CN116997636A

CN116997636A - Thermal cracking of organic polymeric materials using gas-liquid and solid-liquid separation systems

Info

Publication number: CN116997636A
Application number: CN202180094983.8A
Authority: CN
Inventors: 杰里米·J·德贝内迪克蒂斯; 斯坦利·G·普赖贝拉; 多米尼克·O·罗塞斯; 斯科特·M·萨斯; 尼古拉斯·A·万苏克
Original assignee: Altra Energy Co ltd
Current assignee: Altra Energy Co ltd
Priority date: 2021-03-05
Filing date: 2021-08-12
Publication date: 2023-11-03

Abstract

The present application provides systems and related methods for processing organic polymeric feed materials, such as plastics, to form pyrolysis oils. The disclosed system can be operated in a continuous manner and utilize novel liquid-solid separation techniques integrated with novel condensing processes to operate in a product efficient and energy efficient manner.

Description

Thermal cracking of organic polymeric materials using gas-liquid and solid-liquid separation systems

Cross-reference to related applications

The present application claims the priority and benefit of U.S. patent application Ser. No. 63/157,316, "organic polymer material processing and related product separation" (Organic Polymeric Materials Processing And Related Product Separation) (2021, 3, 5, submission), U.S. patent application Ser. No. 63/157,371, "thermal cracking System for processing organic polymer materials" (Thermal Cracking Systems For Processing Organic Polymeric Materials) (2021, 3, 5, submission), U.S. patent application Ser. No. 63/157,391, "condenser System for processing organic polymer materials" (Condenser Systems For Processing Organic Polymeric Materials) (2021, 3, 5, submission), U.S. patent application Ser. No. 63/157,414, "liquid-solid separation System for processing organic polymer materials" (2021, 3, 5, submission), and U.S. patent application Ser. No. 63/193,669, "spray gun seal assembly and related method" (Lance Seal Assemblies and Related Methods) (2021, 3, 27, submission). The entirety of the above-mentioned application is incorporated herein by reference for any and all purposes.

Technical Field

The present disclosure relates to the field of processing organic polymeric materials to form hydrocarbonaceous products, and also to the field of liquid-gas separation and liquid-solid separation.

Background

While there is considerable interest in industry in converting polymer waste into condensable, non-condensable and solid hydrocarbon products, existing such processes exhibit a number of inefficiencies and shortcomings. In particular, existing processes appear to be incapable of continuous operation, and their inability to operate continuously is generally related to the inability of existing processes to effectively process solid products (e.g., char) produced in such processes. Accordingly, there is a long felt need in the art for improved processes for converting polymer waste into condensable, non-condensable and solid hydrocarbon products.

Disclosure of Invention

In order to meet the above-mentioned long-standing need, the present disclosure provides, inter alia, a system for converting an organic polymeric material into a hydrocarbonaceous material, the system comprising: a thermal cracking train configured to molecularly crack polymeric material fed to the thermal cracking train; a condensing train configured to receive thermal cracking products from the thermal cracking train and condense at least a portion of the thermal cracking products to produce pyrolysis oil products from the thermal cracking products; and a separation train configured to receive a first liquid comprising solid material and the pyrolysis oil products from the condensation train, the separation train configured to separate at least some of the pyrolysis oil products from the first liquid.

The present invention also provides a process comprising operating a system according to the present disclosure (e.g., according to any one of aspects 1-12) to convert a polymeric material to char, gas, and pyrolysis oil products, the process optionally being carried out continuously.

The invention also discloses a method, which comprises the following steps: performing thermal cracking of the polymeric material to produce thermal cracking products and char; optionally devolatilizing and collecting at least some of the char; condensing at least a portion of the thermal cracking product to produce (1) a first liquid comprising at least some of the char and pyrolysis oil products, and (2) a first overhead comprising at least some of the pyrolysis oil products; separating at least some of the pyrolysis oil product from the first liquid; condensing a portion of the first overhead to produce (1) a second liquid comprising the pyrolysis oil product, and (2) a second overhead; and collecting the second liquid.

The invention also provides a thermal cracking process train comprising: a rotary kiln reactor; the rotary kiln reactor configured to receive an organic polymer feed material, the rotary kiln reactor defining at least one interior wall defining an interior volume of the rotary kiln reactor, the interior volume defining an inlet and an outlet along a direction of travel of the organic polymer feed material, the rotary kiln reactor comprising a section containing one or more purging features configured to purge a portion of the at least one interior wall as the rotary kiln rotates, the rotary kiln comprising a section containing one or more lifting features extending from the at least one interior wall and configured to urge material disposed on the one or more features into the interior volume of the rotary kiln reactor interior as the rotary kiln reactor rotates; a burner configured to provide heated gas to the rotary kiln reactor, the burner optionally configured to receive and combust uncondensed hydrocarbon-containing vapors; and a devolatilizing component train optionally comprising a first valve, a holding chamber, and a second valve, the first valve configured to interrupt fluid communication between the interior volume of the rotary kiln reactor and the holding chamber, and the second valve configured to interrupt fluid communication between the holding chamber and an environment outside the holding chamber.

The invention also provides a method comprising: operating a thermal cracking train according to the present disclosure (e.g., in accordance with any of aspects 22-37) to produce a thermal cracking product and char, optionally devolatilizing and collecting at least some of the char, and optionally conveying the cracking product to one or more condensers.

The invention also discloses a method, which comprises the following steps: effecting transfer of an organic polymer feed material within a rotary kiln reactor having at least one interior wall, exposing the organic polymer feed material to two or more different temperature zones within the rotary kiln reactor, at least one of the two different temperature zones effecting thermal cracking of the organic polymer feed material into (1) thermal cracking products comprising pyrolysis oil products and (2) char; at least partially devolatilizing the char to produce a first devolatilized char; collecting at least some of the first devolatilized char in a holding chamber; optionally interrupting fluid communication between the holding chamber and the rotary kiln reactor; further devolatilizing at least some of the first devolatilized char in the holding chamber to produce a second devolatilized char; collecting the char of the second devolatilization component.

Furthermore, the present invention provides a condensing train comprising: a first condenser configured to condense a first liquid comprising pyrolysis oil products from feed vapor provided to the first condenser, the first condenser optionally configured as a downflow condenser; a second condenser in fluid communication with the first condenser, the second condenser configured to receive a first overhead from the first condenser, the second condenser configured to condense a second liquid comprising the pyrolysis oil product from the first overhead; and an optional third condenser in fluid communication with the second condenser, the third condenser configured to receive a second overhead from the second condenser, the third condenser configured to condense a third liquid comprising pyrolysis oil products from the second overhead.

The invention also provides a method comprising: delivering a feed comprising vapor comprising pyrolysis oil products to a first condenser, optionally a downflow condenser; operating the first condenser so as to produce a first liquid comprising the pyrolysis oil product and a first overhead comprising the pyrolysis oil product; recycling at least some of the first liquid to the first condenser; said first overhead is passed to a second condenser; operating the second condenser so as to produce a second liquid comprising the pyrolysis oil product and a second overhead comprising the pyrolysis oil product; said second overhead is passed to a third condenser; and operating the third condenser to produce a third liquid comprising the pyrolysis oil product and a third overhead comprising uncondensed material.

The invention also discloses a separation group column, which comprises: a separation module configured to receive a feed material comprising char and pyrolysis oil products, optionally from a condenser, the separation module operable to separate the char and pyrolysis oil from each other; a receiving line configured to receive pyrolysis oil products from the separation module.

The invention also provides a solid-liquid separation method, which comprises the following steps: introducing a feed comprising pyrolysis oil product and char to a separation module, performing separation of the pyrolysis oil product and char fluid from each other using the separation module; collecting the char; and collecting at least some of the pyrolysis oil product.

The present disclosure also provides an operating device comprising: a first compartment; a second compartment; a conduit extending through the first compartment and into the second compartment, the conduit being at least partially surrounded by a conduit jacket, the conduit jacket defining an outer diameter, the conduit fluidly connecting the second compartment with an environment outside the compartment, the second compartment comprising a wall facing the conduit jacket, and the second compartment being rotatable relative to the first compartment; a seal defining a boundary between the first compartment and the second compartment, the seal extending radially from a wall of the second compartment toward the conduit jacket, the seal comprising a first flange secured to and extending from a wall of the second compartment, the first flange defining an inner diameter, (a) the seal comprising a layered portion comprising a plurality of annular portions, an inner diameter of at least one of the annular portions being less than an outer diameter of the conduit jacket such that the at least one annular portion rotatably abuts the conduit jacket, an outer diameter of the conduit jacket optionally being no more than about 1.25cm greater than an inner diameter of the at least one annular portion, or (b) the seal comprising a brush rotatably abutting the conduit jacket.

