FIELD

[0001 ] Embodiments herein relate to a device for preparing feedstock for pyrolysis and other processes. In particular, embodiments herein relate to a device and method for removing water and air from feedstock for processes that require an inert environment, such as pyrolysis.

BACKGROUND

[0001 ] Plastic waste is a major pressing environmental issue facing the world. It is estimated that 380 million tonnes of plastic products will be produced in 2018. Geyer, Jambeck, and Law estimate that, of the 8.3 billion tonnes of plastics produced, 6.3 billion tonnes have become plastic waste, of which only 9% has been recycled (“Production, use, and fate of all plastics ever made”, Science Advances, 19 Jul 2017, vol3, no.7). The vast majority of plastic waste is deposited in landfills or, worse still, accumulate in the environment as litter.

[0002] Rubber waste, such as that from discarded automobile tires, also poses a significant environment problem, due to their non-biodegradability, flammability, and chemical composition, which can result in the leaching of toxic substances into the ground when disposed of in landfills, or emission of toxic fumes upon incineration.

[0003] One effective method of recycling plastic and rubber waste is pyrolysis, which is the thermal decomposition of materials in an inert (i.e. substantially oxygen free) environment at high temperatures, for example 400-900°C. Pyrolysis is an attractive alternative to incineration or landfilling of waste plastics and rubber, as it generates fewer dioxins relative to incineration, while breaking down the material into reusable and saleable constituents, and does not present the leaching issues of landfilling.

[0004] The pyrolysis of plastic, rubber tires, and other feedstock produces condensable and non-condensable gases and char, as well as steel belting in the pyrolysis of tires. The condensable gases yield raw hydrocarbon constituents which can be further treated to produce valuable products, such as low-sulphur gasoline, diesel, and synthetic gas. The non-condensable gases are either incinerated or used as fuel, such as for power generation or to supply burners used in the pyrolysis process. In the case of the pyrolysis of plastics, gasoline and diesel derivatives are produced together with a waxy compound.

[0005] Conventional pyrolysis technologies involve the use of heated kilns and/or molten zinc bath reactors to batch pyrolyze feedstock. To mitigate oxidative combustion and undesirable chemical reactions, air and water must be substantially removed from the feedstock before it enters the kiln/reactor. Air and water can be removed from feedstock by passing it through a pre-feed chamber configured to remove air and water therefrom. An upstream end of the pre-feed chamber is configured to receive the feedstock, and a downstream end of the pre-feed chamber is connected directly or indirectly to the upstream end of the pyrolysis reactor/kiln. The pre-feed chamber typically comprises doors at both ends to allow feedstock to enter and leave the chamber while preventing air and water from entering the pyrolysis reactor/kiln. The first door located at the upstream end of the pre-feed chamber is opened periodically to receive feedstock material from a feed mechanism, such as a conveyor or auger, while the second door located adjacent the downstream end is closed to isolate the reactor/kiln from the chamber. Once the feedstock to be pyrolyzed has entered the pre-feed chamber, the first door is closed to isolate the pre-feed chamber from the feed mechanism. Air and water are then purged out of the pre-feed chamber by filling the chamber with an inert gas, such as nitrogen, to flush the air and water out of a removal port while the first and second doors remain closed. Once air and water have been removed from the feedstock and pre-feed chamber, the second door is opened to allow the air-and-water-free feedstock to enter the reactor/kiln for pyrolysis, while the first door remains closed. The pre-feed chamber used in current technology necessitates in an intermittent feed process where feedstock is pyrolyzed in batches. Additionally, the current technology requires the use of an inert purge gas such as nitrogen, which introduces complexity into the pyrolysis process and adds cost.

[0006] A challenge with the known processes for pyrolysis of plastics, rubber tires, and other materials has been in the development of a system and method that will allow for the continuous introduction of feedstock into the pyrolysis process so as not to interrupt the pyrolysis process. A continuous pyrolysis process is more economical as the rate of pyrolysis of feedstock can be increased.

