrolysis process and pyrolysis product molecular distribution, thereby improving the quality and yield of the by-products and making the overall process continuous.
  • the proposed invention overcomes the above drawback, limitations, and shortcomings associated with the existing pyrolysis reactors used for plastic pyrolysis processes.
  • the proposed invention enhances the plastic pyrolysis process and pyrolysis product molecular distribution, for improving the quality and yield of the by-products and making the overall process continuous.
  • the proposed invention achieves dry pyrolysis of plastic waste and generates fuel such as carbon/coke from the plastic waste, without requiring water and without generating any effluent water.
  • the proposed invention achieves pyrolysis of plastic waste at an industrial scale while achieving improved cost-effectiveness and efficiency.
  • the proposed invention provides a pyrolysis reactor enables the user to enhance the heat transfer with ease in control of the plastic pyrolysis process and pyrolysis product molecular distribution by changing parameters such as the composition of the feedstock, cracking temperature, heating rate, operation pressure, residence time, speed of agitation and application of catalyst.
  • the proposed invention provides an annular reactor with an in-built carbon scrapper cum agitator that facilitates the mixing of received molten plastic waste and also facilitates efficient scrapping and collection of carbon/coke generated in the reactor.
  • the proposed invention provides an annular reactor with an in-built carbon scrapper cum agitator, which is thermally stable and has long operating life.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

La présente divulgation concerne un réacteur annulaire (100) avec un racleur de carbone (108)-agitateur. Le réacteur (100) comprend un cylindre interne (102) ayant un cylindre supérieur (102-1) fixé de manière coaxiale sur un cylindre inférieur (102-2) de telle sorte qu'une partie de rebord (102-3) est créée entre ceux-ci. Le cylindre interne (102) est entouré par un cylindre externe (104) de telle sorte qu'un espace annulaire (106) est créé. Une plaque de support d'engrenage (110) est configurée de façon mobile sur la partie de rebord (102-3), qui est reliée à un moteur par l'intermédiaire d'un agencement d'engrenage conique (116, 118). Un agitateur-racleur (108) s'étend à partir du fond de la plaque de support d'engrenage (110) dans l'espace annulaire (106), qui, lors de la rotation par l'agencement d'engrenage, facilite le mélange de mélange fondu reçu dans l'espace annulaire (106) à partir d'un dispositif de fusion et racle en outre du carbone accumulé à partir de la surface interne de l'espace annulaire (106). L'agitateur-racleur (108) fonctionne en tandem avec un transporteur à vis (122) qui collecte le carbone raclé et le transfère à un réservoir.
PCT/IB2024/055263 2023-04-08 2024-05-30 Réacteur annulaire avec un racleur de carbone cum agitateur et son procédé de pyrolyse Pending WO2024214093A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN202321026345 2023-04-08
IN202321026345 2023-04-08

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WO2024214093A1 true WO2024214093A1 (fr) 2024-10-17

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3206287A (en) * 1960-05-10 1965-09-14 Crawford & Russell Inc Material treatment apparatus
CN104368300A (zh) * 2013-08-12 2015-02-25 上海金匙环保科技股份有限公司 具有清焦功能的热解反应装置及其系统与方法
WO2019056110A1 (fr) * 2017-09-20 2019-03-28 Envirollea Inc. Réacteur stationnaire et ses éléments internes pour produire du combustible liquide à partir de déchets d'hydrocarbures et/ou de matières organiques et/ou d'huiles contaminées, processus thermiques, utilisations et systèmes de gestion associés
WO2021207413A1 (fr) * 2020-04-07 2021-10-14 Mcclure Vance E Cuve de réaction pour pyrolyse catalytique en phase liquide de polymères

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3206287A (en) * 1960-05-10 1965-09-14 Crawford & Russell Inc Material treatment apparatus
CN104368300A (zh) * 2013-08-12 2015-02-25 上海金匙环保科技股份有限公司 具有清焦功能的热解反应装置及其系统与方法
WO2019056110A1 (fr) * 2017-09-20 2019-03-28 Envirollea Inc. Réacteur stationnaire et ses éléments internes pour produire du combustible liquide à partir de déchets d'hydrocarbures et/ou de matières organiques et/ou d'huiles contaminées, processus thermiques, utilisations et systèmes de gestion associés
WO2021207413A1 (fr) * 2020-04-07 2021-10-14 Mcclure Vance E Cuve de réaction pour pyrolyse catalytique en phase liquide de polymères

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