Related methods of using the disclosed operating device are also provided.

Drawings

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, and not by way of limitation, various aspects discussed in the present document. In the drawings:

fig. 1 provides a depiction of an exemplary system according to the present disclosure.

FIG. 2 provides a cross-sectional view of a process module according to the present disclosure; and is also provided with

Fig. 3 provides a cross-sectional view of a seal according to the present disclosure.

Detailed Description

The present disclosure may be understood more readily by reference to the following detailed description of the ideal embodiments and the examples included therein.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In the event of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

No specific number of a reference includes a plurality of references unless the context clearly dictates otherwise.

The term "comprising" as used in the present specification and claims may include embodiments consisting of and consisting essentially of … … and … …. The terms "comprising," "including," "having," "can," "containing," and variations thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the noted elements/steps and allow the presence of other elements/steps. However, this description should be construed as also describing a composition or process consisting of and consisting essentially of the recited components/steps, which allows for the presence of only the recited components/steps and any impurities that may result therefrom, as well as the exclusion of other components/steps.

The terms "about" and "equal to or about" as used herein mean that the amount or value in question may be some other approximation or substantially the same value as the specified value. As used herein, it is generally understood that unless otherwise indicated or inferred, it is a variation of ±10% from the nominal value indicated. The terms are intended to express the meaning that similar values promote equivalent results or effects recited in the claims. That is, it should be understood that the amounts, dimensions, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximated and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, as well as other factors known to those of skill in the art. Generally, amounts, dimensions, formulations, parameters, and other amounts and characteristics are "about" or "approximately", whether or not explicitly stated as such. It is to be understood that where "about" is used before a quantitative value, the parameter also includes the particular quantitative value itself, unless specifically stated otherwise.

Unless indicated to the contrary, numerical values should be understood to include numerical values which, when reduced to the same number of significant figures, differ from the stated numerical values by less than the experimental error of the conventional measurement technique type described in the present application to determine the value.

All ranges disclosed herein are inclusive of and independent of the recited endpoints (e.g., "2 grams to 10 grams and all intermediate values" is inclusive of 2 grams, 10 grams, and all intermediate values). The endpoints of the ranges and any values disclosed herein are not limited to the precise range or value; they are sufficiently imprecise to include values approximating these ranges and/or values.

Approximating language, as used herein, may be applied to modify any quantitative representation that could vary without resulting in a change in the basic function to which it is related. Thus, in some cases, a value modified by one or more terms such as "about" and "substantially" may not be limited to the precise value specified. In at least some cases, the approximating language may correspond to the precision of an instrument for measuring the value. The modifier "about" should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression "about 2 to about 4" also discloses a range of "2 to 4". The term "about" may refer to plus or minus 10% of the indicated number. For example, "about 10%" may mean a range of 9% to 11%, and "about 1" may mean 0.9-1.1. Other meanings of "about" are apparent from the context, e.g., rounded, so that, for example, "about 1" may also mean 0.5 to 1.4. Furthermore, the term "comprising" should be understood to have an open meaning of "including", but the term also includes a closed meaning of the term "consisting of … …". For example, the composition comprising components a and B may be a composition comprising A, B and other components, but may also be a composition made of only a and B. Any documents cited herein are incorporated by reference in their entirety for any and all purposes.

Polymer processing and hydrocarbon products

Condensable hydrocarbon products include, for example, synthetic petroleum and its various fractions including, but not limited to, light low sulfur crude oil, fuel additives, base oils, slack wax, paraffin wax, microcrystalline wax, and aromatic petroleum hydrocarbon-based condensate. The non-condensable hydrocarbon product is a gas. The solid hydrocarbon product comprises finely divided char.

For many years, there has been a search for the conversion of waste polymers (such as plastics) into useful end products by pyrolysis. Existing processes typically rely on batch, semi-batch, or continuous batch processes, which are limited by their complexity and inability to operate in a continuous manner without fouling. Some have attempted to address this unmet need by employing a serial batch process comprising a series of batch reactors operated stepwise in a set sequence, but this approach is inefficient and requires continued attention from the operator.

The polymer conversion process includes a primary process of chemical depolymerization, partial oxidative gasification, and thermal cracking (including pyrolysis with or without catalytic cracking and reforming), and a secondary process of hydrogenation.

Chemical depolymerization is mainly limited to the decomposition of polyesters such as PET and polyurethane, and secondarily to polyamides, polycarbonates and polyacetals. This process is generally limited to the decomposition of condensation polymers and aims at monomer yields.

Gasification and partial oxidation of waste polymers is generally intended to produce a mixture of carbon monoxide and hydrogen (commonly referred to as synthesis gas). Although partial oxidation may be a more efficient process than steam methane reforming in terms of reactor size and process rate, the hydrogen yield produced by partial oxidation is relatively low. Few, if any, condensable hydrocarbons are produced.

Thermal cracking processes employ thermal decomposition, resulting in complex mixtures. The reaction temperature and the retention time of the molecules in the respective desired temperature range are the most important reaction variables affecting the polymer conversion and the molecular distribution of the converted product. Therefore, effective control of the reaction temperature and residence time is critical to maximize the yield of the desired product mixture. Batch, semi-batch, and continuous batch processes encounter difficulties in efficiently achieving and maintaining control of reaction temperature and residence time due to problems such as inefficient heat transfer through the waste polymer, which exhibits poor thermal conductivity. Unlike continuous processes that achieve dynamic process equilibrium to maintain control of reaction temperature and residence time, batch, semi-batch, and continuous batch processes are continually in an unbalanced state, presenting long-term control challenges for each process cycle and sharp problems of reactor fouling. Other variables including catalyst are optimization factors; while catalytic cracking and reforming offer the advantage of decomposing polymers at lower temperatures and higher rates and increase control over product quality, catalytic cracking presents challenges including process complexity, deposition of active-impeding residues, catalyst poisoning, high capital and operating costs of catalyst reactors, and disposal costs of spent catalyst.

Hydrogenation is a fundamental step in petroleum refining and petrochemical production and has been applied to the secondary processing of oils produced by thermal cracking processes. This secondary process is typically combined with distillation for the production of petroleum-based fuels and process fractions requiring hydrogen saturation of olefins and removal of heteroatoms. The term "heteroatom" is understood to mean any atom that is not carbon or hydrogen and has been used to denote that a non-carbon atom has been substituted for a carbon in the molecular structural backbone or for a hydrogen or alkyl group bonded to the molecular structural backbone. Typical heteroatoms are nitrogen, oxygen, sulfur, phosphorus, chlorine, bromine, fluorine and iodine. Hydrogenation is a secondary process used in petroleum refining and petrochemical production. Hydrogenation is capital intensive and can have high operating costs due to high pressure operation, hydrogen costs, costs of waste heat removal, and other factors.

Existing systems involving pyrolytic decomposition of polymers have not achieved widespread acceptance or success due to high operating costs, inability of the system to continuously process contaminated waste streams and waste streams of varying composition, prohibitive or lacking market availability of uncontaminated raw material streams, inability to reliably and efficiently control temperature and pressure process conditions, inability to continuously provide adequate amounts of off-specification raw materials to plants requiring large amounts of materials to remain operational, inability to control fouling of the system by char, terephthalic acid, benzoic acid, minerals, metals, etc., attempts to produce fuels having relatively narrow market-driven specification ranges from widely varying raw material compositions, inability to control heteroatom content of the finished oil, thereby limiting product market acceptance, inability to continuously and effectively manage safety issues arising from worker exposure to hazardous vapors and solids in each batch reactor cycle and the generation of hazardous waste (including but not limited to char, wastewater and non-specification hydrocarbon-containing liquids).

