U.S. patent application number 11/429753 was filed with the patent office on 2006-11-09 for pyrolytic method and apparatus.
Invention is credited to Andreas Gaertner.
Application Number | 20060249364 11/429753 |
Document ID | / |
Family ID | 37393102 |
Filed Date | 2006-11-09 |
United States Patent
Application |
20060249364 |
Kind Code |
A1 |
Gaertner; Andreas |
November 9, 2006 |
Pyrolytic method and apparatus
Abstract
A method and an apparatus for pyrolytically decomposing
carboniferous materials provided with a reactor connected by a
carbonization gas conduit to a multiple stage condenser for
fractionally recovering pyrolysis oils in a collection container, a
central heating element connected to an external heat source, a
pre-heating chamber for receiving material after pyrolysis and
material prior to pyrolysis for an exchange of heat therebetween,
first conveying means for alternatingly moving non-pyrolyzed and
pyrolyzed material from the pre-heating chamber into an out of the
reactor and second conveying means for moving non-pyrolyzed and
pyrolyzed material out of and into the pre-heating chamber. For
moving and pyrolyzing the material is preferably retained in
basket-like receptacles. The condenser may be connected to the
external heat source for utilizing residual carbonization as
supplemental heat energy. To render the apparatus moveable, the
reactor gas conduit and condenser, the pyrolysis oil collection
container, the first and the second conveying means are mounted in
separate but connectable container modules.
Inventors: |
Gaertner; Andreas;
(Magdeburg, DE) |
Correspondence
Address: |
Law Offices of Karl Hormann
P.O. Box 381516
Cambridge
MA
02238-1516
US
|
Family ID: |
37393102 |
Appl. No.: |
11/429753 |
Filed: |
May 8, 2006 |
Current U.S.
Class: |
201/25 ; 201/18;
202/262; 202/96 |
Current CPC
Class: |
B09C 1/06 20130101; C10B
47/46 20130101; C10B 53/00 20130101; C10B 7/14 20130101 |
Class at
Publication: |
201/025 ;
201/018; 202/096; 202/262 |
International
Class: |
C10B 29/00 20060101
C10B029/00; C10B 57/04 20060101 C10B057/04; C10B 35/00 20060101
C10B035/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 7, 2005 |
DE |
DE 102005021647.1 |
Claims
1. A method of pyrolyzing in a heated reactor material containing
at least one of carbon and other pollutant, comprising the steps
of: a) placing at least one first charge of material for pyrolyzing
into the reactor for a predetermined time; b) preparing at least
one second charge of material to be pyrolyzed; c) providing a
pre-heating chamber; d) placing the pyrolyzed at least one first
charge into the pre-heating chamber upon termination of the
predetermined time; e) placing the at least one second charge into
the pre-heating chamber for pre-heating by heat exchange with the
pyrolyzed at least one first charge; f) placing at least one third
charge of material for pyrolyzing into the reactor for said
predetermined time; g) preparing at least one fourth charge of
material to be pyrolyzed; h) removing the pyrolyzed at least one
first charge from the pre-heating chamber; i) moving the pyrolyzed
at least third charge from the reactor into the pre-heating
chamber; j) placing the at least second charge of material for
pyrolyzing into the reactor for the predetermined time; k) placing
the at least fourth charge of material into the pre-heating chamber
for pre-heating by heat exchange with the pyrolyzed at least one
third charge; and l) thereafter sequentially removing pyrolyzed
charges from the pre-heating chamber for replacement by pyrolyzed
charges from the oven and moving pre-heated charges from the
pre-heating chamber to the reactor for replacement by charges of
material to be pyrolyzed.
2. The method of claim 1, wherein the at least one charge is placed
into at least one receptacle of basket-like structure.
3. The method of claim 2, wherein the reactor is heated by a
heating element centrally positioned therein and wherein the
receptacle is positioned adjacent to the heating element.
4. The method of claim 1, wherein the temperature is about
500.degree. C.
5. The method of claim 1, wherein the predetermined time is about
100 minutes.
6. The method of claim 1, further comprising the steps of: moving
carbonization gases developed by the pyrolysis through a duct and
over condensing means for fractionally precipitating liquids
contained in the gas.
7. The method of claim 6, wherein the carbonization gases are moved
by a blower.
8. The method of claim 6, further including the step of moving the
carbonizing gas through an after-heater.
9. The method of claim 6, further including the step of purging
carbonizing gases by an inert gas.
10. The method of claim 9, wherein the purging is carried out with
nitrogen.
11. The method of claim 6, further including the step of feeding at
least some of the carbonization gas to the heating element for
combustion thereby.