[0007] Further, feedstock such as plastics and rubber typically possess a relatively low density, limiting the throughput of pyrolysis systems. The material handling and containment associated with the high volume, low density feedstock complicate the maintenance of the conditions conducive to efficient pyrolysis. The continuous removal of air and liquids, and reduction of the volume of the feedstock, is preferred for economic considerations and to avoid hindering the objectives of improving throughput.

[0008] There is a need for a device and method that provides for the continuous introduction of low density, air/liquid-contaminated feedstock into a kiln or reactor for pyrolysis, as well as the reduction of feedstock volume.

SUMMARY

[0009] Embodiments of an injection nozzle apparatus are disclosed herein for removing air and moisture from pyrolysis feedstock, and forming a plug therefrom that prevents air and moisture from entering into a pyrolysis section of a pyrolysis system. The injection nozzle apparatus compresses feedstock passing therethrough to force air and moisture from feedstock without the need for flushing with an inert gas, thus simplifying the operation and maintenance, and reducing the cost, of the pyrolysis system. The feedstock forms a dynamic plug or door as it is compressed and heated by heat from the downstream pyrolysis section to a pliable state, preventing air and moisture from entering into the pyrolysis section. Such compression of feedstock has the further advantage of increasing the density of the feedstock entering the pyrolysis system, thereby increasing the throughput of the system. In embodiments, an inert gas may be used to purge air and water from the feedstock and assist the function of the injection nozzle apparatus.

[0010] In a general aspect, a feedstock injection nozzle for removing air and moisture from feedstock comprises a generally tubular nozzle body having an inlet end and an outlet end, and defining a main cavity, the main cavity having a cross- sectional area, and one or more openings establishing communication between the main cavity and an exterior of the nozzle body; wherein the cross-sectional area decreases towards the outlet end such that the feedstock is compressed and a feedstock plug is formed at a feedstock plug location within the main cavity.

[0011 ] In an embodiment, the injection nozzle comprises a collection chamber formed at least partially around the perimeter of the nozzle body, and in communication with the main cavity via the one or more openings, and one or more ports formed in the collection chamber, wherein air and moisture from the feedstock pass to the collection chamber for removal therefrom. [0012] In an embodiment, the outlet end is adapted for discharge of the compressed feedstock to downstream equipment having a diameter larger than that of the outlet end.

[0013] In an embodiment, the injection nozzle further comprises a void- creating element located adjacent the outlet end.

[0014] In an embodiment, the void-creating element is a sizing ring having a diameter smaller than that of the outlet.

[0015] In an embodiment, the void-creating element is a profiler tab located at a top portion of the main cavity.

[0016] In an embodiment, the injection nozzle further comprises at least one temperature control mechanism configured to maintain a temperature of the feedstock plug within a temperature range.

[0017] In an embodiment, the at least one temperature control mechanism comprises a heating coil located around at least a portion of the nozzle body.

[0018] In an embodiment, the at least one temperature control mechanism comprises a cooling coil located around at least a portion of the nozzle body.

[0019] In an embodiment, the nozzle body defines a first fluid injection port in communication with the main cavity for receiving a first inert gas therethrough into the main cavity. [0020] In an embodiment, the injection nozzle further comprises a conduit portion defining a conduit bore therein located downstream of the main cavity; and one or more thermal insulators located around the conduit portion.

[0021 ] In an embodiment, the conduit portion is a manifold having a first end in communication with the main cavity and a plurality of channels at a second end.

[0022] In an embodiment, each channel is fitted with a respective one of the one or more thermal insulators.

[0023] In an embodiment, each channel defines a second fluid injection port in communication with a respective channel bore of each channel for receiving a second inert gas therethrough.

[0024] In an embodiment, the conduit portion defines a second fluid injection port in communication with the conduit bore for receiving a second inert gas therethrough.

[0025] In an embodiment, a void-creating element is located in each channel of the plurality of channels.