More specifically, batch or semi-batch processes must overcome the challenges of thermal inefficiency to facilitate conversion. Given that polymer waste has poor thermal conductivity, batch reactor systems typically rely on some arrangement of mixing elements within the reactor or complex arrays of raw material containing drums placed in batch reactors or concentric tubular devices containing raw materials subjected to thermal energy or tubular heat transfer geometries deployed within the batch reactor body, etc., in order to increase the raw material surface area and thus the surface exposure to thermal energy that would otherwise be poorly transported through the less thermally conductive material. Complex mechanical and/or geometrical solutions to these limitations are inherent to batch reactors.

In addition, most, if not all, batch reactors, whether alone or in series, must be charged with hydrocarbonaceous feedstock, purged of oxygen-containing atmosphere, heated to the desired temperature upon extraction of product vapors, and then cooled to a temperature below the flash point of the residual solids in order to remove them. The repeated thermal cycles experienced by these systems have poor thermal efficiency, which in turn results in excessive energy consumption to complete the polymer conversion. The presently disclosed technology seeks to at least partially address the shortcomings of existing approaches.

Drawings

The following description of the drawings is merely illustrative and does not limit the scope of the disclosure or the appended claims.

Fig. 1 provides a depiction of an exemplary system 100 in accordance with the present disclosure. For convenience, the element numbers of FIG. 1 are provided below

100-System

102-feed (e.g., organic polymeric material)

104-additives (optional; which may be, for example, oxides, hydroxides and/or carbonates of group 1 elements; oxides, hydroxides and/or carbonates of group 2 elements; and/or oxides, hydroxides and/or carbonates of group 8 elements, for example CaO, ca (OH) ₂ 、CaCO ₃ 、NaOH、KOH、Fe ₂ O ₃ And FeO

106-feeding to an extruder

108-extruder

110-feeding to Rotary kiln reactor

112-rotary kiln reactor

114-flue gas leaving a rotary kiln reactor

115-pyrolytic carbon outlet

116-devolatilization array

118-pyrolytic carbon

120-feed to a first condenser (also referred to as "thermal cracking feed" or "thermal cracking product" in some cases)

122-first condenser (also referred to in some cases as "direct contact condenser")

124-feeding the second condenser (the overhead from the first condenser, also referred to in some cases as "first overhead")

126-second condenser

128-second liquid

130-feeding a third condenser (overhead from the second condenser, also referred to in some cases as "uncondensed second overhead")

132-third condenser

134 a-overhead from the third condenser (also referred to in some cases as "uncondensed light products")

134 b-condensate from the third condenser (light products, also referred to in some cases as "condensed light products")

136-vapor reduction series (gas-liquid separation tank, seal tank, demister)

138-uncondensed materials (e.g. synthesis gas)

140-Synthesis gas to flare

142-synthesis gas to burner

144-first liquid (liquid from first condenser)

146-first liquid recycled from first condenser

148-feed to separation train

150-liquid-solid separation array

152-control input to split group column

154-information output from separate group columns

156-solids from separation train (e.g. char)

158-pyrolysis oil from separation train

160-pyrolysis oil product

As shown in FIG. 1, in system 100, a feed 102 and optional additives 104 (e.g., inorganic additives such as oxides, hydroxides, and/or carbonates of group 1 elements, oxides, hydroxides, and/or carbonates of group 2 elements, and/or oxides, hydroxides, and/or carbonates of group 8 elements, e.g., caO, ca (OH) ₂ 、CaCO ₃ 、NaOH、KOH、Fe ₂ O ₃ And FeO) is provided to an extruder 108 via feed stream 106. Without being limited by any particular theory or embodiment, the additive (or additives) may be present in the material fed to the extruder 108 in an amount of up to about 5 wt.% relative to the weight of the feed 102.

Without being limited to any particular theory or embodiment, the feed 102 may include, but is not limited to, thermoplastic and/or thermoset plastics, elastomers (e.g., scrap tires, rubber residue, rubber tape, EPDM rubber sheet, film or extrudate), wire casing (insulation), and the like. The feed is not required to be free of impurities; for example, the feed may include a non-polymeric material. Exemplary feed materials are PCR (post consumer residue) containing >70% polyolefin (composed of various types of polyethylene and some polypropylene), some other non-polyolefin polymers, very low PET, very low PVC and some contaminants (fillers, additives, external contaminants such as dust, fibers (paper, cardboard, etc.), etc. the feed materials may also be post industrial waste, which is often a well-characterized plastic mixture, such feeds may be recyclable, but this is not required.

Extruder 108 may operate to combine feed 102 and additives (when present) and may then transfer the material to rotary kiln reactor 112 via transfer path 110 (which may be a pipe or other conduit). Exemplary rotary kiln reactors are also described elsewhere herein, for example in fig. 2, 3, and aspects 91-119. It should be appreciated that gases (e.g., nitrogen, other inert gases) may be introduced into the transfer path 110, although this is not required.

The extruder may be configured to subject the feed to one or more of, for example, compression, dewatering, shearing, melting, destabilization, and dehalogenation, before the feed is delivered to the rotary kiln reactor 112.

The rotary kiln reactor 112 may be, for example, a rotary kiln reactor that can rotate in either direction. The rotary kiln reactor 112 is operable to have one temperature zone within the reactor, but in some embodiments the rotary kiln reactor 112 is also operable to have multiple temperature zones within the reactor. As a non-limiting example, a rotary kiln reactor may contain heaters at different locations along the length of the reactor that are operated to create zones of different temperatures within the reactor. For example, the rotary kiln reactor may define three zones along its length, a first zone having a temperature of about 400 ℃ to about 425 ℃, a second zone having a temperature of about 450 ℃ to about 475 ℃, and a third zone having a temperature of about 500 ℃ to about 525 ℃.

The rotary kiln reactor may also be configured with an external manifold that receives a heated fluid, such as heated air or other gas. The manifold then distributes the gas to different compartments located outside the reactor and along the length of the reactor. The heated fluid may be dispensed such that different compartments are heated to different temperatures, for example, a first compartment is heated to a temperature of about 400 ℃ to about 450 ℃, a second compartment is heated to a temperature of about 450 ℃ to about 500 ℃, and a third compartment is heated to a temperature of about 500 ℃ to about 550 ℃. The rotary kiln reactor may include a control system configured to achieve and maintain a preset temperature at certain locations within the rotary kiln reactor. In this way, the rotary kiln reactor is operable to achieve different temperatures in different locations along the length of the rotary kiln reactor, which in turn allows the rotary kiln reactor to operate as needed to accommodate different feed materials.

In one embodiment, hot gases from a burner (not shown) are introduced through a manifold to a muffle (which may be a ceramic lined outer tube containing hot gases and allowing the gases to rotate around the interior compartment of the rotary kiln reactor) surrounding the reactor tubes within the rotary kiln reactor 112. There may be a conduit for hot gas to enter the inlet manifold of the muffle and then feed the gas to one or more other conduits for the hot gas to continue to the muffle. A second manifold (exhaust manifold) may be present above the first manifold for exhausting hot gases from the muffle. The second manifold may include a duct exiting the muffle that transitions to a larger duct leading to the exhaust fan and the exhaust stack.

The zone may be defined by a refractory material (e.g. in the form of a ring) arranged between and surrounding the muffle and the interior compartment of the rotary kiln reactor. There may be one zone or multiple (e.g., 2, 3, 4, 5, 6) zones, and each zone may be fed (and discharged) from one or more pipes from the inlet manifold (and one or more pipes from the exhaust manifold). The areas need not be equal in length, but may be equal. In such embodiments, the temperature of the rotary kiln reactor (the amount of total energy provided to the rotary kiln reactor) may be adjusted by the burner temperature (which in turn may be a function of the flow rate of natural gas or other fuel to the burner) and the rate of delivery of heating fluid from the burner to the rotary kiln reactor. Additional air may be added to increase the velocity of the hot air entering the muffle and/or rotary kiln reactor.

The temperature of the various zones may be controlled in a variety of different ways. In one embodiment, the temperature zones closest to the rotary kiln reactor outlet may be the hottest of these zones and may have a temperature set by the burner exhaust temperature and hot gas flow rate. Once the temperature of the zone is set, the dampers of the other zones can be adjusted to allow ambient air to control (lower) the temperature of each zone.

