JP2021105187A - Char separator and method - Google Patents

Abstract

To provide a device for processing reusable fuel.SOLUTION: The device provided for processing the reusable fuel comprises: a support body (75); a plurality of augers (76) disposed inside the support body; a driving system (68) connected to drive and control the plurality of the augers; a discharge system (72) connected to the support body; a gearbox housing (69); and a thermal expansion system (79) connected to the support body, wherein the gearbox housing (69) has an upper part, a lower part, and a ventilation system (70) between the upper part and the lower part, the lower part is connected to the discharge system (72), the lower part is housed in the gearbox housing, and the ventilation system (70) is entirely disposed within structure of the gearbox housing (69).SELECTED DRAWING: Figure 3

Description

The present invention generally relates to devices and methods for heat exchange techniques. More specifically, it relates to an apparatus and method that is part of a reusable fuel processing unit that allows the absorption of char contained in the steam for processing and purification as it exits the reactor.

It is known to use feeder airlock systems in reusable energy devices. Examples of known devices include Amrain et. Al's U.S. Pat. No. 5,762,666, Tailor's U.S. Pat. No. 3,151,784, and Kullgren et. al. Includes US Pat. No. 3,129,459. These patents teach airlocks with side gates (Amrain et. Al.), Rotary feeders for airlocks with blades, and extruders with electric heating (induction). is doing. Tailor's device teaches a rotary device in which steel blades are mounted on a shaft and rotate within a rounded housing. The openings are above and below the housing, allowing material to flow in and out of the housing. The blades block the pressure difference between the inlet and outlet. However, there are a number of restrictions on this design. The first limitation is that prior art reusable energy devices will not be able to withstand heat as the prior art disclosed structural design expands to allow internal pressure to leak out. Is. Another constraint is that the blades act as pockets and also carry the atmosphere from the inlet to the outlet. The third constraint is related to the rotational speed. The speed of rotation must be slow to allow the material time to fall out of the release, otherwise the material will be carried back around and prevent refilling from the inlet. A fourth limitation is that prior art devices will not allow molten materials, such as hot plastics, to traverse through them.

Amrein's device discloses a feeder airlock system that uses two valves and has a hopper or pipe between them to allow material filling. This design withstands heat, but allows the atmosphere to enter the feeder through the inlet and pass through to the outlet. This is a constraint as atmospheric gas may not be tolerated in some processes as it causes problems downstream. The second limitation in the case of this device is that it will not allow a molten material such as hot plastic to traverse through it.

Kullgren's device teaches an induction heating extruder. This extruder employs induction heating using an electric coil. The limitations of this device are that it does not create an airlock and therefore does not allow continuous feeding of the plastic material, and requires extremely high horsepower to achieve the internal pressure and heat required to melt the plastic. It requires a thick and long barrel and requires high output.

Recyclable energy devices of the prior art present challenges when certain carbon chars need to be removed from the fuel in order to produce high quality fuel. Conventional techniques typically use the following methods to remove char from liquid fuel: There is filter filtration to remove large particulate matter from the fuel, but the filter becomes clogged and cycles. Cleaning is required; although there are distillations that can remove 99.9% of carbon-based materials, distillation is a subprocess outside the reactor and increases the cost of producing reusable fuels; cyclones. Systems are often used to try to remove most of the particles, but only large particles can be removed, the cyclone requires a heat source and prevents the vapor from condensing to form a liquid that recollects char. The bag filter is limited to the heat that the filter bag can withstand and fails when absorbing liquid fuel.

U.S. Pat. No. 5,762,666 U.S. Pat. No. 3,151,784 U.S. Pat. No. 3,129,459

Therefore, there is a need to create more effective reusable energy devices that provide the ability to optimize available and reusable fuel vapors. There is also a need to provide improved systems to reduce and / or remove contaminants without the need for additional equipment expenditures or additional filter filtration processes to achieve them.

According to the first broad aspect, the present invention provides a device for processing reusable fuel and drives a support body, a plurality of augers disposed inside the support body, and a plurality of augers. A gearbox that is coupled to control and a drive system, a discharge system that is connected to a support body, and a gearbox housing that is connected to the discharge system, wherein the drive system is housed in the gearbox housing. -Includes a housing and a ventilation system located inside the gearbox housing.

According to a second broad aspect, the present invention provides a device for processing reusable fuel, a support body, a plurality of screw type augers disposed inside the support body, and a plurality of augers. A drive system and a gearbox housing that are coupled to drive and control the gearbox housing, which is disposed inside the gearbox housing and the gearbox housing in which the drive system is housed in the gearbox housing. A ventilation system and an exhaust system, one end of which is attached to the support body and the other end of which is attached to the gearbox housing. And to remove carbon char from steam containing non-condensable hydrocarbons, it is configured to rotate against the flow of steam.

