Description of the invention

Field of the invention

The present invention is a complex device and method for pyrolysis of organic raw materials and organic wastes that obtains syngas and its by-products from domestic wastes, sludge, used oil, and all other combustible wastes by fast pyrolysis at high temperatures. The technical name of this first invention is called ABB AT- 10. ABB AT- 10 is purposed for processing all kinds of organic raw materials and organic wastes. In other words, the present invention relates to the field of thermochemical processing industry and the technology of organic materials and wastes.

Organic raw materials and waste can be understood as all kinds of coals, woods, packages, bags, thermoplastics, resins, used oils, bones, food wastes, sludge, fabric wastes, leather, industrial and domestic wastes, synthetic organic materials, petroleum wastes, and medical wastes.

Summary of State of the art

Pyrolysis reactor

The inventor designed and developed the pyrolysis reactor of ABBAT-01 in 2017, which was published with a publication number of PCT/IB2018/000048 on the website of the World Intellectual Property Organization with “A” category of international search report in 2017. Since then, ABBAT- 01 was redesigned, further developed, and tested 9 times resulting in the invention of ABBAT-10. Therefore, ABBAT-01 can be a relevant device, which is shown in Figure 1.

The pyrolysis reactor of ABBAT-01 consisted of a raw material inlet /I/, product outlet 111, gas outlet pipe /3/, hot air outlet pipe /4/, fire blower 151, gas separating bearing 161, outer body 1 1, raw material transferring screw /8/, fire distributing screw 191, electric motor /10Z, outside pipe of reactor /l l/, inside pipe of reactor /12/, and insulator /13/.

Outside body 7 of the reactor is made of a regular steel sheet and insulated by a fire retardant material 13. The outside pipe of reactor 11 and the hot air outlet pipe 4 are fixed on the outside body of the reactor. Raw material inlet pipe 1 , reaction products outlet pipe 2, and gas outlet pipe 3 are mounted on the reactor’s body. All these pipes are made of fire-resistant steel GB/T12459.

Raw material transferring screw 8 is placed in the inside pipe of reactor 12 which is placed inside of reactor outside pipe 11 , that is connected with gas sealing bearing 6. The inside pipe reactor as well as the raw material transferring screw is made of a fire-resistant steel GB/T 12459.

Fire distributing screw 9 is placed inside the pipe of reactor 12. The fire distributing screw is also made of a fire-resistant steel.

Fire blower 5 blows fire through the inside pipe of the reactor, fire distributing screw distributes the fire to the inside pipe of the reactor and raw material transferring screw. The rest of the fire comes out from the other side of the inside pipe of the reactor and turned back running through an annulus between the outside pipe of the reactor and reactor body. Therefore, the reactor with pyrolysis reaction is heated from both sides resulting in an even distribution of high temperature. Additionally, the inside pipe of the reactor rotates with raw material transferring screw utilizing a driving motor and bearing, resulting in pyrolysis reaction rate increase due to simultaneous raw material mixing.

Annulus with raw material transferring screw is heated from both inside and outside resulting in temperature gains of 700-1000°C in a very short time, which is the main advantage of this device.

The reactor needs to be warmed up and tested before starting operations.

The disadvantage of the relevant device of ABBAT-01

Particular relevant ABBAT-01 has the following major disadvantages:

Cooling down and firmly sealing of bearing 6 for inside pipe of reactor 12 was technically very difficult due to its high temperature and rotation at the same time.

Gasifying resident time was not enough for raw materials with the size of 10-20 mm and obtained a large amount of semi-coke.

Feeding raw material into the reactor took 2 steps which were first by screw then by valve resulted in some raw materials to get stuck on the screw and the valve.

Purpose of the invention The purpose of the present invention ABB AT- 10 is to correct all disadvantages of relevant device ABBAT-01, and without by-products, high rate of conversion of flash pyrolysis and gasification reaction, and high economic efficiency. This invention ABBAT-10 or complex device and method for pyrolysis of organic raw materials and organic wastes is designed and developed as a combination of medium temperature fast pyrolysis turbine reactor and high-temperature flash pyrolysis cylindrical reactor.

Summary of present invention

• The main characteristic of the present invention is that solid material has a variety of impurities that are expanded differently when they heated up, resulting in the solid material to crack itself.

• Flat blade turbine with high rotating speed throws high-temperature coal particles onto a hot surface, obtaining very fine coal particles with much higher total surface area causing a high reaction rate.

• Breaking down raw materials by the mechanochemical method significantly increases the reaction rate.