As a non-limiting example, a rotary kiln reactor may define 4 temperature zones from its inlet to its outlet. The temperature of the first zone (closest to the inlet) may be about 315 ℃ to about 593 ℃, the temperature of the second zone may be about 482 ℃ to about 593 ℃, the temperature of the third zone may be about 482 ℃ to about 593 ℃, and the temperature of the fourth zone (closest to the outlet) may be about 537 ℃ to about 704 ℃.

The temperature of each zone in the rotary kiln reactor may be configured to perform different treatments on the material fed to the rotary kiln reactor. As a non-limiting example, the first zone may be configured to effect melting of material fed to the rotary kiln reactor; the first zone may also be configured to effect initial cracking of the feed material. The second zone may be configured to initiate cleavage of olefinic material present in the reactor. The third zone may be configured to effect devolatilization, e.g., to drive off volatiles therein. These volatiles may be vented through vents in fluid communication with the interior of the reactor; the volatiles may be delivered to a condenser. The fourth zone may be configured to effect devolatilization of the char.

Without being limited by any particular theory or implementation, excessive temperatures may excessively crack the polymer (e.g., plastic) material being processed and may release excessive gases. Too low a temperature may not crack all of the plastic and the molten plastic will leave with the char. Also without being limited by any particular theory or embodiment, when the plastic is fed to the rotary kiln reactor at a higher rate (determined by the extruder), a higher temperature may be required to process the plastic and avoid the molten plastic from exiting the rear of the rotary kiln reactor. In contrast, when plastic is fed to the rotary kiln reactor at a lower rate (during testing or warming), the temperature may be slightly lowered.

As shown in fig. 1, the rotary kiln reactor 112 may be heated by a heating fluid (e.g., hot air or other gas) supplied by a burner (not shown). The combustor may also be supplied with syngas or other uncondensed products 142 from other areas of the system 100. One or more heating elements may be provided near, above or even inside the kiln in order to supply heat to the kiln.

The rotary kiln reactor 112 may be oriented such that the rotary kiln reactor is horizontal, but this is not required. The rotary kiln reactor may be inclined such that it is negatively inclined or sloped, i.e. lowered, with respect to the horizontal so that the inlet end of the rotary kiln reactor is at a higher elevation than the outlet end of the rotary kiln reactor, thereby allowing gravity to assist in transporting partially decomposed material through the lowered thermal rotary kiln reactor; the internal components of the thermal rotary kiln reactor can also be configured to facilitate transport in conjunction with gravity. The negative inclination may deviate from the horizontal by between about 1 ° and about 20 °, a negative inclination from the horizontal of between about 1.0 ° and about 6 ° being particularly suitable. The rotary kiln reactor 112 may also be oriented or tilted in an opposite or positive tilt direction, such as when the internal components of the rotary kiln reactor 112 are configured to physically propel the feed material against gravity through rotation of the rotary kiln reactor. The positive tilt may be between about 1 deg. to about 20 deg. from the horizontal, with a preferred positive tilt being about 1.0 deg. to about 6 deg. from the horizontal. The rotary kiln reactor can be angled, for example, from about-20 deg. (declination) to about +20 deg. (inclination) with respect to horizontal.

The rotary kiln reactor may be configured such that materials communicated to the rotary kiln reactor undergo one or more of mixing, molecular destabilization, and pyrolysis.

The rotary kiln reactor may be operated such that the internal reactor temperature ranges from about 232 ℃ (450°f) to about 704 ℃ (1300°f) for the blend of raw materials introduced into the rotary kiln reactor, and is at an in situ derived reactor pressure, typically at a micro vacuum (e.g., less than 5 inches of water) or at about 1 atmosphere. The residence time of the raw material (feed) is, for example, about 30 minutes to about 90 minutes. Without being limited by any particular theory or example, the lack of oxygen coupled with the high temperatures within the desired residence time results in various pyrolysis reactions, controlled by higher order reaction kinetics, occurring that decompose the polymeric material into volatile vapor and char materials. The vapor stream consists essentially of vapor, but may also contain aerosol liquid and condensable molecules. The vapor stream is subjected to further downstream processing (described elsewhere herein) wherein condensable and non-condensable vapors are separated. The condensable vapors may form liquids including oils, light sweet crude oils, fuel additives, and base oils. The heavier fractions may form solid products, for example in the form of waxes. Non-condensable vapors or gases are recovered and may optionally be sent to a generator set to generate electricity. As an illustrative example, the feed may be subjected to a residence time in the kiln of about 30 to about 90 minutes across all areas of the kiln. The feed may have a residence time of about 10 to about 30 minutes in the first zone of the kiln (e.g., placing the feed in molten plastic form). The feed may then have a residence time of about 10 to about 30 minutes in the second zone of the kiln (e.g., such that the second zone effects pyrolysis of the plastic in the feed). The feed may then have a residence time of about 10 minutes in the third zone of the kiln (e.g., to achieve vapor/liquid form) and then about 5 minutes in the fourth zone of the kiln (e.g., to provide vapor and to dry solids). The foregoing residence time and description are merely illustrative and do not limit the present disclosure.

The rotary kiln reactor may have an internal compartment of constant cross-section (e.g. a cylindrical or tubular compartment), but such constant cross-section is not required. As one example, a rotary kiln reactor may have compartments that narrow, taper or otherwise define a variable or non-constant cross-section along its length. For example, a rotary kiln reactor may have compartments defining an inner diameter of about 2 meters along 70% of the length of the interior compartment, which then narrows to an inner diameter of about 1 meter along the last 30% of its length. In certain embodiments, the rotary kiln reactor may include an auger or other module to transport char or other materials within the rotary kiln reactor. As an example, in a rotary kiln reactor defining a cross section narrowing from 2 meters to 1 meter, the rotary kiln reactor may include an auger for helping to move material from the wall of the rotary kiln reactor at the region of 2 meters in diameter to the wall of the rotary kiln reactor at the region of 1 meter in diameter.

The final yield of condensable hydrocarbons and the relative mass balance of oil, gas, char, and inorganic residues are affected by several factors. These factors include, but are not limited to, operating temperature, the geometry of the rotary kiln reactor and feedstock throughput interactions, residence time required for the pyrolysis reaction to complete, the desired degree of completion of the reaction, raw material composition, and product recovery. The geometry of the rotary kiln reactor may vary with a variety of factors including, but not limited to, the length of the compartments of the hot rotary kiln reactor, the diameter of the rotary kiln reactor, the internal design of the rotary kiln reactor, and the rate of mass loss through vapor escape and venting.

Operation of the rotary kiln reactor can result in significant loss of feed material quality as continuously advancing feed material is pyrolyzed and vapors are vented from the reactor. The rotary kiln reactor may operate as a boiler in which the feed material being pyrolyzed presents a boiling and dynamic transition interface for vapors above the feed material that is not completely pyrolyzed. The transition surface evolves as it boils under dynamic equilibrium conditions until the feed material is effectively pyrolyzed, leaving behind solid char material and any incompletely pyrolyzed feed material. As pyrolysis proceeds to completion, there is a concomitant change in the viscosity of the feed material in the reactor.

Where accelerated removal of product vapors is desired, and depending on the desired product mixture, a non-condensable carrier gas may be introduced into the rotary kiln reactor. The optional addition of carrier gas results in a proportional increase in the vapor flow rate exiting the rotary kiln reactor. Such non-condensable carrier gases may consist of, for example, nitrogen and/or recycled non-condensable gas fractions resulting from the operation of the present invention and/or methane from natural gas or any blend of these non-condensable gases. The use of recycle gas and/or methane as a nitrogen substitute for the carrier gas has the advantage of increasing the BTU content of the process gas produced without the need for nitrogen dilution, as well as reducing operating costs by eliminating the need to purchase or produce nitrogen. Depending on the raw material composition and the range of operating conditions, this aspect of the disclosure may also result in the unexpected benefits of increased oil production, the unexpected benefits of slightly increased hydrogen concentration of the reactor atmosphere in the pyrolysis environment, and the unexpected improvements in hydrogen concentration of the resulting process gas.

Char formed in rotary kiln reactor 112 may exit rotary kiln reactor 112 through line 115. The char may then be processed through a pneumatic valve assembly 116 (also referred to as a "drying train" or "devolatilization train" or "dual dump valve" in some cases). Without being limited to any particular theory or implementation, the pneumatic valve assembly 116 may include a first valve, a holding chamber, and a second valve. It should be understood that "devolatilizing" may include removing volatile materials.