[0026] In another general aspect, a pyrolysis system comprises a conveying mechanism; a feedstock injection nozzle configured to receive feedstock from the conveying mechanism, the injection nozzle comprising a generally tubular body having an inlet end and an outlet end, and defining a main cavity therein, the main cavity having a cross-sectional area that decreases towards the outlet end; and a pyrolysis section located downstream from, and adjacent to, the outlet end of the injection nozzle; wherein the pyrolysis section is configured to produce enough heat to cause the feedstock adjacent the outlet end of the injection nozzle to become pliable and form a feedstock plug.

[0027] In an embodiment, the conveying mechanism comprises an auger that terminates inside the main cavity of the injection nozzle.

[0028] In an embodiment, the pyrolysis section comprises a plurality of pyrolysis streams, and further comprising a manifold in communication with the outlet end of the injection nozzle at a first end and having a plurality of channels at a second end in communication with the plurality of pyrolysis streams.

[0029] In another general aspect, a method of treating feedstock in a pyrolysis system comprises receiving the feedstock in a feedstock injection nozzle; heating feedstock to a temperature at which the feedstock becomes pliable; compressing the feedstock against a decreasing cross-sectional area of a main cavity of the injection nozzle to force air and moisture out therefrom and form a feedstock plug; and sealing an outlet of the injection nozzle with the feedstock plug to prevent air and moisture from entering a pyrolysis section downstream therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1A is a cross sectional side view of an embodiment of an injection nozzle apparatus connected to a feedstock feed section having an auger therein and extending into the nozzle for transporting feedstock to the injection nozzle apparatus and a pyrolysis section comprising a pyrolysis tube;

[0031 ] Figure 1 B is a partial cross sectional side view of an alternative embodiment of an injection nozzle apparatus;

[0032] Figure 1 C is a cross-sectional front view through line A-A of Figure 1A depicting an annular sizing ring extending from the interior wall of the nozzle;

[0033] Figure 1 D is a cross-sectional front view through line B-B of Figure 1 B depicting a tab extending from the interior wall of the nozzle;

[0034] Figure 1 E is a cross-sectional side view of the injection nozzle apparatus of Figure 1 A, showing the formation of a feedstock plug or door within the nozzle apparatus;

[0035] Figure 2A is a cross sectional side view of an alternative embodiment of an injection nozzle apparatus with a distribution manifold connected to a feedstock conveying section having an auger therein and extending into the nozzle for transporting feedstock to the nozzle apparatus and a pyrolysis section with multiple pyrolysis streams;

[0036] Figure 2B is a cross-sectional front view through line C-C of Figure 2A depicting a distribution manifold with multiple channels distributed in a generally circular formation; [0037] Figure 2C is a cross-sectional front view through line C-C of Figure 2A depicting an alternative embodiment of a distribution manifold with multiple channels distributed in a linear formation;

[0038] Figure 3A is a cross-sectional side view of a pyrolysis apparatus showing an injection nozzle apparatus connected to a feed section and a pyrolysis section with a pyrolysis tube; and

[0039] Figure 3B is a cross-sectional side view of a pyrolysis apparatus showing an injection nozzle apparatus connected to a feed section and a pyrolysis section with a pyrolysis kiln.

DESCRIPTION

[0040] Generally, with respect to Figs. 3A and 3B, a pyrolysis system comprises a feedstock feed section 10 configured to receive feedstock 6 and convey it downstream to a pyrolysis section 14, wherein the feedstock 6 undergoes pyrolysis, and an outlet section 16 to direct the products created from the pyrolysis process to the appropriate streams for processing. The pyrolysis section 14 can comprise a kiln heated by combustible gases, a molten metal reactor or heat exchanger, a directly or inductively heated chamber or tube, or any other suitable technology for pyrolyzing feedstock 6. Applicant has described one such pyrolysis section 14 in a co-pending patent application filed on September 11 , 2019 and claiming priority to US 62/729,498 filed on September 11 , 2018.