• Pyrolysis, gasification reactions, and breaking down particles occur simultaneously.

• The pyrolysis and gasification reactions occur continuously in one housing, first in a medium temperature fast pyrolysis turbine reactor then in a high-temperature flash pyrolysis cylindrical reactor, resulting high conversion in short resident time.

• Nowadays a big challenge for processing organic wastes is that the feeding system gets clogged and stuck when a variety of different raw materials are used. The present invention overcomes this big challenge.

Description of the drawings

A complex device for pyrolysis of organic raw materials and organic wastes is shown in Figure 2. General principles are explained from the schematic image of the present invention.

Embodiments of the complex device are:

1, 2 - hopper container for feeding materials, 3, 4 - Inlet valves for hopper container,

5, 6 - Inlet of hopper container,

7, 8 - outlet valves for hopper container,

9, 10 - Feed transferring screw,

11, 12 - Electric motor for feed transferring screw,

13, 14 - Electric motor for hopper container mixer,

15 - Tubular chain conveyor,

16 -Turbine reactor,

17 - Heating pipe for the reactor,

18 - Electric motor for tubular chain conveyor,

19 - Pipe for cooling oil,

20 - Vacuum pump,

21 - Oil container,

22 - Hollow shaft with cooling,

23 - Screw on the hollow shaft,

24 - Flat blade turbine on the hollow shaft,

25 - Heat absorbing-distributing thick barrier,

26 - Cylindrical reactor,

27 - Outlet pipe of the gas mixture,

28 - Pipe for warm oil backflow,

29 - Mixing and washing perforated screw barrier, 30 -Decanter,

31 - Barriers for the cylindrical reactor,

32 -Pipe for oiled solid residue outlet of the decanter,

33 - Pipe with cooling,

34 - Inorganic solid residue container,

35 - Inorganic solid residue removing the screw,

36 -Electric motor for ash removing the screw,

37 - Fire blower,

38 - Fire chamber,

39 - Fire outlet pipe,

40- Cleaned gas mixture outlet pipe,

41 - Separated oil outlet from the decanter,

42- Whirlpool ear of barrier,

43- Feeding material inlet,

44- Vacuum pump for gas,

45- Vacuum pump outlet pipe,

46- Valve for hopper container 1,

47- Valve for hopper container 2,

48 - Mixer for hopper containers,

49- Oil cooler

50- Outlet of pyrolysis products Working principles and technological process of the present invention

A solid material has many impurities, when it is heated the impurities expand depending on its expanding coefficient, as a result, it can break itself down due to the impurity’s different expansion rate. Therefore, the vibration of atoms in a solid material becomes very intense and causes them to become extremely brittle. Solid materials are substantially easy to break when they encounter mechanic force in the aforementioned condition.

Heat diffusion into the center of organic solid materials is a slow process when they are conducted through thermochemical and mechanochemical processes due to organic materials having a low heat conductivity. Because of this, the organic solid materials needed to be smaller in order to head the entire volume faster. In other words, volumes of solid organic materials heat faster with a much higher reaction rate when broken down to smaller particles. Additionally, when broken down the small organic solid material possesses a high surface area per mass compared to large particles of the same mass. Therefore, the chemical reaction rate of solids and volatile components will be much faster.

A flash pyrolysis technology is developed based on the aforementioned physical and mechanochemical principles. It works as follows:

1. High rotation speed flat blade turbine hits and throws the hot solid materials inside the reactor causing them to break down until micro and nano-sized particles. Additionally, the temperature of the reactor inside the surface including the flat blade turbine is ranged from 350°C to 600°C.

2. The more the solid material breaks down the better the reaction rate becomes causing the exothermic reaction to overcome the endothermic reaction, in which case the process turns more efficient in terms of reactor heating.

3. Whirling motion of the fine raw materials at 700-1000°C causes flash pyrolysis process.

The present invention with high conversion, no by-products, high economic efficiency, and environmentally friendly technology is designed and developed based on aforementioned physical and mechanochemical processes. Solid raw materials are processed by the mechanochemical and thermochemical method creating fine particles of semi-coke which are washed by oil then separated from the oil in a decanter. After the decanter, the oiled (adsorbed oil) semi-coke and iron particles are added to the feeding raw material and flow back to the reactor. This absorbed oil in pores of semi- coke causes an exploding effect when it is dropped into a hot reactor due to fast vaporization. Additionally, the flat blade turbine hits and throws them to the hot barrier, heating pipe, and inside surface of the reactor which causes micro explosions and high pressure peaks at the moment of hitting the hot surface.