The char may initially be placed on top of the first valve where the char may be devolatilized by applying heat within the rotary kiln reactor. The first valve may be actuated so that char enters the holding chamber, for example by gravity. (the first valve may then be closed). While in the holding chamber, a heated fluid (e.g., a gas such as nitrogen; such gas may be heated) may be introduced to further devolatilize the char. After exposure to the heated fluid, the second valve may be opened and then the devolatilized char exits the holding chamber and communicates via char outlet line 118. Some char may be entrained in the vapor within the rotary kiln reactor 112, which then exits the rotary kiln reactor in the feed 120. Without being limited to any particular theory or implementation, a gas (e.g., nitrogen or other inert gas) may be introduced at the feed 120 into the vapor and gas transported from the rotary kiln reactor 120.

The char exiting the kiln reactor may include three components:

1. calcium oxide (or other additives) and calcium compounds, e.g. CaCl ₂ 、Ca(OH) ₂ CaS, etc.

2. Metals and inorganic materials that may be present as external contaminants of the filler and/or feedstock.

3. In situ carbon generated during pyrolysis.

In one exemplary embodiment, the polymer materials carrying 1 and 2 (above) enter the kiln as a molten mass and are conveyed through the kiln at elevated temperatures, for example, from about 480 ℃ (inlet) to about 593 ℃ (outlet). The kiln may be at a slight inclination (1 degree) so that gravity assists in transporting the molten plastic. Carbon (3, above) is formed when the plastic decomposes to form (condensable) vapor and (non-condensable) gas. The carbon is combined with 1 and 2 (above) to form char. The completion of the plastic decomposition may occur along a path of about 1/2 to 2/3 of the length of the kiln.

The molten mass is propelled forward by a sweeping chain and a drag chain within the reactor. The reactor wall is kept clean by means of a sweeping chain and a dragging chain. The thermal contact between the walls of the reactor and the molten plastic is improved by using a drag/sweep chain, which allows the contact surface to be continuously updated.

The chain provides motive force for advancement, while the dykes provide a barrier or limit for advancement. The balance between the chain and the dykes may provide an optimised forward movement (and thus an optimised residence time) of the molten plastic in the heating kiln. In the current system configuration, the height of the dike is minimal.

When the plastic mixture is cracked and forms vapor/gas, the char (as a whole) may be saturated with gas/vapor. To aid the char drying process, a lifter is placed at the rear 1/3 of the kiln. The lifter may be an inverted angle iron welded to the inner wall of the kiln. They are placed in the best mode to provide the greatest movement of char rather than producing significant high shots of char in the kiln volume. The char suitably leaves the kiln in a dry state and remains dry. The vapor suitably exits the kiln in a moist state with minimal char entrainment.

As the char dries at the relatively hot exit zone of the kiln, it can be received by a triple start screw conveyor, which may be a short "screw" conveyor mechanism for capturing/transporting the char out of the kiln. When the char leaves the triple start screw conveyor, it lands on the top flap valve of the double dump flap valve assembly and is temporarily held there. After a period of time (e.g., about 30 seconds), the valve is opened for a few seconds, during which time char flows from the top flap valve to the bottom flap valve. When the top flap valve is closed again, the char is now located between the two valves. Pressurized, heated nitrogen may be introduced between the flap valves and forced back into the kiln. This helps to keep the char dry. The nitrogen moving backwards helps to prevent hydrocarbons from moving forward. After a period of time (e.g., about another 30 seconds), the lower flap valve is opened for a few seconds and then closed again. Equal portions of char located between the two flap valves do not enter the char cooling screw.

The double dump flap valve assembly (shown and described herein) can be heated to, for example, about 482 c, insulated from the outside, and purged internally with hot nitrogen (e.g., about 482 c). The purpose of the double flap valve assembly is to move the char forward to the cooling screw assembly, which can reduce the temperature of the char (e.g., from 482 ℃ to about 49 ℃) without allowing air to diffuse back into the kiln and without allowing condensable hydrocarbon vapors from the kiln to escape into the char.

The principle of operation of the double-flap valve assembly is therefore as follows:

1. upper and lower flap valve sequence, opening interval time and opening time.

2. The sequence of nitrogen between the valves was used for purging and drying.

As shown, vapors and gases from the rotary kiln reactor 112 are delivered to a first condenser 122 (also referred to as a "direct contact condenser" in some cases) as a feed 120 to the first condenser. In certain embodiments, the first condenser 122 may be a downflow condenser. As shown, the first condenser is operable to condense at least a portion of the first condenser feed 120 into a first liquid 144, which may include char. (char is produced during operation of the rotary kiln reactor 112, as described elsewhere herein). The first liquid 144 may also include pyrolysis oil, and may also include other relatively heavier materials.

Pyrolysis oil is the product of pyrolysis of organic polymeric materials (e.g., plastics) and is similar to (but not exactly the same as) natural crude oil. Pyrolysis oil contains paraffins, olefins, isoparaffins, aromatics, naphthenes. Pyrolysis oils may contain at least 15 wt% olefins, while natural crude oils typically contain little or no olefins. The pyrolysis oil may boil at about 35 ℃ to about 649 ℃.

Uncondensed material from the first condenser 122 can be conveyed as feed 124 to a second condenser 126. The second condenser 126 can operate to produce uncondensed material that is delivered as feed 130 to a third condenser 132. The feed 124 to the second condenser 126 may be condensed by the second condenser 26 into a liquid (the second liquid 128, also referred to as "second condensate" in some instances) that may contain, for example, an amount of pyrolysis oil. As shown, the second liquid (or second condensate) 128 can form at least a portion of a pyrolysis oil product stream 160, which can be collected.

As shown, feed 130 may be passed to a third condenser 132. Third condenser 132 can be operated to condense at least a portion of feed 130 to produce condensate 134b from third condenser 132. Condensate 134b (also referred to as "third liquid" or "light product" or "light pyrolysis oil" or "third condensate" in some cases) may be collected.

The light pyrolysis oil 134b may comprise at least some pyrolysis oil. The light pyrolysis oil 134b may also comprise relatively light materials, such as naphtha. (naphtha may boil, for example, at about 35 ℃ to about 232 ℃).

The overhead 134a from the third condenser 132 may contain uncondensed materials (e.g., syngas). Overhead 134a is passed to a vapor reduction train 136, which may include, for example, one or more of a knock-out pot, a seal pot, or a mist eliminator. It should be appreciated that vapor reduction train 136 is optional and need not be present. Uncondensed material 138 (which may include syngas or other gases) may be sent (e.g., via stream 140) to a flare. The uncondensed materials may also be sent via stream 142 to a combustor or other unit configured to provide hot gases and/or vapors for heating the rotary kiln reactor 112.

Returning to the first condenser 122, operating the first condenser to at least partially condense the feed 120 from the rotary kiln reactor 112 may produce a first liquid 144 (sometimes referred to as a "first condensate") that may contain a quantity of particulate matter (e.g., char) deposited therein. First liquid 144 may be passed to filter bank column 150; as shown, a portion of the first liquid 144 can be delivered back to the first condenser 122 via a recycle stream 146. Without being limited to any particular theory or implementation, at least some of the first liquid returned to the first condenser 122 may be available for operation of the condenser 122. As just one example, when the first condenser 122 is a downspray condenser, the first liquid 146 returned to the first condenser 122 may be used as a spray, such as by contacting (e.g., by spraying) the returned first liquid with the feed 120 of the first condenser 122.

The first liquid (as feed 148) may then be delivered to a separation train 150. The separation group train 150 may include, for example, a filter, a centrifuge, a decanter centrifuge, and/or a multi-phase decanter centrifuge. The separation array may include a continuous filter, continuous filtration, and/or continuous filtration device. As just one example, the filters in the separation group column 150 may be configured such that the filters are continually wiped or "scraped" so that the filters operate in a continuous manner and do not need to be offline. The separator stack 150 may also include a backwash filter that continuously removes and collects accumulated material.

As shown, the split stack column 150 may include an input module 152 that may be used to provide operational inputs to the split stack column 150. The split stack column 150 may also include an information output 154 that may provide operational data (e.g., internal conditions) related to the split stack column. It should be appreciated that other elements of the disclosed system (e.g., extruder 108, rotary kiln reactor 112, first condenser 122, second condenser 126, third condenser 132) may also include control input and/or data output modules.