[0041 ] In embodiments described herein, a feedstock injection nozzle apparatus 20 is located upstream of the pyrolysis section 14 for removing undesirable material such as air, water, or other fluids from the feedstock 6 as feedstock 6 is introduced continuously into the pyrolysis section 14. Best seen in Fig. 1 E, the injection nozzle apparatus 20 forms a dynamic plug 8 from the feedstock 6 for substantially preventing the ingress of air and water into the pyrolysis section 14 from the feed section 10. Further, the injection nozzle 20 compacts low density feedstock 6, thus providing a denser feedstock 6 to the pyrolysis section 14 for more efficient processing.

[0042] The injection nozzle apparatus 20 can be incorporated into any existing pyrolysis system to replace a pre-feed chamber or other device for removing air and water from feedstock 6. For example, with reference to Fig. 3A, an injection nozzle apparatus 20 can be located between the feed section 10 and the pyrolysis section 14 comprising a pyrolysis tube extending through a kiln. With reference to Fig. 3B, an injection nozzle apparatus 20 can be located between the feed section 10 and the pyrolysis section 14 comprising a traditional kiln.

[0043] In an embodiment, with reference to Fig. 1A, the injection nozzle apparatus 20 comprises a generally tubular body 22 defining a main cavity 24 located between, and in communication with, an inlet 26 and outlet end 28.

[0044] With reference also to Fig. 1 E, the main cavity 24 radially converges or tapers downstream towards the outlet end 28 such that feedstock 6 is compressed as it passes through the injection nozzle 20, thereby squeezing water and air out of the feedstock 6. For example, the nozzle body 22 can have a frusto-conical shape, of generally circular cross-section, such that a diameter D / cross-sectional area of the main cavity 24 converges or decreases towards the outlet end 28. The converging of the main cavity 24 towards the outlet end 28 compacting the feedstock 6 within the main cavity 24 of the nozzle 20, together with the heat emanating from the pyrolysis section 14, also creates a door/plug 8 out of the feedstock 6 material itself that substantially prevents the extracted air or water from entering the pyrolysis section 14 through the nozzle 20. In other words, the injection nozzle apparatus 20 creates a dynamic door/plug 8 from the feedstock 6 as it is being compressed in the main cavity 24 while proceeding therethrough towards the pyrolysis section 14.

[0045] A plurality of openings 30, such as slots or holes, are formed in the wall of the body 22 to permit communication between the main cavity 24 and the exterior of the body 22. In some embodiments, a circumferential housing 32 is located about the nozzle body 22 and forms a collection chamber 34 in communication with the main cavity 24 via the openings 30 for receiving moisture L and/or air G forced out of the feedstock 6 as it is compressed in the main cavity 24.

[0046] One or more removal ports 36 can be formed in the circumferential housing 32 to permit the evacuated air G and water L to be removed for further processing and/or disposal. In embodiments, an upper port 36a can be configured to evacuate air G from the collection chamber 34, and a lower port 36b can be configured to evacuate water L from the collection chamber 34.

[0047] In the embodiment depicted in Fig. 1A, a single circumferential housing 32 extends around the perimeter of the housing 22, forming a circular/toroidal collection chamber 34. However, a person of skill in the art would understand that the collection chamber 34 does not need to encircle the nozzle body 22, but can instead be comprised of one or more discrete circumferential sections forming multiple collection chambers 34.

[0048] In other embodiments, no circumferential housing 32 is present, and the air G and moisture L forced out of the feedstock 6 simply exits the main cavity 24 to the environment through the openings 30.

[0049] The injection nozzle apparatus 20 can also have one or more fluid injection ports 38 formed in its body 22 and in communication with an inert gas source, such that an inert gas such as nitrogen N2 can be injected into the cavity 24 to displace any remaining air and/or moisture from the feedstock 6 or main cavity 24 before it enters the pyrolysis section 14 for maintaining a substantially inert environment therein. Such fluid injection ports 38 may be desirable when pyrolyzing feedstock 6 such as shredded rubber tires, which by their nature are not easily compressed or consolidated by mechanical compression alone to remove air and water to a sufficient degree for pyrolysis. The inert gas can be continuously injected into the main cavity 24 such that air and moisture are continuously removed from feedstock 10 progressing through the cavity 24.