According to a third broad aspect, the invention provides a method of removing carbon char from the vapor in the reactor and accepts the vapor flow of condensable and non-condensable hydrocarbons in the supporting body. And controlling the temperature inside the support body and rotating the multiple augers placed inside the support body against the flow of steam, each flight of the multiple augers Includes crossing, rotating, and releasing low carbon vapors from the support body as reusable fuel.

The accompanying drawings exemplify exemplary embodiments of the invention, which are incorporated herein to form part of the specification, and are shown in the general description above and below. Along with a detailed description, it helps to explain the features of the present invention.

It is the schematic of the reusable energy apparatus which concerns on one Example of this invention. It is an assembly drawing and the exploded view of the heating airlock feeder of the reusable energy apparatus of FIG. 1 which concerns on one Example of this invention. It is an assembly drawing and the exploded view of the char separator of the reusable energy apparatus of FIG. 1 which concerns on one Example of this invention.

If the definition of a definition term deviates from the common meaning of that term, Applicant intends to use the definition provided below unless otherwise stated.

It should be understood that the general description above and the detailed description below are merely exemplary and descriptive and do not limit any of the subject matter claimed. In this application, the use of the singular includes the plural unless it is clear that it is otherwise specified. It should be noted that the singular forms "a", "an" and "the" are in context when used in the specification and the appended claims. It means that it contains multiple referents, unless it is clearly required above. In this application, the use of "or (or)" means "and / or (and / or)" unless otherwise specified. Also, the use of the term "inclusion" and other forms such as "include", "includes" and "included" is not limited.

For the purposes of the present invention, the term "comprising", the term "having", the term "inclating", and variants of these terms shall be open-ended. It means that there may be additional elements other than those listed.

For the purposes of the present invention, "top", "bottom", "upper", "lower", "upper", "lower", "left", "right", "horizontal", "vertical", "rising" Directional terms such as, "plumb bob", etc. are used solely for convenience in describing various embodiments of the present invention. The embodiments of the present invention may be oriented in various ways. For example, the charts, devices, etc. shown in the drawings may be turned over, rotated 90 degrees in any direction, inverted, and the like.

For the purposes of the present invention, a value or property is "based" on a particular value, property, condition fulfillment, or other factor, which is that the value makes a mathematical calculation or logical decision. This is the case when it is derived by execution using a value, characteristic, or other factor.

It is noteworthy for the purposes of the present invention that, in order to provide a more concise explanation, some quantitative expressions as defined herein are not diminished by the term "about". That's what it means. To be understood means that any quantity defined herein, whether or not the term "about" is explicitly used, refers to a given value in reality, as well as such given value. It also means pointing to an approximation of such a given value that would be reasonably inferred based on one of ordinary skill in the art, including approximations due to experimental and / or measurement conditions for. be.

For the purposes of the present invention, the term "ambient air temperature" generally refers to the temperature of the ambient environment, more specifically the temperature of the ambient environment of the disclosed cyclone-type condensation and cooling systems.

For the purposes of the present invention, the term "fractionation" refers to the separation of a mixture of hydrocarbon chains into groups of carbon chains, i.e., separation.

For the purposes of the present invention, the term "substantially" refers essentially to a large or significant degree.

For the purposes of the present invention, the term "pyrolysis" refers to a process typically used by a refiner to decompose the carbon chains of a petroleum compound so that the desired carbon compound can be obtained. This process typically involves high heat, distillation, reboil, and energy intensive cooling processes.

Description Although various modifications and alternative forms are possible in the present invention, specific examples thereof are shown in the drawings as an example and will be described in detail below. However, it should be understood that it is not intended to be limited to the particular form in which the invention is disclosed, and otherwise all modifications to which the invention falls within the spirit and scope of the invention. , Equivalents, and alternatives.

The application relates to equipment that is part of a reusable fuel processing unit. The plastic waste material may be fragmented and fed into, for example, a pyrolysis reactor. Applying heat above 350 degrees Celsius will melt and evaporate the fragmented plastic material. In one disclosed embodiment, the heated airlock feeder or system is an apparatus in which fragmented plastic material is fed into a pyrolysis reactor. It was found that prior art did not pre-allow continuous feeding of heated plastic to the feeder while maintaining the airlock. In an exemplary design, the disclosed examples may include the following equipment as described below.