12. An apparatus for the pyrolytic decomposition of carboniferous
materials, comprising: a reactor comprising a housing shell and a
bottom plate mounted thereon for selective movement between open
and closed positions; a heating element centrally disposed within
the reactor and heated from an external heat source; a condenser
comprising a plurality of stages for fractionally condensing
pyrolysis oil; a gas conduit means for feeding carbonization gases
from the reactor to the condenser; means connectable to the
condenser for collecting pyrolysis oil; at least first and second
receptacles for receiving carboniferous material for pyrolyzing; a
pre-heating chamber for receiving one of the first and second
receptacles after pyrolyzing and the other of the first and second
receptacles prior to pyrolyzing; first conveying means for
alternatingly moving the first and second receptacles between the
pre-heating chamber and the reactor; hoisting means for
alternatingly raising and lowering the first and second receptacles
into and out of the reactor; and second conveying means for
alternatingly moving the first and second receptacles into and out
of the pre-heating chamber prior to and after pyrolyzing.
13. The apparatus of claim 12, further comprising a blower for
feeding carbonization gases from the reactor to the condenser.
14. The apparatus of claim 12, further comprising means for purging
the reactor, gas conduit and condenser from carbonization gas.
15. The apparatus of claim 14, wherein the purging means comprises
a source of inert gas.
16. The apparatus of claim 12, wherein the means for collecting
pyrolysis oil comprises an equalizing container.
17. The apparatus of claim 12, wherein the reactor, gas conduit and
condenser, the first conveying means and the hoisting means, the
pyrolysis oil collection means, and the second conveying means are
mounted in separate container modules.
18. The apparatus of claim 12, further comprising means for feeding
carbonization gases from the condenser to the external heat source.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel method and an
apparatus for pyrolytically decomposing materials and mixtures of
materials of, in particular, solid carbon compounds such as
plastics, rubber and materials and mixtures of materials
contaminated by solid or liquid toxic or noxious substances.
[0003] 2. The Prior Art
[0004] Processes and apparatus of an industrial kind are known for
thermally decomposing plastics and rubbers. The materials are
initially fed into a closed container, also known as a reactor, and
the reactor is then heated from the exterior in the manner
reminiscent of an oven. Temperature and dwell or reaction time are
selected or determined as a function of the kind of material to be
decomposed.
[0005] The pyrolytic reaction is carried out under the effect
either of pressurized air as disclosed, for instance, by German
patent specification DE 42 43 063 C2 or without pressure as
disclosed, for instance, by German patent specifications DE 102 19
440 A1, DE 29 49 983 A1, DE 103 09 530 A1.
[0006] The known methods and apparatus share the disadvantage of
requiring heating of the reactor containers from the exterior, by
way of, or through, their shell. The particular drawback in
connection with a pyrolytic process utilizing such reactor
containers is that heat penetration takes place but slowly,
particularly in the case of large diameter reactors, and that the
distribution of heat within the reactor is substantially irregular
or non-uniform. This at best mitigates against an optimized process
control and practically renders impossible any kind of economic or
efficient use of energy.
[0007] The reaction products are solids, usually carboniferous
granular products containing admixtures of other substances,
carbonization gases and mixtures of so-called pyrolysis oils
condensed from the gases.
[0008] Such pyrolytic processes and apparatus are also unsuitable
for thermally recovering contaminated materials and mixtures
thereof, such as, for instance, soil contaminated by industrial
plants, construction sites or road traffic, or by accidents.
[0009] The known pyrolytic processes are practiced in stationary
apparatus which, of course, requires transportation of the material
to be pyrolyzed to the pyrolysis plant.
OBJECTS OF THE INVENTION
[0010] It is an object of the invention to provide a pyrolytic
method and compact apparatus for practicing the method which makes
possible an improved and effective endothermal use of the energy
for generating the heat required for the process.
[0011] Another object is to provide a pyrolytic apparatus which is
mobile and may, therefore, be used where it is needed.
[0012] Furthermore, it is an object of the invention to provide an
apparatus of the kind referred to which allows in situ processing
of liquid pyrolysis products to various fractions.