[0050] In some embodiments, the injection nozzle apparatus 20 further comprises a generally tubular conduit portion 40 towards its outlet end 28, having a conduit bore 42. The conduit portion 40 connects the main cavity 24 with the pyrolysis section 14. As shown in Fig. 1A, in one embodiment, the conduit portion 40 can have a substantially constant inner diameter.

[0051 ] At the location where the diameter D of the main cavity 24 is at its minimum, the nozzle body 22 forms a primary annular constriction 44 prior to the pyrolysis section 14. With reference to Fig. 1 C, the injection nozzle apparatus 20 may further comprise a secondary annular constriction 46 prior to outlet end 28 to the pyrolysis section 14. The secondary annular constriction 46 causes the feedstock 6 to have a smaller cross sectional area than that of the conduit bore 42 or pyrolysis section 14 as it passes through the secondary constriction 46.

[0052] For example, as best shown in Figs. 1A, 1 C, and 1 E, the secondary annular constriction 46 can be a sizing ring 48 located at the small end of the main cavity 24 upstream of the conduit bore 42. The secondary constriction 46 compresses the feedstock 6 into a smaller diameter than the inside diameter of the conduit bore 42 or pyrolysis section 14. Such a secondary annular constriction 46 functions as a void-creating element, providing a void or headspace for gases produced in the pyrolysis section 14 to escape along the section 14 and out to the outlet section 16, thereby mitigating a“burping” effect that can occur if a confined space, such as a pyrolysis tube, is entirely filled with molten feedstock 6 such that gases formed during pyrolysis expand and push non-pyrolyzed molten feedstock 6 into the outlet section 16. Such an effect is undesirable, as non-pyrolyzed molten feedstock 6 prematurely enters into a part of the pyrolysis system intended for pyrolyzed products such as gases and solid pyrolysis residue (e.g. char).

[0053] With reference to Figs. 1 B and 1 D, in an alternative embodiment, the secondary constriction 46 is a profiler tab 50 extending across a top portion of the small end of the main cavity 24 upstream of the conduit bore 42, should it be preferable to create a smaller void for the gases to escape during the pyrolysis of the feedstock 6. Preferably, the profiler tab 50 is located at an upper portion of the small end of the main cavity 24 upstream of the conduit bore 42 where gases typically collect. In further alternative embodiments, the radius of the inner wall of the conduit bore 42 can increase after decreasing to a minimum radius at the primary annular constriction 44 to perform the same function as the secondary constriction 46 of compressing the feedstock 6 into a smaller diameter than the inside diameter of the conduit bore 42 or pyrolysis section 14, creating a void for gases to collect.

[0054] In some embodiments, to facilitate the removal of gases produced in the pyrolysis section 14 and/or to improve the yield of usable pyrolysis products, nitrogen N2 or other suitable inert gases can be introduced via a second fluid injection port 39 at a location upstream of the pyrolysis section 14, such as in the main cavity 24 downstream of where the feedstock plug 8 is formed or in conduit bore 42, to act as a carrier gas and promote downstream flow of gases produced during pyrolysis. In embodiments of the injection nozzle 20 having a sizing ring 48 or profiler tab 50, the nitrogen can be introduced at a location downstream of the sizing ring 48 or profiler tab 50.

[0055] In some embodiments, catalysts can be introduced at a location upstream of the pyrolysis section 14, such as via first and fluid injection ports 38,39, to improve the yield of usable pyrolysis products. For example, catalysts such as mesoporous MCM-41 and/or microporous zeolite ZSM-5 (industry designations for now-common catalysts initially developed by Mobil Oil Company) may be introduced to the feedstock 10 to improve the yield of saleable products. Either or both catalysts can be injected upstream and/or downstream of the secondary annular constriction 46 via first and/or second fluid injection ports 38,39.