Existing gearboxes designed to be as short as possible to reduce manufacturing materials and labor have been restricted against this conventional patent application so that short gearboxes are restricted in terms of cantilever loading. The force attempted to hold the functional and long heave shaft exerts extreme pressure on the main bearings, resulting in reduced bearing life or for heavy work to handle the forces. Bearings are needed. When heavy duty bearings are used, they lead to larger bearings and larger pockets are created in the gearbox housing. Larger pockets reduce the capacity of the housing to support the bearings, so the housing will then be made thicker. This increases the cost of standard gearboxes. This design expands the space between the bearings and reduces the load on the bearings. Further isolation of the bearings reduces the cantilever load, may result in smaller bearing dimensions, may result in thinner housings, reduce total cost and improve performance. The further away the points of connection with the bearings, the more straight the shafts will be aligned, the less wear will be and the longer the life of the gearbox will be.

The flat bar mounted between the cart and the frame allows the device to expand and contract due to heat transfer as it incorporates a thinner material into the reactor that allows for better heat transfer.

The numerous thermal regions employed, such as the two heater zones, allow the plastic material to transform from a solid fragmented state to a liquid state (the first solid fragmentation of the feeder). Plastic material and the final liquid state of the feeder). Between the fragmented solid and liquid states, there is a molten plastic material. The molten plastic material is thick and sticky, allowing the formation of the required pressure to create the airlock needed to prevent air from entering the reactor.

The use of steam gas (natural gas or syngas) and clamshell burners allows for external heating that should be possible in the processing of plastic materials, whereas prior art uses electric heating bands and internal pressure. As a result, high power consumption was caused to produce the heat required to process the plastic material. The use of steam gas and clamshell burners allows for less power consumption, faster processing times, and more accurate and consistent heat production.

The use of a clamshell burner allows heat to be generated on the entire outer surface of the penetration pipe and also allows access to the reactor tube. The use of clamshell burners allows for a low profile for the internal reactor, reducing the amount of space between the heat source and the surface of the perforated pipe and increasing heat transfer without increasing the BTU value required by the burner system. Let me. The clamshell design combines both convective heating and radiant heating to create a uniform heating source around the perforated pipe. The combination of the two types of heating is achieved with the use of a perforation screen, which extends over the entire length of the perforation tube and one-third to the top inside the bottom of the clamshell burner. There is. This design also prevents hot spots that normally occur in burner boxes. Another difference in this system compared to existing systems is that the ignition source is inside the clamshell burner box adjacent to the perforation screen. The system includes a flame sensor as well as a fan pressure switch to ensure airflow. Double gas streams are used by adjusting the amount of gas or air, whereas existing systems use complex air control dampers to create a uniform fuel that creates irregular flame dimensions. Adjust the air / gas ratio that may cause non-combustion. The design of the clamshell, which is part of the heated airlock feeder, is that the refractory material is not lined up all over, but only in the upper half of the clamshell. The fact that the lower half of the clamshell is not lined with refractory material allows any heat formation to dissipate through the entire box surface. This design also reduces the chance of automatic ignition of the mixed gas.

The disclosed examples allow the application of back pressure to the feed material between the cold material and the material that is heated and melted (molten plastic). The main components of the heated airlock feeder system are the drive, coupling, gearbox, auger, housing, clamshell burner box, expansion cart, and support frame. FIG. 1 shows the entire assembly of the reusable energy reactor system 100. FIG. 2 shows a heated airlock feeder 200 that is part of the entire assembly of a reusable energy reactor system. The drive system may include the helical gear drive device of FIG. 2, 59, which has a high torque ratio. The gear drive 59 is selected with a vertical installation area to reduce the overall length of the system. This drive may be coupled to a shear coupling. The coupling is designed to separate to protect the gearbox under overload conditions.

In an exemplary embodiment, the coupling consists of two custom-built augers, 51 in FIG. In a carefully selected embodiment, the auger 51 is a machined three-part system. The first part of the auger is the drive shaft, one drive shaft may be longer than the second drive shaft. They are elongated and rotatable in the axial direction. The middle section of the auger is an elongated, axially rotatable screw, each with an elongated shaft, the elongated shaft being the length of each shaft that starts at the gearbox and leads to a smooth surface auger that rotates axially. Featuring a spiral flight that extends outward along a half of the sword, the smooth portion of each auger on the output side of the device is machined and therefore between each auger and the elongated tubular barrel housing. Space is smaller than 2.54 cm (1 inch).

The auger 52 is located inside 53 of FIG. 2, which is 61 inside of FIG. One auger has a left-handed flight and the other auger has a right-handed flight that overlaps the left-handed flight. One of the augers 51 of FIG. 2 is longer than the other and protrudes through the gearbox and connects to a drive coupling located in the gearbox 57 of FIG. The auger is constructed from solid material with a connection slip for machining purposes. Ogres are built into segments to reduce labor costs for manufacturing materials and assemblies. Segments are also compatible with simpler artifacts. The gear drive of the gearbox 57 is key-coupled to the shaft and sealed on both sides. The gearbox consists of a double lip seal, bearings, and spur gears. The length of the gearbox is extended to support the cantilever load of the screw flights 51 and 52 of FIG.