BRIEF SUMMARY OF THE INVENTION
[0013] In the accomplishment of these and other objects, the
invention provides for a pyrolytic method in which the pyrolysis
material is filled into a receptacle of basket-like structure,
placing the receptacle and its contents into a heated chamber for
pre-heating, moving the pyrolysis material into the pyrolysis
reactor, creating slight vacuum pressure in the reactor during a
reaction time depending upon the kind of pyrolysis material to
remove carbonization gases from the reactor, heating the
carbonization gases in an after-heater, fractionally removing
pyrolysis oils from the gases by condensation, feeding the
condensates to collection containers and feeding the gases to a
heat generator for heating the pyrolysis reactor, controlling the
reaction temperature and the temperature of the after-heaters and
the condensers as a function of the pyrolysis material and of the
temperature of the carbonization gases, the thermal control of the
pyrolytic process being carried out as a ratio control of the
temperatures of the heating element, the interior of the reactor,
the carbonization gas, the after-heater and condenser, terminating
the carbonization process in response to a signal from a sensor in
the condenser, introducing an inert gas or a mixture of inert gases
into the reactor and into the condensation chamber for purging the
carbonization gas containing areas of the pyrolysis apparatus,
removing the heated receptacles and any solid pyrolysis product
contained therein from the reactor and placing them into the
pre-heating chamber for pre-heating, by heat-exchange, further
receptacles filled with fresh pyrolysis material contained therein
and, once an exchange of heat has taken place after a predetermined
dwell-time, removing the receptacles and pyrolytic products
contained therein from the pre-heating chamber, emptying the
receptacles and returning them to the pyrolytic process loop.
[0014] In accordance with a preferred embodiment of the invention,
the apparatus for practicing the pyrolytic method consists of main
component groups including a heat generator, the pyrolysis material
receptacles, a feeding device, at least one pre-heating chamber, a
pyrolysis reactor, a carbonization gas conduit, a blower, at least
one carbonization gas after-heater, a distillation column or
condenser, a process control and regulating device as well as an
inert gas purging device, charge, discharge and conveyor devices
for pyrolysis materials, pyrolysis products and condensates.
[0015] Preferably, the structural groups are arranged in either a
closed or a frame-like container or in more than one connectable
modular closed or frame-like containers. They may be variably
grouped in horizontal and/or vertical arrangements. For charging
and discharging, the pyrolyses reactor is provided with a bottom
plate for selectively opening and closing the reactor. To this end,
either the bottom plate or the bonnet-like upper portion of the
reactor may be vertically movable for respectively charging and
discharging the receptacles containing the pyrolyses material or
products. The basket-like structure of the receptacles is such that
their sidewall is permeable by heat and that their bottom prevents
escape of either the pyrolyses material or product.
[0016] The reactor is provided with at least one centrally disposed
heating element or with additional heating elements within the
reactor and in the side surfaces thereof. In order to prevent
back-flow of the condensed carbonization gases to the reactor or to
prevent the gas conduit from becoming congested, the carbonization
gases are conducted and after-heated in a manner that provides for
their condensation at fraction stages provided for it.
[0017] Since the apparatus is housed within a container or within a
plurality of connectable container modules such as, for instance, a
reactor module, heater module, fuel-tank module, condenser module,
charging module for the pyrolyses material and/or unloading module
for the pyrolyses product, the method and apparatus in accordance
with the invention are mobile and thus suitable for use at any site
where they may be needed.
[0018] The energy efficiency is significantly improved as a result
of the process sequence as well as the structure of the reactor
including its centrally arranged heating element and the
conductance and inclusion of the carbonization gases as well as,
optionally, low-value condensates into the heating system.
DESCRIPTION OF THE SEVERAL DRAWINGS
[0019] The novel features which are considered to be characteristic
of the invention are set forth with particularity in the appended
claims. The invention itself, however, in respect of its structure,
construction and lay-out as well as manufacturing techniques,
together with other objects and advantages thereof, will be best
understood from the following description of preferred embodiments
when read in connection with the appended drawings, in which:
[0020] FIG. 1 is a view in longitudinal section of a pyrolysis
reactor module and a condenser column;
[0021] FIG. 2 is a view in longitudinal section of a pyrolysis
material receptacle including a conveyor and lifting device;
[0022] FIG. 3 depicts a pre-heating chamber charged with pyrolysis
material receptacles in longitudinal section;
[0023] FIG. 4 is a view in longitudinal section of a pyrolysis
reactor module with closed bottom and centrally disposed heating
element, carbonization gas conduit, condenser for fractioning
distillation, after-heater and blower;
[0024] FIG. 5 depict a condensate collection container; and
[0025] FIG. 6 is a schematic block diagram of the modular container
structure of the pyrolysis apparatus including charging and
discharging devices as well a pre-heating chamber.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] The initial step in carrying out a pyrolytic process in
accordance with the invention is the filling of receptacles 13 with
material to be pyrolyzed such as, for instance, oil contaminated
soil. The receptacles have a capacity of about 300 liters. The
filled receptacles 13 are moved by appropriate conveying means,
such as carriages 15, to a pre-heating chamber 17 where they will
stay for the duration of a pyrolytic reaction cycle for the purpose
of warming up by heat exchange with previously pyrolyzed material
in receptacles 13 removed from a reactor 1. Thereafter, they are
moved into the reactor 1 through an opening formed by removal of a
bottom plate 9 of the reactor 1 and placed around a central heating
element 2, which preferably is a radiation heater. The source of
heat (not shown) for the heating element 2 is an external one and
may be electric, oil or gas fired, including by gas recovered from
the pyrolytic process in accordance with the invention. As shown in
FIGS. 2 and 3, the bottom plate 9 serves as a support for the
charged receptacles 13. Removal of the reactor bottom plate 9 for
loading the receptacles is accomplished by vertical relative
movement between the bottom plate 9 and the reactor shell.