This continuous process of the present invention can be divided into 3 sections:

1. Raw material entering section,

2. Pyrolysis section,

3. Discharging section.

Continuous fast pyrolysis processing technology for organic raw materials and organic wastes with iron catalyst is:

1. Raw material entering process; this is

Raw material enters into a storage hopper container 1 or 2 through an inlet 5 or 6 when a valve 3 or 4 opens then the raw material is fed in a tubular chain conveyor 15 by a feeding screw 9 or 10 controlled by a valve 7 or 8 driven by an electrical motor 11 or 12,

2. Flash pyrolysis process; this is

The continuous running tubular chain conveyor 15 takes feed from the storage hopper container 1 or 2 and drops it into a medium temperature fast pyrolysis turbine reactor 16 through an inlet 43,

The dropped raw material heats up while it is falling and falls on a high rotating speed screw 23 to break and thrown to a flat blade turbine to break and thrown to the inside surface of the reactor, a heating pipe 17, a heat-absorbing barrier 25 and became fine particles with high temperature during these mechanochemical and thermochemical processes,

At the same time with latter, a naked tubular chain conveyor 15 runs the upper side of the turbine reactor, stuck solid material on the naked tubular chain 15 falls and is cleaned by solid materials that are thrown from the flat blade turbine 24

Inorganic residue of pyrolysis reaction drops down on a removing screw 35 which is placed in the bottom of the turbine reactor and removed,

Product of the turbine reactor flows into a high-temperature flash pyrolysis cylindrical reactor 26 and conducts higher temperature pyrolysis and at the same time whirls using a whirlpool earing 42 of barrier 31 which is placed around the heating pipe 17,

Discharging process; this is

Products of the cylindrical reactor 26 enter the gas outlet pipe 27 and are mixed at a mixing-washing perforated screw barrier 29 with warm oil which comes after cooling down the tubular chain conveyor, solid particles are washed with oil and a cleansed gas flows into a pipe 40, solid particles and oil mixture flows in a decanter 30 to get separated, the separated oil flows into an oil storage container 21 through a pipe 41, the separated oiled solid particle flows in the tubular chain conveyor through a pipe 32.

The aforementioned 3 basic processes are described as follows:

1. Raw material feeding section:

Organic raw materials and organic wastes which are prepared to a size of 1-30 mm are collected in hopper containers 1 and 2. The hopper containers need to be sealed tightly. The hopper container is equipped with a mixer 48 to prevent stacking of materials. A required amount of organic material enters the tubular chain conveyor 15 from the hopper container using screws 9 and 10. Tubular chain conveyor transfers the organic material into the turbine reactor 16 through inlet 43 and they are dropped down by gravity. Hot tubular chain conveyor 15 and 26 is cooled down by cold oil which came from pipe 19 after running out from the pyrolysis reactor 16. Additionally, some gases are collected in the hopper container during the pyrolysis process, which is sucked by vacuum pump 44 and pumped through a pipe 45 into the tubular chain conveyor for recycling.

2. Pyrolysis section:

This part starts from the raw material inlet, continues through the turbine and cylindrical reactor processing, and finishes at the products outlet. This part is divided into 2 main sections including the medium temperature fast pyrolysis turbine reactor 16 and the high-temperature flash pyrolysis cylindrical reactor 26. Note that the cylindrical reactor 26 is designed like an ending part of the turbine reactor 16.

• Medium temperature fast pyrolysis turbine reactor 16. This turbine reactor consists of a pushing screw 23 and a flat blade turbine 24 which are fixed on a high rotating speed hollow shaft 22, and a screw 35 to remove solid residue. The hollow shaft 22 has a space in the center of it to run water for cooling. Upper inside of the turbine reactor is placed on a heating pipe 17 and many thick barriers 25 are vertically fixed on the inner top surface of the turbine reactor around it to distribute heat into the turbine reactor. A naked tubular chain conveyor line is placed beneath the heating pipe 17 along with it.

• High-temperature flash pyrolysis cylindrical reactor 26.

This cylindrical reactor has the highest temperature due to contacting with the heating pipe 17 first. The heating tube 17 and under beneath this naked tubular chain conveyor are placed at the center of the cylindrical reactor. Additionally, many barriers 31 with whirlpool earing 42 for whirling of flow are placed along its cross-section area of the cylindrical reactor.