Solids 156 (e.g., pyrolytic carbon) may be collected from the separation train 150. Without being limited by any particular theory or implementation, the water mass fraction of solids (e.g., char) from separation group train 150 may be in the range of about 0 wt.% to about 40 wt.%. Also without being limited by any particular theory or embodiment, the char solids from the separator may contain, for example, about 0 wt% to about 40 wt% water, 0 wt% to about 40 wt% pyrolysis oil, about 50 wt% to about 100 wt% carbon, and about 0 wt% to about 25 wt% additives or related compounds. The solids may be collected in bulk bags or other containers.

As shown, pyrolysis oil 158 may be collected from the separation train 150. The pyrolysis oil 158 collected from the separation train 150 may form at least a portion of a pyrolysis oil product stream 160, which may be collected.

FIG. 2 provides a cross-sectional view of a portion of a process module (also referred to as an "operating unit" in some places) using seals according to the present disclosure. Such a module may be, for example, a pyrolysis reactor or a system, such as a reactor for pyrolyzing hydrocarbonaceous materials. Examples of such reactors and systems can be found, for example, in U.S. published patent applications US2016/0024390 and US 2016/0017232.

As shown in fig. 2, conduit 222 may be used to convey material (e.g., waste plastic, rubber, etc.; the material may be solid, liquid, or even molten) to second compartment 218; the conduit 222 may extend through the first compartment 220. As shown, the first compartment 220 may include a rotatable joint 224 that may allow relative rotation between the first compartment and the second compartment. Rotatable joint 224 may be a face-to-face seal, such as a face-to-face seal comprising one or more graphite seals, carbon rope seals, metal leaf seals, and the like. As an example, the rotatable joint may include two O-rings made of braided carbon rope having a cross section of 1 square inch. Each O-ring may be located in a groove and then spring pressed against the panel.

The first compartment 220 may also define an interference fit joint 226, which interference fit joint 226 may be surrounded by a fabric 228, which may be arranged to surround a bellows or other housing of the first compartment 220. It should be appreciated that the fabric 228 may be a coated fabric, such as a flexible composite structure. The fabric 228 may be a multi-layer material, such as a sandwich material, a material having alternating layers, or the like. Fabric 228 may be, for example, a rubber impregnated mesh or screen material.

The conduit 222 may extend through the conduit jacket 202, and the conduit jacket 202 may be configured as a sleeve or collar. The seal 204 may extend (e.g., radially outward) from the conduit jacket 202 toward the wall 200 of the second compartment 218. In certain embodiments, an industrial process (e.g., pyrolysis, combustion, dehalogenation, cracking, etc.) is performed in the second compartment 218. By the seal 204, products and byproducts of the process performed in the second compartment 218 are retained in the second compartment 218 and do not enter (or are at least partially restricted from entering) the first compartment 220. In this way, the seal 204 and the first compartment 220 cooperate to prevent products and byproducts of the process performed in the second compartment 218 from exiting the process module and entering an environment external to the process module. Without being limited to any particular theory, the process module may be arranged to rotate the second compartment 218 about an axis, e.g., to rotate the second compartment 218 about the conduit 222 and/or the conduit jacket 202. Portions of the seal 204 may also be rotatable; in this way, the second compartment 218 may be rotated while retaining products and byproducts from the process performed in the second compartment 218.

Although not shown in fig. 2, the unit may also include one or more lines (e.g., parallel to the conduit 202) for delivering a fluid (e.g., nitrogen) into the second compartment 202. Such lines may be sealed within the conduit 202; they may also be parallel to the conduit 202 and at least partially sealed within the conduit jacket 202.

Fig. 3 provides a closer-cut cross-sectional view of the seal 204. As shown, the seal 204 may separate the first compartment 220 from the second compartment 218. Also as shown, the seal 204 may extend radially from the conduit jacket 202 toward the wall 200 of the second compartment. The seal may include a first flange 206. The first flange 206 may be attached (e.g., by welding or other fastening means) to the wall 200 of the second compartment 200. The first flange 206 may comprise a metal, such as stainless steel or carbon steel, or the like. The fastener 208 may secure the first flange 206 to the first washer 210. As shown, one or both ends of the fastener 208 protrude beyond the first flange 206 and the first washer 210. However, this is merely exemplary, as the ends of the fasteners 208 may be flush with one or both of the first flange 206 and the first washer 210. The ends of the fastener 208 may also be recessed from the surface of the first washer 210 and/or the first flange 206.

As shown, the fastener 214 may secure the first washer 210 to the layered portion 212 and the second washer 216. As shown, one or both ends of the fastener 214 protrude beyond the first washer 210 and the second washer 216. However, this is merely exemplary, as the ends of the fastener 214 may be flush with one or both of the first washer 210 and the second washer 216. The ends of the fastener 214 may also be recessed from the surface of the first washer 210 and/or the second washer 216.

The stratified portion 212 may comprise a plurality of material layers that may be identical to one another, but may also differ from one another in material, characteristics (e.g., pore size, weave, etc.). As shown, the layered portion 212 may contact the catheter jacket 202, for example, by an interference fit.

Although not shown in fig. 2, the seal 204 may include a brush. Such brushes may replace the layered portion 212. However, this is not necessary, as a brush may be used in addition to the layering section 212. The brush may suitably comprise metal bristles or other bristles formed from a refractory material.

In some embodiments, the inlet end of the kiln (i.e., the portion of the kiln prior to the outlet end of the lance or conduit 222) may be maintained at a lower temperature than the melting and pyrolysis section of the kiln. As an example, the inlet end may be 288 ℃ and the temperature of the pyrolysis zone within the kiln may be 371 ℃ to 649 ℃. Although the temperatures vary throughout the kiln, the different parts of the kiln are open and thus in thermal and fluid communication with each other, meaning that products (e.g., liquid hydrocarbons, vapors of waxy hydrocarbons) or byproducts (e.g., char particulates) are also in communication with the inlet end of the kiln. A bellows may be attached to the panel, which bellows does not rotate.

The inlet end of the kiln may include end plates (which do not rotate at the diameter of the kiln), carbon seals, fabric composite bellows (having an external temperature of 150 ℃), inlet ports and through-spray guns (for feeding molten plastic). Although the kiln may operate at a slight negative pressure relative to the atmosphere, materials (e.g., vapors and particulates) generated in the melting/pyrolysis zone and in the interior volume of the kiln may migrate to the inlet end of the kiln and coat lower temperature surfaces. The relatively cool portions of the kiln inlet, including the inlet ports, seals and bellows, may undergo a coating process. As noted, the bellows may include a multi-layer assembly, including for example, fluoropolymer films, reinforced rubbers, and the like.

The disclosed lance seal provides a barrier that allows gases (such as nitrogen and hydrocarbons) to flow through without pressure drop, but does not allow liquids or waxy hydrocarbons (which may condense on the kiln interior surfaces) or particulates (which may be captured by the coated braid structure of the lance seal) to pass through. Thus, the lance seal may allow non-condensibles (natural gas, nitrogen) to flow through while also capturing particulates and condensibles. This in turn provides the following benefits:

1. Cleaning is simpler between plant runs (if needed). By using the disclosed gun seal, there is little build-up of material in the bellows, as compared to the large amounts of material that are built up in the bellows using prior methods.

2. The stress of the rotatable seal is reduced.

3. Reducing damage to the fabric composite bellows.

4. Access to the inspection port is easier after completion.

Aspects of the invention

The following aspects are merely illustrative and do not limit the scope of the disclosure or claims.

Aspect 1. A system for converting an organic polymeric material to a hydrocarbonaceous material, the system comprising: a thermal cracking train configured to molecularly crack polymeric material fed to the thermal cracking train; a condensing train configured to receive thermal cracking products from the thermal cracking train and condense at least a portion of the thermal cracking products to produce pyrolysis oil products from the thermal cracking products; and a separation train configured to receive a first liquid comprising solid material and the pyrolysis oil products from the condensation train, the separation train configured to separate at least some of the pyrolysis oil products from the first liquid.

Aspect 2. The system of aspect 1, the thermal cracking train is configured to expose the polymeric material to a plurality of temperature zones.