Preferably, the outer or lower surface of the bottom plate 9 or the
load surface of the carriage 15 is provided with an appropriate
hoisting apparatus 16 schematically indicated in FIG. 2. After
closure of the reactor 1, the pyrolytic process proper is commenced
by raising the operating temperature within the reactor chamber to
about 500.degree. C. Any carbonization gases developing during the
pyrolytic reaction cycle are fed by a blower 5 through a conduit 3
and an after-heater 4 across coolers 6 of a condenser column or
distillation device 7 for the fractional precipitation of the
condensate into different cavities connected by conduits 10, 11,
and 12 to different compartments of a collection container 18 (see
FIG. 5). As shown in FIG. 2 by way of example, the condenser column
7 consists of three stages. After passing the condenser column 7,
the gases are fed by way of appropriate channels (not shown) as a
supplemental source of energy, to the heat generator for heating
the reactor 1. It will be understood by skilled artisans that the
reactor 1 and the gas conduit 3 and appurtenant distillation stages
7 are insulated to prevent heat from escaping from or penetrating
into them.
[0027] The pyrolytic process cycle usually terminates after about
100 minutes and is followed by purging the carbonization gas
conducting units, such as conduit, channels and chambers with an
inert gas such as, for instance, nitrogen. Thereafter, the bottom
plate 9 of the reactor 1 is opened for removal of the receptacles
13 containing pyrolyzed products, such as carbonization coke and
soil substances, by the carriage 15 for positioning in the
pre-heating chamber 17. Here, the receptacles 13 and their contents
are cooled by heat exchange with other receptacles 13 filled with
new material to be pyrolyzed. Thereafter, the pyrolysis products
are discharged from their receptacles 13 which may then be returned
into the process loop to be charged with fresh material to by
pyrolyzed.
[0028] The apparatus for practicing the pyrolytic process consists
of such major structural component groups as a heat generator,
pyrolysis material receptacles 13, a conveyor device or carriages
15, a pre-heating chamber 17, a pyrolysis reactor 1 including a
conduit 3 for carbonization gases, a blower 5, a carbonization gas
after-heater 4, a condenser or distillation column 7, a process
control and regulating device (not shown), an inert gas purging
device including a container 8 for inert gas and, last but not
least, charging and discharging devices for pyrolysis materials and
substances 14, such as coke, coke mixed with other solids, and the
condensates.
[0029] By way of example, the component groups consisting of the
pyrolysis reactor 1 including the carbonization gas conduit 3, the
blower 5, the carbonization gas after-heater 4, the condenser or
distillation column 7, the process control and regulating device as
well as the inert gas purging device may be arranged within a
container module 20 which may, for instance, be a frame
structure.
[0030] The condensate collection container 18 including an
equalizing container 19 may be mounted in a container module
21.
[0031] The pre-heating chamber 17 for providing heat exchange
between "new" receptacles 13, i.e. the ones containing material to
be pyrolyzed, and "used" receptacles 13, i.e. those removed from
the reactor 1 and containing pyrolyzed substances, and the hoisting
device 16 for charging and discharging the reactor 1 are mounted in
a container module 22.
[0032] A further container module 23 of frame-like structure is
provided to accommodate a charging unit for the pyrolysis material
14 as well as a discharging unit for the residual pyrolysis coke
mixture and pyrolyzed soil substances.
[0033] The reactor module 20 is preferably placed over the
pre-heating chamber module 22. The condensate collection container
module 21 is placed over the charging and discharging module 23.
The pyrolytic reactor 1 is provided with a bottom plate 9 which can
be selectively opened and closed for respectively charging and
discharging the reactor 1 from and into the lower pre-heating
chamber module 22 by means of the hoisting device 16. Preferably,
it is the bottom plate 9 rather than the reactor shell which is
moved. It will, however, be understood by those skilled in the art
that as an alternative the shell of the reactor 1 could be lifted
off the bottom plate 9. The receptacles 13 for the pyrolysis
material are of a basket-like structure having a bottom preventing
the contents of the receptacle 13 from escaping and a side wall
easily penetrated by heat from the heating element 2 which is
preferably disposed in the center of the reactor 1 so that a
plurality of receptacles 13 may be placed around it.
* * * * *