All surfaces are machined on the contact side of both items 51 and 52 in FIG. 2 after welding. The housing 53 of FIG. 2 is pre-welded prior to machining the interior to require a straight design. The connecting flanges and inlets at both ends are consistent with the gearbox and reactor bolt pattern. 54 of FIG. 2 is tapered to reduce the outlet area and increase the back pressure inside the heated airlock feeder (FIG. 2). The feeder assembly is welded to the reactor matching flange 55 of FIG. 2 and then to the body 53. Item 52 of FIG. 2 is welded to item 51 of FIG. 2, and then the entire assembly slides through the body 53 of FIG. 2 and projects flush with the end 54 of FIG. 2 at the exit port. do. The gearbox and assembly housing rest on the support frame of 67 in FIG. This assembly is bolted to the rear, which is the main anchoring point for the entire reactor. The heated airlock feeder expands in the vertical direction when it expands due to heat. To address the expansion, the device is supported by the cart 60 of FIG. 2 and allows the machine to expand without causing stress on the support. Existing prior art applications used shorter sections constructed from extremely thick materials to be bolted to each other to absorb heat. In the disclosed embodiments, the exemplary design utilizes thinner materials for better heat transfer, but requires a movable support system.

The solid, fragmented plastic material (ambient temperature) is delivered to the heated airlock feeder of FIG. 2 56, the heat is applied in 61 of FIG. 2, and the molten heated plastic material is 51. Created from a solid, fragmented plastic material (ambient temperature) at the location connected to 52 of 2. The connection of 51 to 52 provides a continuous auger located on the inner 53 located on the inner 61. The airlock is created at the end 52 of FIG. 2 from back pressure from a solid, fragmented plastic material (ambient temperature) that presses against it.

This device is used to guide the heated plastic material into the main reactor and at the same time act as an airlock. By applying back pressure to the plastic material sent between the solid fragmented plastic material and the melted material (molten plastic material), the dead spot shown in FIG. 252 is created. There is no flight on the shaft at 52. This dead spot created by this process, shown in FIG. 2 52, is the arrival of solid fragmented plastic material (ambient temperature) in which the molten plastic material is sent into the device at 56 in FIG. ) Allows the formation of pressure. The area 52 also has a large shaft area that fills the void between 52 and 53. This oversized shaft increases internal pressure and creates an airlock effect. The release of the airlock feeder is at 54 in FIG. 2 due to two openings whose dimensions are significantly reduced compared to the openings in which the solid fragmented plastic material (ambient temperature) is sent in 56 in FIG. It is also restricted. When the feeder is stopped, the plastic material remains inside the feeder in the area 52 of FIG. 2 because the plastic material is 53 of FIG. 2 even when the feeder auger of 51 of FIG. 2 continues to rotate. It will not be pushed out of the housing. The reason for this is that when a new solid fragmented plastic material (ambient temperature) is introduced, the heated molten plastic material is only extruded. The incoming plastic material creates pressure and forces the molten plastic material in area 52 to move. This means that as the airlock feeder cools, the remaining plastic material will turn solid and seal until the next step. When the next step occurs, the plastic material is reheated and melted, allowing the auger 51 in FIG. 2 to rotate.

The disclosed device also heats the plastic material to a vapor and liquid state with the clamshell burner of FIG. 61. The heating source for this airlock feeder may include a plurality of clamshell heaters shown in FIGS. 2 to 65. In the exemplary embodiment illustrated in FIG. 2, these two clamshell heater boxes generate the heat required to create an airlock seal and initiate evaporation of the plastic in the feeder. The plastic material is heated from the end of the discharge section to the middle of the airlock feeder. By having two heater zones, the material changes from a liquid state at one end to a fragmented state at the other end. During this transition, there is a molten plastic material. This molten plastic is thick and sticky, forming the required pressure and creating an airlock effect. The clamshell box contacts an airlock feeder with the seal 63 of FIG. This allows for greater expansion of the housing 53 of FIG. 4 from the clamshell fire box, because the box is insulated on the inside and does not allow the metal to expand on the outside. Is. The heated airlock feeder has two clamshell box burners. One box covers 52 of FIG. 2 of the inner auger and the other heats 51 augers of the auger. The advantages of the two clamshell heater box burners are demonstrated at the start and stop of the reactor. Allowing the auger 51 of FIG. 2 to cool to the point where the plastic seal is achieved in order to create the airlock needed to initiate the stop. The molten plastic is cooled solidly around the auger and housing to seal the feeder. The ability to cool quickly is also a major advantage of using a clamshell heater. The burner flame may be extinguished and the fan may continue to run to cool the housing 53 in FIG.