Temperature Control

[0056] Various temperature control mechanisms may be employed to maintain the temperature of the feedstock plug 8 within an ideal temperature range, wherein the plug 8 is pliable enough to seal the pyrolysis section 14 from air and moisture, but not so hot so as to melt and lose its sealing capability. As one of skill in the art would understand, the ideal temperature range for the plug 8 will be contingent upon the nature of the material being pyrolysed. For example, low density polyethelyne (LDPE) and high density polyethelyne (HDPE) plastics begin to melt at 120°C, polystyrene at 210°C, and polypropylene at 160°C.

[0057] Significant heat can be generated by the pyrolysis section 14 during operation. Therefore, to preserve the integrity of the feedstock plug 8 and prevent it from melting and losing its sealing capability when the conveying mechanism 12 is stopped, the injection nozzle 20 may be shielded from the heat of the pyrolysis section 14 by employing one or more thermal insulators 52, such as a ceramic insulator 52, as shown in Figs. 1A and 1 E. For example, the ceramic insulator 52 can be inserted into the conduit portion 40 at or near the outlet end 28 of the nozzle 20, downstream of the secondary annular constriction 46.

[0058] In other embodiments, as shown in Figs. 1A and 1 E, the ceramic insulator 52 is a discrete spool located between the injection nozzle 20 and the conduit portion 40, the spool having a bore with an inner diameter substantially equal to that of the conduit bore 42. The thermal insulator 52 shields the nozzle body 22 from excessive heat that may emanate from the pyrolysis section 14, and can be configured to shield a sufficient amount of heat to maintain the feedstock plug 8 within an ideal temperature range.

[0059] With reference to Fig. 2A, a cooling coil 54 can be installed around at least a portion of the nozzle body 22 or manifold 60, such as a pipe in communication with a pump (not shown) having water or another suitable coolant circulated therethrough to cool the nozzle apparatus 20 and feedstock plug 8 therein. Alternatively, or additionally, the nozzle 20 may include heating coils 54 installed around at least a portion of the nozzle body 22 or manifold 60 to heat the feedstock plug 8 such that it remains pliable enough to maintain its sealing capability. In either case, the cooling/heating coils 54 and/or thermal insulation 52 can be configured to maintain the temperature of the feedstock 6 in the injection nozzle 20 within an ideal temperature range for the feedstock plug 8 to maintain a functional seal to prevent air or water from entering into the pyrolysis section 14. As one of skill in the art would understand, other methods of maintaining the temperature of the feedstock plug 8 within an ideal range may be employed without deviating from the scope of the invention. For example, another heat source, such as a burner or other heater, can be fixed or located adjacent to the injection nozzle apparatus 20.

Conveying Mechanism Design

[0060] With reference to Figs. 1 A, 1 E, 2A, 3A, and 3B, in order to enhance the ability of the injection nozzle apparatus 20 to remove air and/or water entrained in the feedstock 6, the conveying mechanism 12 may comprise an auger that is designed such that the diameter of the spiral flutes (or helical screw) at the downstream terminal end of the auger diminishes progressively in a manner that corresponds to the taper of the main cavity 24. Connection to Manifold