Aspect 3 the system of any one of aspects 1-2, further comprising a supply of at least one inorganic additive for communication with the thermal cracking train.

As described elsewhere herein, the oxides, hydroxides, and/or carbonates of group 1 elements, the oxides, hydroxides, and/or carbonates of group 2 elements, and/or the oxides, hydroxides, and/or carbonates of group 8 elements, such as CaO, ca (OH), may be added at a weight percent of a few percent by weight of the polymeric material, such as at about 1 to about 5 percent by weight of the polymeric material ₂ 、CaCO ₃ 、NaOH、KOH、Fe ₂ O ₃ And FeO.

Aspect 4 the system of any one of aspects 1-3, wherein the thermal cracking train is configured to devolatilize char derived from cracking of the polymeric material. As described elsewhere herein, in certain embodiments, devolatilizing may include removing water.

Aspect 5 the system of any one of aspects 1-4, wherein the thermal cracking train comprises a reactor (e.g., a rotary kiln reactor) defining a reaction compartment having a length and operable to have a plurality of temperature zones along the length of the reaction compartment. Such reactors may be, for example, rotary kiln reactors, as well as other reactor types.

Aspect 6 the system of any one of aspects 1-5, wherein the condensing train comprises a first condenser in fluid communication with the thermal cracking train, the first condenser optionally configured as a direct contact condenser (e.g., a downflow condenser), and the first condenser is configured to receive thermal cracking feed from the thermal cracking train.

Aspect 7 the system of aspect 6, wherein the first condenser effects contact between (1) recycled first liquid received by the first condenser from the separation train and (2) thermal cracking feed received by the first condenser from the thermal cracking train. Such contacting may be by, for example, injecting the recycled first liquid downwardly into the thermal cracking feed received by the first condenser.

Aspect 8 the system of any one of aspects 6-7, wherein the condensing train comprises a second condenser configured to receive a first overhead from the first condenser, and the second condenser is configured to produce a condensed pyrolysis oil product and an uncondensed second overhead from the first overhead.

Aspect 9 the system of aspect 8, wherein the condensing train comprises a third condenser configured to receive the uncondensed second overhead from the second condenser, and the third condenser is configured to produce uncondensed products and condensed light products from the uncondensed second overhead.

Aspect 10 the system of aspect 9, wherein the thermal cracking train is configured to combust the uncondensed products to produce heat for use in the thermal cracking train. As just one example, the uncondensed products may comprise syngas that is delivered to a combustor that supplies heat to the rotary kiln reactors of the thermal cracking train.

Aspect 11 the system of any of aspects 9-10, further comprising a flare stack configured to combust the uncondensed products.

Aspect 12 the system of any one of aspects 1-11, wherein the system is configured to return at least some of the first liquid exiting the condensing-bank to the condensing-bank. As an example, as shown in fig. 1, at least some of the first liquid 144 exiting the first condenser 122 can be recycled to the first condenser as stream 146.

Aspect 13. A process comprising operating the system of any one of aspects 1-12 to convert a polymeric material to char, gas, and pyrolysis oil products, the process optionally being carried out continuously.

Aspect 14. The method of aspect 13, wherein the pyrolysis oil product has a boiling range of about 35 ℃ to about 704 ℃. As some examples, the pyrolysis oil product may have a boiling range of from about 35 ℃ to about 704 ℃, or from about 38 ℃ to about 649 ℃, or from about 66 ℃ to about 593 ℃, or from about 82 ℃ to about 538 ℃, or from about 110 ℃ to about 510 ℃, or from about 149 ℃ to about 427 ℃, or from about 177 ℃ to about 343 ℃.

Aspect 15 the method of any of aspects 13-14, wherein the pyrolysis oil product comprises from about 10 wt% to about 70 wt% olefins, such as from about 15 wt% to about 55 wt% olefins, from about 16 wt% to about 54 wt% olefins, from about 17 wt% to about 53 wt% olefins, from about 20 wt% to about 50 wt% olefins, from about 22 wt% to about 45 wt% olefins, from about 25 wt% to about 40 wt% olefins, or from about 30 wt% to about 35 wt% olefins.

Aspect 16. The method of aspect 15, wherein the pyrolysis oil product comprises from about 20 wt% to about 45 wt% olefins.

Aspect 17. A method, the method comprising: thermal cracking of the polymeric material is effected to produce thermal cracking products and char; optionally devolatilizing and collecting at least some of the char; condensing at least a portion of the thermal cracking product to produce (1) a first liquid comprising at least some of the char and pyrolysis oil products, and (2) a first overhead comprising at least some of the pyrolysis oil products; separating at least some of the pyrolysis oil product from the first liquid; condensing a portion of the first overhead to produce (1) a second liquid comprising the pyrolysis oil product, and (2) a second overhead; and collecting the second liquid.

Aspect 18 the method of aspect 17, further comprising contacting at least some of the first liquid with the thermal cracking product.

Aspect 19 the method of any one of aspects 17-18, wherein separating at least some of the pyrolysis oil product from the first liquid is performed by centrifugation. Such centrifugation may be achieved by, for example, multiphase centrifugation.

Aspect 20 the process of any one of aspects 17-19, further comprising condensing at least a portion of the second overhead product to produce synthesis gas and a light product output.

Aspect 21. The method according to any one of aspects 17 to 20, wherein the method is performed in a continuous manner.

Aspect 22. A thermal cracking process train comprising: a rotary kiln reactor; the rotary kiln reactor configured to receive a polymer feed material, the rotary kiln reactor defining at least one interior wall defining an interior volume of the rotary kiln reactor, the interior volume defining an inlet and an outlet along a feed material travel direction, the rotary kiln reactor comprising a section containing one or more purging features configured to purge a portion of the at least one interior wall as the rotary kiln reactor rotates, the rotary kiln comprising a section containing one or more lifting features extending from the at least one interior wall and configured to urge material disposed on the one or more features into the interior volume of the rotary kiln reactor interior as the rotary kiln reactor rotates; a burner configured to provide heated gas to the rotary kiln reactor, the burner optionally configured to receive and combust uncondensed hydrocarbon-containing vapors; and a devolatilizing component train optionally comprising a first valve, a holding chamber, and a second valve, the first valve configured to interrupt fluid communication between the interior volume of the rotary kiln reactor and the holding chamber, and the second valve configured to interrupt fluid communication between the holding chamber and an environment outside the holding chamber.

Aspect 23 the thermal cracking train of aspect 22, further comprising an auger configured to convey material into, along, or out of an interior volume of the rotary kiln reactor.

Aspect 24 the thermal cracking train of aspect 23, wherein the screw conveyor is configured to convey material out of an outlet of an interior volume of the rotary kiln reactor.

Aspect 25 the thermal cracking train of any one of aspects 22-24, further comprising a gas delivery train configured to deliver gas to the holding chamber. The gas delivery train may include conduits, pumps, etc.

Aspect 26. The thermal cracking train of any one of aspects 22-25, further comprising a gas delivery device configured to deliver gas to the interior volume of the rotary kiln reactor.

Aspect 27. The thermal cracking train of any one of aspects 25-26, wherein the gas is nitrogen. Without being limited by any particular theory, nitrogen (or other gases, including inert gases, non-condensable gases, etc.) may be used to reduce the accumulation of material on the inner walls of the rotary kiln reactor.

Aspect 28 the thermal cracking train of any one of aspects 22-27, wherein the rotary kiln reactor defines one or more compartments disposed about an interior volume of the rotary kiln reactor, the one or more compartments configured to receive heating fluid from the burner.

Aspect 29. The thermal cracking train of aspect 28, wherein the rotary kiln reactor comprises one or more baffles configured to regulate an amount of heating fluid distributed to the one or more compartments.

Aspect 30. The thermal cracking train of any one of aspects 28-29, wherein the amount of heating fluid received by the one or more compartments achieves regions of different temperatures along the direction of travel of the material.

Aspect 31. The thermal cracking train of any one of aspects 22-30, wherein the rotary kiln reactor is configured to define a plurality of temperature zones of different temperatures along a direction of material travel. As an example, the rotary kiln reactor may define a first temperature zone that operates at a temperature 20 ℃ lower than the temperature of a second temperature zone.