Clamshell burner boxes are used because heated airlock feeders require a continuous and uniform heat supply to produce molten plastic. The exact amount of heat controlled is important to the process for a consistent material flow. Processes of this nature require heat from all directions. The need for high speed airflow in a circular box would be sufficient for this process. A heater box with a process structure that penetrates the box will also require a sealing system to prevent leaks. Expansion of the penetration structure in both length and diameter is taken into account in this design. Both heating and cooling capacities are required in this process. The penetration structure requires supportability to prevent damage to the heater box seal. The penetration structure (pipe or tube) needs to be supported on the outside of the heater box. Movable support is required due to the thermal expansion of the penetration structure. Requirements for controlling the direction of expansion are also required to prevent warpage of the penetration structure and deflection that would damage the heater box seal, and deflection in the direction that may damage the equipment. Requires a control support system to limit. Furnace heater boxes are used in a number of processes to produce the required heat for incineration, cooking, melting, and other heat-requiring processes. If the cylinder or tube penetrates the heater box, problems with uneven heating, seal leaks, and expansion can occur. Also, the need to access penetrating tubes and pipes is needed. The clamshell design is implemented for those reasons. The clamshell design allowed a circular shape to match the profile of the penetrating pipe or tube. This close profile ensures uniform heating around the perforation pipe, along with high speed airflow. The clamshell design has a very low profile interior, reducing the amount of space between the heat source and the surface of the perforated pipe and increasing heat transfer without increasing the BTU value required by the burner system. Compared to a standard burner box where the burner is mounted on one side of the box at a distance that does not allow an open flame to touch the penetration pipe, this design uses a very small flash point and the penetration pipe. Distribute heat to one-third of the way around. This reduces the total BTU value. This design combines both types of heating, convection and radiation, creating a uniform heating source around the penetration pipe.

What was used was the perforation screen 61a of FIG. 2, which distributes the gas fuel, controls the flame height, and at the same time allows the air flow to pass through the heater box. Shelf burner packages may be used to supply both gas and air mixtures for ignition. The difference in this system is the inner clamshell burner box, which is the ignition source and is adjacent to the perforated screen. Flame sensors are used to ensure ignition and fan pressure switches are used to ensure airflow. Double gas may be used by adjusting the amount of gas or air. Existing systems use complex air-controlled dampers to adjust the air-to-gas ratio, causing uneven combustion of fuel and creating irregular flame dimensions. The speed and pressure of the air should be in a fixed ratio to ensure that the gas mixture exits the perforation hole as needed so that it does not allow the gas mixture to ignite under the perforation screen. Must be. This design overcomes this problem by stopping the gas flow and allowing the air to continue when the temperature exceeds a given set point. As the system cools, the gas at the lower set point is allowed to return into the mixture and is reignited. This control is achieved, for example, by using a standard PIO controller with a thermocouple to indicate the internal temperature. The clamshell design allows access to the refractory liner located only in the upper half of the clamshell. All known heater boxes are normally lined with refractory material on all surfaces. The lower half of this clamshell has no refractory liner, allowing any heat formation to dissipate through the box surface, ensuring that the surface temperature stays below the auto-ignition point. The perforated screen acts as a pressure regulator between the mixed gas and the flame above. The chamber is supplied with ambient air and mixed gas, both at ambient temperature. This keeps the lower half of the clamshell cool for cooling. There is no refractory material in the lower clamshell and no replacement of refractory material is necessary. The radiant heat from the flame does not come into contact with the bottom portion of the penetration tube 53 of FIG.

The airflow from the burner forces the air around the penetrating tube and, thanks to natural disturbances, carries the heat completely around the penetrating tube. This movement of air regulates the radiant heat surface of the piercing tube by forcing the air around the piercing tube into an air stream that passes through the discharge point. The perforation screen has a small flame that extends to the entire length and one-third around the perforation tube. This prevents hotspots that normally occur in burner boxes. By heating the penetrating tube in all directions, expansion occurs in all directions. The expansion direction is controlled by a support system to prevent bending or misalignment of the penetration tube while heating. The support is attached to the inflatable tube to prevent it from moving in an undesired direction. The cart consists of a cam follower sandwiched between two structural flat bars, one on each side of the cart. The cart width is designed so that the width between the two structural flat bars is within one-eighth of 2.54 cm (1 inch), thus falling between the structural flat bars to ensure lateral movement. do. The cam follower (roller) supports the weight of the penetration tube while preventing it from expanding up or down. This allows control of swelling, and the only direct action is lateral movement.