3. Discharging section:

In this part, products of pyrolysis reactor such as gas mixture, water steam, tar, solid residues, and unreacted solid particles are separated from each other:

• Gas mixture exiting pipe 27. Mixing washing perforated screw barrier 29 is fixed on the middle of this pipe where products of pyrolysis are mixed with oil which came from through a pipe 28.

• Solid residue mixed with oil flows into the decanter 30 while cleaned gas mixture flows in pipe 33 with cooling through pipe 40.

• Decanter 30. Oil mixed with solid residue is separated from each other in this decanter, separated oiled solid residue transferred in tubular chain conveyor 15 through a pipe 32 while separated oil from solid residue flows into oil storage container 21 through a cooler 49.

• Ash removing screw 35. The ash or solid residue removing screw is placed on the bottom of the turbine reactor 16 and removed ash into ash storage container 34 produced during pyrolysis processes.

Continuous processing mechanism of the complex device and fast pyrolysis reactor for pyrolyzing of organic raw materials and organic wastes

Continuous processing of the complex device for pyrolyzing of organic raw materials and organic wastes is

Inlet section of organic materials for fast pyrolysis and gasification processes; this consists of

This inlet section contains oiled solid residue transferring pipe 32 from the decanter 30 to the tubular chain conveyor, required amount of organic raw material transferring screws 9 and 10 with valves 7 and 8 from hopper containers 1 and 2, and vacuum pump 44 sucks air from hopper container then pumps into tubular chain conveyor,

Cylinder reactor section; this consists of primary step medium temperature fast pyrolysis turbine reactor 16 consists of the organic material inlet 43, flat blade turbine 24 is fixed on the high rotating speed shaft 22 with cooling, reaction residue ash removing screw 35, heat collecting and distributing many barriers 25, naked tubular chain conveyor 15 under beneath of heating pipe 17 placed upper side of the turbine reactor 16, and fire chamber 38, final step high-temperature fast pyrolysis cylindrical reactor 26 consisted of many barriers 31 with whirlpool earing 42 which is placed around reactor heating pipe 17 and naked tubular chain conveyor under beneath of this pipe 17,

Discharging section; this consists of tubular chain conveyor 15 comes out from the cylindrical reactor 26, which connects to an oil cooling pipe 19, a gas exiting-mixing pipe 27 with a mixing-washing perforated screw barrier 29, a gas mixture exiting pipe 41 connects to a pipe 33 with cooling connects to an oil storage container 21, an oil running pipe 41 with an oil cooler 49, a decanter 30 connects to an oiled solid residue transferring pipe 32 connects to the tubular chain conveyor 15.

The working principles of the complex device are drawn in Figure 2 as follows:

Feeding material enters into the hopper container 1 and 2 from inlets 5 and 6 through valve 3 or 4, which opens and closes turn by turn. One of the valves closes if its hopper container is filled up. From the hopper container, 1 and 2 feeding raw material enters in tubular chain conveyor 15, when one of them is opened another one is closed. Valve 7 or 8 opens, screw 9 or 10 turns utilizing electric motor 11 or 12 and the required amount of feeding material enters in tubular chain conveyor 15.

Hopper containers 1 and 2 are equipped with mixer 48 to prevent stacking of organic materials on the wall. The tubular chain conveyor 15 works in a continuous motion and brings the organic feeding materials to inlet 43 and drops down by gravity into the medium temperature fast pyrolysis turbine reactor 16. Tubular chain conveyor 15 becomes without outside tube when run through the upper side of turbine reactor which is placed parallel with heating pipe 17. So, materials stuck on tubular chain conveyor 15 will be reacted and dropped, otherwise cleaned by high-speed solid materials thrown from high-speed flat blade turbine 24. Left stuck organic materials on the naked tubular chain will be reacted and cleaned in the high-temperature fast pyrolysis cylindrical reactor 26 by higher temperature.

The pyrolysis reactor section is designed like a high-temperature flash pyrolysis cylindrical reactor in the ending part of the medium temperature fast pyrolysis turbine reactor which is placed in one housing. The housing of this pyrolysis reactor is covered by a heat insulating material. The medium temperature fast pyrolysis turbine reactor is meant for primary fast pyrolysis reaction at medium temperature and at the same time to break down big raw materials into finer particles. The high- temperature fast pyrolysis cylindrical reactor is meant for completion of reaction at a higher temperature of unreacted particles from the turbine reactor. The tubular chain conveyor has no outside tube when inside of the cylindrical reactor.