[0061 ] With reference to Fig. 2A the injection nozzle apparatus 20 can be connected to a distribution manifold 60 that will direct the feedstock 6 into two or more pyrolysis streams 15 of the pyrolysis section 14. A distribution manifold 60 can be used when it is desired to use a single conveying mechanism 12 for transporting feedstock 6 to a pyrolysis section 14 comprising multiple pyrolysis streams 15. The manifold 60 comprises a manifold bore 62, a first end 64 for receiving feedstock 6 from the main cavity 24, and a second end 66 having a plurality of channels 68, each having a channel bore and configured to deliver feedstock 6 to a corresponding pyrolysis stream 15. Fig. 2B shows a distribution manifold 60 having a circular second end 66 with twelve (12) channels 68 to feed twelve (12) parallel pyrolysis streams 15. Fig. 2C shows a distribution manifold 60 having a rectangular second end 66 with four (4) channels 68 to feed four (4) vertically spaced, parallel pyrolysis streams 15. As can be seen in Fig. 2A, the manifold 60 can take the place of the conduit portion 40. As above, the feedstock plug 8 is formed upstream of the primary annular constriction 44 of the injection nozzle 20. Fleating/cooling coils 54 are wrapped around the nozzle body 22 and/or the manifold 60. Each channel 68 can have a thermal insulator 52 for absorbing heat from the pyrolysis section 14 and maintaining the temperature of the feedstock plug 8 within a desired range. Further, each channel 68 can have a respective secondary annular constriction/void-creating element 46 to mitigate the“burping” effect in each pyrolysis stream 15. Additionally, a respective second fluid injection port 39 can be in communication with each of the channels 68 to facilitate the downstream flow of gases produced in the pyrolysis streams 15 and/or to improve the yield of usable pyrolysis products.

Operation

[0062] In use, and with reference to Fig. 1 E, a feed conveying mechanism 12 of the feed section 10, such as an auger, hydraulic ram/plunger, or similar device, can be operated to supply feedstock 6 to the main cavity 24 of the injection nozzle 20. The pyrolysis section 14 can be connected directly or indirectly to the outlet end 28 of the nozzle 20. Water and air are forced out of the feedstock 6 by the injection nozzle 20 prior to entering the pyrolysis section 14 and undergoing pyrolysis. The feedstock 6 transported towards the injection nozzle 20 by the conveying mechanism 12 enters through the inlet 26 of the injection nozzle apparatus 20 and accumulates in the main cavity 24. As additional feedstock material 6 is transported into the main cavity 24, the feedstock 6 will begin to collect and becomes compressed by the reducing radial cross-sectional area of the main cavity 24 as it moves toward the outlet end 28. As the feedstock 6 is compressed, air and water are forced out of the feedstock 6 and directed through the plurality of openings 30 formed in the nozzle body 22 into the circumferential collection chamber 34 therearound, where they can subsequently be removed via the removal ports 36 of the collection chamber 34 to avoid compromising the pyrolysis conditions. In this manner, air and water are substantially removed from the feedstock 6 before it enters the pyrolysis section 14, maintaining a largely inert environment for efficient pyrolysis to occur. For example, the mechanical compression of feedstock 6 inside the main cavity 24 can remove about 95% of air and moisture from the feedstock. Should it be desirable or necessary to remove more air and water from the feedstock 6 than can be removed by mechanical compression alone, an inert gas such as nitrogen N2 can be used to flush the main cavity 24 via first fluid injection port 38 and force the remaining air and water out via openings 30.

[0063] The compacting of the feedstock 6 within the main cavity 24 the nozzle 20 also creates the door/plug 8 out of the feedstock 6 material that substantially prevents the extracted air or water from entering the pyrolysis section 14 through the nozzle 20. It may be desirable to introduce nitrogen N2 or another inert gas into the pyrolysis section 14, such as through second fluid injection ports 39, as soon as the plug 8 has been formed to purge the pyrolysis section 14 of oxygen and/or moisture before the feedstock 6 begins to be pyrolyzed.

[0064] Should the pyrolysis process need to be stopped, the feedstock plug 8 can be held in place by the stationary feedstock conveying mechanism 12, such that the pyrolysis section 14 continues to be sealed from air and moisture. The temperature control mechanisms can also be used to maintain the plug 8 in a pliable state to continue to seal the pyrolysis section 14 from air and moisture while the pyrolysis process is stopped.

Applications

[0065] As one of skill in the art would recognize, although embodiments of an injection nozzle apparatus herein are described in the context of pyrolysis operations, the injection nozzle can be used in any context wherein it is desired to displace and remove gas or fluid entrained in a feedstock material.