Continuing with FIG. 2, a typical pipe support roller allows expansion in multiple directions. This design limits expansion to lateral movement only and protects the penetration tube from misalignment. The assembly is mounted on a steel skid mounting frame 67. The clamshell heater box is composed of an upper section 61 and a lower section 64. These sections are connected to a corresponding bolted flange and a seal chamber 63 that surrounds the penetration tube. The gas-air inlet box is mounted in the bottom section 64 to allow the air-gas mixture to enter the lower section. The lower section has a perforated metal screen 64a welded about 7.62 cm (3 inches) above the lower section 64. It acts as an air chamber to distribute the mixed air and gas through the perforation screen. The amount and diameter of the holes in the perforated screen are important for controlling the flame height while allowing the volume of the gas and air mixture to pass through. The lower clamshell 64 also has a mixture box 65 and a burner connection port 65a connected to it. The mixer box 65 has a flare structure to evenly distribute the air-gas mixture under the perforated screen 64a. The mixer box 65 creates some back pressure on the air-gas mixture, ensuring a consistent gas-air ratio for each opening of the perforated screen 64a.

The burner may be connected to port 65a. The burner igniter, along with the flame indicator, is located above the perforation screen 64a. The access pipe 64b is used to penetrate both the lower clamshell 64 and the perforation screen 64a for the igniter and for the flame sensor 64c to be mounted. A continuous pilot light 64c is installed through this pipe and stops above the perforation screen 64a. A pilot light proof of flame is required to indicate that there is a flame until the gas is allowed in the air-gas mixture. When the heating set point is reached, only the gas from the air-gas mixture is terminated, while the fan continues to run, pushing fresh air through the burner box. Pilot Light continues to run at this stage of the heating process. A PID controller is used for heat control. This controller is sent by a thermocouple located on the upper clamshell 61. A wide range of temperatures may be achieved and controlled in this type of process. Performance for switching between fuel gases is also possible with this design. The two sets of solenoid valves are located on the burner 65b and have an adjustable orifice that allows a fixed amount of gas to enter a consistent amount of air. Natural gas mixed with air will require different air mixing ratios, so syngas will need the same air capacity. Adjustment of the fixed orifice allows switching between gases. The expansion of the penetration tube 53 is controlled by the cart support 60. The cart is composed of a heavy metal plate structure mounted between two flat bar retainers 60b welded to the frame 67. This allows the cam follower to roll on a smooth surface and prevent it from moving up and down. The cart width is only 299.72 cm (118 inches), less than the space between the flat bars 60c, hindering lateral and vertical movements, while allowing only left and right movements.

By preheating and evaporating the plastic biomass material under positive pressure and high heat, the main reactor shown in FIG. 1 is shortened by about 1219.2 cm (40 ft) and the performance that the standard reactor section would do. Get the same performance as. This reduces the expansion length of the reactor (FIG. 1) with the auger of FIG. This reduction in dimensions increases the torque in this area as the auger is shorter. The auger of the upper reactor shown in FIG. 1 is where maximum torque is required due to the large amount of liquid plastic contained inside the reactor. The further the plastic moves below the reactor shown in Figure 1, the more plastic material is converted to steam and the less work the auger has to do.

The burner box shown by 61 in FIG. 2 has two sections. This makes it possible to control the heating zone. This control is necessary to maintain the airlock effect between the start and stop of the reactor. The reactor will heat up and will begin to build pressure inside. This pressure will find a way out of the reactor. The first is a heating reactor feeder, the device that is the subject of this patent application shown in FIG. 2, and the second and third are areas where pressure can exit the system, ash / char release. Part 400 (FIG. 1) and the char separator 300 shown in FIG. The ash / char discharge unit 400 is a seal with a sliding gate that prevents steam loss. The char separator 300 shown in FIG. 3 allows steam to be removed, as described below.

The advantage of the disclosed embodiment allows the absorption of char contained in the steam emitted from the reactor. The char that the disclosed device allows for its absorption, the carbon ash, is created when the fragmented plastic entering the reactor comes into contact with the hot surface area of the reactor. The fragmented plastic comes into contact with the hot surface of the reactor so that it spreads thinly over the entire surface of the reactor and the heat from the reactor evaporates the plastic fragmented by design.

The thin layers of fragmented plastic and the contaminants contained within the fragmented plastic are left behind in the steel tubing of the reactor and vaporized into solid char, which then floats. Small particles of char, such as about 3 microns or less, become suspended and move with the fuel vapor. This char is collected by vapor and condensed into a liquid at a high concentration, turning the manufactured fuel into a substantially, in some cases, very concentrated liquid, because the char is a solid contained in the liquid. Because it is a particle. This unique carbon char is required to be removed from the fuel for the purpose of producing high quality fuel.