Raw material falls into the turbine reactor at a temperature of 350-600°C through inlet 43, is hit and pushed by screw 23 which is fixed on the high rotating speed hollow shaft 22. After that, the raw material is hit by a flat blade turbine with a rotating speed of 1000-2500 rpm, in result braking down and throwing all-around to hit to the heating pipe 17 and heat distributing barrier 25 until reaching very fine particles. The breaking down of raw material and the pyrolyzing reactions happen simultaneously.

The cooling medium runs through the hollow shaft to prevent overheating.

Unreacted organic materials in the turbine reactor go through the flash pyrolyzing reaction at 700- 900°C in the cylindrical reactor with a whirling motion created by whirlpool earing 42 of the barrier 31. Because of this 2-step process, the final conversion of pyrolyzing and gasification reaction reaches a much higher level.

Inorganic residues are collected on the bottom of the turbine reactor where the residue removing screw 35 transfers them into ash storing container 34.

All pyrolysis products and by-products of the cylindrical reactor 26 go into the gas outlet pipe 27, then mixed with oil that comes from pipe 28 at the middle of pipe 27 where the washing perforated screw barrier 29 is fixed. As result, solid residues are absorbed in oil and a cleaned gas mixture flows through the gas outlet pipe 40 and enters pipe 33 with cooling. Solid residues are separated from the oil by decanter 30 and the oiled solid residues are run through pipe 32 enters the tubular chain conveyor 15. The cleaned oil runs through oil cooler 49 into oil storage container 21.

Heavy fractions are condensed and flow into oil storage container 21 when gas and vapors from gas outlet pipe 40 run through pipe 33 with cooler. The temperature of this pipe 33 is approximately 100°C, so water vapor will not condensate. Vacuum pump 20 will sack oil from storage container 21 and pump it through pipe 19 to recycle. Extra oil flows out from oil storage container 21 through pipe 50.

The tubular chain conveyor 15 came out from turbine 16 and cylindrical reactor 26 will be hot which is cooled down by cold oil which comes through pipe 19. The tubular chain conveyor will run continuously using driving motor 19.

Fire blower 37 blows fire into heating pipe 17 through fire chamber 38, resulting in the heating pipe temperature is reached 900-1100°C. This high-temperature heating pipe 17 heats first the cylindrical reactor then the turbine reactor and run out by a pipe 39.

Significance of the invention

A significance of the present invention is that feeding material size can be at a wide range of 1-30 mm which is a relatively big size considering it will be broken down until nano and 10 micro-sized particles at the same time conducting in the pyrolysis process.

In the other words, the raw material does not need an expensive preparation process such as crushing, drying, and screening resulting in high economic efficiency.

Additionally, waste of the present invention can be only ash, conversion of the pyrolysis reaction is very high, in result environmentally friendly.

Advantages of the present invention

1. The reactors are heated up from inside which brings high thermal efficiency. 2. The feeding organic material does not need to crush until fine powder because the flat blade turbine with high rotating speed will do that job. Therefore, feeding material crushing processes can be skipped, causing high economic efficiency.

3. There are no feed clogging problems which is a huge challenge for current organic waste pyrolyzing and gasifying technologies due to the tubular chain conveyor being placed along the heating pipe. In other words, the reactor can take all kinds of materials.

4. The oiled tubular chain conveyor is less sticky and easy to evaporate in the high-temperature reactor when using oil for the cooldown of the hot tubular chain conveyor.

5. The flat blade turbine with high rotating speed hits organic big-sized material resulting in breaking them down and then throwing them all over. The thrown organic materials hit the heating pipe and another surface inside the reactor with high speed which causes aggressive thermochemical reactions.

6. Organic solid residues are caught by the tubular chain conveyor and recycled with feeding material resulting in reduced by-products while increasing conversion of the feeding materials.

7. Whirlpool barrier of the horizontal cylindrical reactor whirls reaction components and products causing high reaction residence time and high conversion of raw materials.

8. The tubular chain conveyor with oil and some organic solids drags on the hot surface of the horizontal cylindrical reactor results in ablation principles and increase efficiency.

9. Mixtures of iron catalyst, oil, semi-coke powder, water steam, and organic materials are hydrolyzed in the turbine reactor, a hydrogenation reaction occurs in the cylindrical reactor.

10. The medium temperature fast pyrolysis turbine reactor and the high-temperature flash pyrolysis cylindrical reactor are placed in one small space that results in high raw material conversion and efficient process.

11. The medium temperature fast pyrolysis turbine reactor and the high-temperature flash pyrolysis cylindrical reactor are placed in one small space and placed the tubular chain conveyor line without outside tube (naked) in that results in the tubular chain conveyor completely cleaned before moved out from the reactor.