In one exemplary embodiment, the disclosed char separators of the present application not only address the challenges of the prior art, but substantially eliminate them, as discussed above. Turning to FIG. 3, the char separator 300 consists of a plurality of screw conveyor augers 76 extending into a vertical split tube 75 in which their respective flights are arranged to intersect each other. Will be done. The vertical split tube 75 may be considered as a support tube structure to accommodate and provide some protection to the additional structure, as described below. In one disclosed embodiment, the three screw conveyor augers 76 are utilized in a vertical split tube 75. The auger 76 may include any grade of stainless steel. The auger 76 provides a downward rotation and cleans each other from launch as their flights intersect. The hot steam exits the reactor and enters the vertical split tube 75, in which it travels upwards. The steam rises up the vertical split tube 75 and loses heat. The temperature inside the column is controlled, and therefore the preferential hydrocarbon chain vapor passes through the vertical split tube 75 and exits the vertical split tube 75 at the discharge section 73 that collects the vapor. .. The steam will rise and the temperature of the steam will drop to the value at which the high carbon chain fuel would condense, so it will be collected in the auger 76, which will push the condensed fuel back into the reactor. There will be. The temperature of the steam depends on the set point of the reactor and may vary depending on achieving the specified fuel boiling point. For example, in an exemplary embodiment, the steam set point temperature may be established at about 700F-800F. The pattern of steam flow through the char separator 300 generally follows the auger profiles of the three augers 76 as it rises through the unit before being discharged.

Condensed hydrocarbon fuels are sticky substances and may be generally classified as heavy tar with carbon particles. The vapor flowing through the vertical split tube 75 will travel across the sticky hydrocarbon fuel condensed in the auger 76, where the sticky material should be contacted by carbon ash. It will constantly search for matter and will capture carbon ash that moves with the vapor. The collected mass on the auger 76 is then forced downward into a lower reactor (eg, a separate system not shown), where it returns to thermal return of the reactor to the heating zone through the discharge flange 77. .. The collected mass is then reheated in the lower reactor of the reusable fuel system (eg, a separate system not shown) where it evaporates and breaks the high carbon chains into low carbon chains. .. The low carbon chain material will then move back and forth through the vertical split tube 75, and any carbon ash moving with it will pierce the auger 76 again and return, and any The low carbon steam will pass through the vertical split tube 75 and be released from the discharge port 73 as clean steam, for example, ultimately into the fuel cooling system. Thus, clean vapor may be routed through a distillation column and / or a condensing unit for the purpose of condensing or cooling the condensable portion of the vapor stream to return it to a liquid. The condensed liquid forms the final product of the entire process, diesel fuel carbon chain hydrocarbons.

The amount of heat that rises in the vertical split tube 75 may be controlled by both the RPM of the auger and the insulating material on the outside of the column. For example, columns may be insulated by an outer coating to prevent heat from dissipating to the surroundings. The drive system is provided to enable the auger 76 in the vertical split tube 75. The drive system may include an auger gearbox drive 68 that utilizes conduction to drive and control the auger 76. In one embodiment, the auger gearbox drive 68 utilizes spur gears to control the rotation and timing of the auger 76. By controlling the heat in the vertical split tube 75, the carbon chain hydrocarbon fuel selected by the calorific value selected will be able to pass. Steam composed of condensable and non-condensable hydrocarbons can remove carbon char by the char separator 300, because the auger 76 can be configured to rotate against the flow of steam. Is. With sufficient speed adjustment, various parameters may be achieved towards the desired point or result.

The structure of the vertical split tube 75 may consist of a plurality of split tubes. In one disclosed embodiment, the three split tubes 75 may be used to enclose the auger as a defined geometric shape, for example, the clover design of the final assembly shown in FIG. .. The shape of the clover design is utilized by the selected examples, because the augers 76 need to mesh with each other so that self-cleaning can be achieved. Although the clover design is illustrated in FIG. 3, it is easily understood that any design shape suitable for providing an enclosed support structure is optionally disclosed in the disclosed embodiment. It means that it can be used. Thus, one of ordinary skill in the art may utilize more than three augers 76 with accompanying different shapes to form an outer tube all around it. The shapes are welded together and supported by multiple outer support bands or rings 78 to maintain and retain the overall shape of the three split tube 75s, thereby causing the assembled split tube structure to heat warp. It remains intact throughout exposure to and / or due to thermal warpage.

The gearbox drive 68 may be adapted throughout / in the gearbox housing 69 to drive the screw auger 76 via a connected drive shaft of the screw auger 76. In one disclosed embodiment, the gearbox housing 69 is designed with a packing seal space or air gap 70 disposed within the gearbox housing 69, as further described below. The gearbox housing 69 may also include a support flange and a seal 71 for connecting to the discharge housing 72 detailed below.

The connecting flange 74 may be provided at one end of the vertical split tube 75. A discharge system provided as a discharge housing 72 having a corresponding mounting flange 74a at one end may be provided to be mounted on the connecting flange 74 to provide a final connection. In an exemplary embodiment, the discharge port 73 is disposed on the side surface of the discharge housing 72. Another corresponding mounting flange 71a may be provided at the other end of the discharge housing 72 to provide a final corresponding connection with the support flange of the gearbox housing 69 and the seal 71. The vertical split tube 75 may be provided at the other end with a discharge flange 77 configured for connection with, for example, another reactor (eg, a separate system not shown). The plurality of support rings 78 may be arranged at midpoints along the length of the vertical split tube 75 to provide support for it and maintain the outer shape of the vertical split tube 75. To facilitate. The inner circumference of each support ring 78 can correspond to the outer peripheral shape of the vertical split tube 75.

The thermal expansion system is provided as an expansion cart or a rotary cart 79. The expansion cart 79 may include a cam follower 80. In one disclosed embodiment, the expansion cart 79 is disposed around a section of the vertical split tube 75. In some selected embodiments, the vertical split tube 75 may be secured to an expansion cart 79 (eg, via a welded connection). As further described below, the expansion cart 79 is adopted and designed to support the char separator 300 in connection with the support structure of the reusable energy reactor system 100. In addition, while supporting the char separator 300, the expansion cart 79 follows the char separator 300 according to any thermal expansion or contraction of the support structure of the reusable energy reactor system 100 due to temperature fluctuations. Allows exercise.

Emissions are expected to exceed 500 degrees Fahrenheit and can overheat the gearbox 69. To prevent overheating of the gearbox oil, the ventilation system is provided as an air gap 70 and therefore serves as a design feature of the unit to allow ventilation. The vertical split tube 75 is attached to the lower reactor and is configured to travel or move according to any thermal expansion of the reactor and to adapt to that thermal expansion. To do so, the expansion cart or rotary cart 79 is generally disposed on top of the vertical split tube 75. The expansion cart or rotary cart 79 is further configured in a supported relationship along an external structure such as the frame of the reusable energy reactor system 100 (FIG. 1). In one exemplary disclosed embodiment, the rotary cart 79 comprises, for example, wheels received by the corresponding trucks arranged along the adaptive structure of the reusable energy reactor system 100. It is composed. The truck may include a rigid body design sufficient to accommodate the weight of the char separator 300. Since the char handler is bolted directly to the bottom reactor (expanding, contracting, or expanding due to temperature fluctuations) as the reactor expands, the rotating cart 79 responds to expansion in a defined direction. It may roll on the wheels associated with it according to any thermal expansion.

Pillars are attached to a reusable energy reactor system 100, the section of the reactor is smaller in diameter and uses a ribbon-shaped flight, allowing rapid removal of solids. At the same time, it allows steam to return through the ribbon flight. This section has a reversal with respect to the major auger located in the reactor, where the major auger pushes any dry char or heavy fuel deposit towards the char release. This section of the main reactor has two controlled heating zones, which will help reheat and pyrolyze the high carbon chains pushed back into the main reactor by the char separator 300.

The disclosed design advantages provide a modular structure for rapid factory assembly and rapid installation. The disclosed examples allow for easy maintenance in the art. The disclosed modular design can be fully assembled and tested in the factory.

Although many embodiments of the present invention have been described in detail, it will be clear that modifications and modifications can be made without departing from the scope of the invention as defined in the appended claims. It means that there is. Also, it should be understood that all of the examples in the present disclosure are provided as non-limiting examples, exemplifying a number of embodiments of the invention, thus limiting the various aspects so illustrated. It should not be interpreted as a thing.

All documents, patents, journal articles, and other materials cited in this application are incorporated herein by reference.

The present invention has been disclosed with reference to certain examples, but numerous modifications, changes, and changes to the described examples are defined in the appended claims. It is possible without departing from the scope and scope of the invention. Therefore, it is intended that the present invention is not limited to the embodiments described, but has a complete scope defined by the language of the claims and its equivalents.

Claims (1)

Support body (75) and
A plurality of augers (76) arranged inside the support body, and
A drive system (68) connected to drive and control the plurality of augers.
The discharge system (72) connected to the support body and
A gearbox housing (69), the gearbox housing (69) comprising a ventilation system (70) between an upper portion, a lower portion, and the upper portion and the lower portion, wherein the lower portion is the same. Connected to the drainage system (72), the lower portion is housed in the gearbox housing, and the ventilation system (70) is entirely disposed within the structure of the gearbox housing and the gearbox housing. Housing (69) and
A device for processing reusable fuel, including a thermal expansion system (79) coupled to the support body.

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