Aspect 32. The thermal cracking train of aspect 31, wherein the rotary kiln reactor is configured to define at least a first temperature zone and a second temperature zone, the first temperature zone having a temperature different than a temperature of the second temperature zone. It will be appreciated that the rotary kiln reactor may be configured such that material passing through the interior of the reactor (from inlet to outlet) passes through a temperature zone of elevated or equal temperature. However, this is not necessary, as the rotary kiln reactor may define a first zone operating at a temperature T, a second zone operating at a temperature 10% or 15% higher than T, a third zone operating at a temperature 10% or 15% lower than T, a fourth zone operating at a temperature T, and a fifth zone operating at a temperature 15% or 20% higher than T. In this way, the material passing through the interior of the reactor may experience an elevated temperature, a reduced temperature, or an equivalent temperature as the material moves from one region to another. The individual zones may have different lengths such that material passing through the interior of the reactor spends different amounts of time in the different zones. (however, this is not necessary, as the dimensions of the different zones may be designed such that the material passing through the interior of the reactor has the same residence time in at least two different zones.) without being limited by any particular theory or embodiment, each zone of the kiln may define a temperature differential (along the length of the kiln) from about 65 ℃ to about 65 ℃. As an example, the region at one end of the kiln may operate at a temperature of 566 ℃ and the region at the other end of the kiln may operate at a temperature of 482 ℃ thereby defining an end-to-end temperature differential of 84 ℃. As another example, the region at one end of the kiln may be operated at a temperature of 566 ℃ and the region at the other end of the kiln may be operated at a temperature of 454 ℃ to define an end-to-end temperature differential of 122 ℃. Adjacent zones in the kiln may differ from each other by, for example, about 5 ℃ to about 50 ℃, e.g., by 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, even 50 ℃. The temperature of a given zone may differ from its neighboring zones by the same degree, but this is not required. For example, the temperature of the second zone of the kiln may differ from the first zone of the kiln by 10 degrees and also from the third zone of the kiln by 10 degrees. Alternatively, the temperature of the second zone of the kiln may differ from the first zone of the kiln by 10 ℃ and also from the third zone of the kiln by 15 ℃. The temperature of the zone may be measured at a substantial center of the zone within the kiln volume (e.g., at a radial center of the zone) at a midpoint of the axial length of the zone measured along the length of the kiln.

Aspect 33. The thermal cracking train of any one of aspects 22-32, wherein the rotary kiln reactor comprises one or more sections of refractory material defining a plurality of temperature zones of different temperatures along a direction of material travel. The reactor may include one or more ramps, banks, weirs or other features therein.

Aspect 34. The thermal cracking array of any of aspects 22-33, wherein the one or more cleaning elements comprise a chain.

Aspect 35 the thermal cracking array of any one of aspects 22-34, wherein the one or more lifting features comprise a flange, a ridge, or any combination thereof. The flange may be attached to the inner wall of the rotary kiln reactor, for example by bolts, screws or the like. Ridges may be formed in the material of the inner wall of the rotary kiln reactor. Without being limited to any particular theory or embodiment, lifters and/or ridges may help "blast" material on or near the rotary kiln reactor wall (including material resting on the lifters or ridges) away from the wall of the rotary kiln reactor, which may improve the transfer of heat within the rotary kiln reactor to the material being blasted.

Aspect 36. The thermal cracking array of aspect 35, wherein the one or more lifting features are oriented generally parallel to a feed material travel direction. The lifting element may also be oriented at an angle to the feed material travel direction to cause the lifted material to move in the feed material travel direction. However, this is not necessary, as the lifting element may be oriented at an angle such that the element impedes movement of the material in the general direction of travel of the feed material.

Aspect 37. The thermal cracking train of any one of aspects 22-36, comprising a supply of inorganic additive in communication with the extruder.

Aspect 38, a method comprising: operating the thermal cracking train according to any of aspects 22-37 to produce a thermal cracking product and char, optionally devolatilizing and collecting at least some of the char, and optionally conveying the cracking product to one or more condensers.

Aspect 39, a method, the method comprising: effecting transfer of a polymer feed material within a rotary kiln reactor having at least one interior wall, exposing the polymer feed material to two or more regions of different temperature within the rotary kiln reactor, at least one of the two regions of different temperature thermally cracking the polymer feed material into (1) thermal cracking products comprising pyrolysis oil products and (2) char; at least partially devolatilizing the char to produce a first devolatilized char; collecting at least some of the first devolatilized char in a holding chamber; optionally interrupting fluid communication between the holding chamber and the rotary kiln reactor; further devolatilizing at least some of the first devolatilized char in the holding chamber to produce a second devolatilized char; collecting the char of the second devolatilization component.

Aspect 40. The method of aspect 39, further comprising delivering gas to the holding chamber so as to reduce entry of vapor from the rotary kiln reactor into the holding chamber. Such gas may be nitrogen or other inert gas, as described elsewhere herein.

Aspect 41 the method of any one of aspects 39-40, further comprising delivering a gas to remove material accumulation on the at least one inner wall.

Aspect 42. The method of any one of aspects 39-41, wherein the polymer feed material is exposed to a region of 2 two to about six different temperatures within the rotary kiln reactor.

Aspect 43. The method of aspect 42, wherein the polymer feed material is exposed to four different temperature zones within the rotary kiln reactor.

Aspect 44. The method according to any one of aspects 39-43, wherein the method is performed in a continuous manner.

Aspect 45, a condensing train, comprising: a first condenser configured to condense a first liquid comprising pyrolysis oil products from feed vapor provided to the first condenser, the first condenser optionally configured as a downflow condenser; a second condenser in fluid communication with the first condenser, the second condenser configured to receive a first overhead from the first condenser, the second condenser configured to condense a second liquid comprising the pyrolysis oil product from the first overhead; and an optional third condenser in fluid communication with the second condenser, the third condenser configured to receive a second overhead from the second condenser, the third condenser configured to condense a third liquid comprising pyrolysis oil products from the second overhead.

Aspect 46 the condensing array according to aspect 45, wherein said first condenser is configured as a downflow condenser.

Aspect 47 the condensing train of any one of aspects 45-46, further comprising a flare train configured to combust non-condensed products from the third condenser.

Aspect 48 the condensing bank train of any one of aspects 45-47, further comprising a fluid circuit configured to communicate a first liquid to the first condenser. Such transfer may be as a recycle stream.

Aspect 49 the condensing array according to aspect 48, wherein said fluid circuit comprises an adjustable diverter configured to divert at least some of said first fluid to said first condenser.

Aspect 50 the condensing train of any one of aspects 45-49, wherein the first condenser is configured to contact the feed vapor with pyrolysis oil product delivered to the first condenser.

Aspect 51. The condensing train according to any one of aspects 45-50, further comprising a gas delivery train configured to deliver gas to the first condenser, the gas delivery train optionally comprising a transfer tube.

Aspect 52. The condensing array according to aspect 51, wherein said gas is nitrogen.

Aspect 53 the condensing array according to any one of aspects 45-52, wherein said first condenser is configured to operate at about ambient temperature to about 204 ℃.

Aspect 54 the condensing bank according to any of aspects 45-53, wherein the second condenser is configured to operate at about 16 ℃ to about 54 ℃.

Aspect 55 the condensing bank according to any one of aspects 45-54, wherein the third condenser is configured to operate at about 2 ℃ to about 21 ℃.

Aspect 56 the condensing bank according to any one of aspects 45-54, wherein the third condenser is operated at a sub-ambient temperature.

Aspect 57 the condensing bank train of any of aspects 45-56, further comprising at least one of a knock-out pot, a single seal pot, or a mist eliminator. As shown in fig. 1, a knock out pot and/or seal pot (136) may be in communication with the third overhead 134 a.

Aspect 58 the condensing train of aspect 57, comprising a knock-out pot.

The vapor outlet of the kiln is vertical and condensable vapors (and non-condensable gases) move vertically upward out of the kiln. After passing a certain distance, the vapor moves down to the quench tower through a pipe inclined at an angle of 45 degrees to vertical, for example. The conduit diameter may be, for example, about 14 to 16 inches to limit internal accumulation of char and hydrocarbon vapors.

A plurality of hot nitrogen nozzles are energized to help keep the tube walls clean as the vapor is transported through the tube. As the vapor enters the quench tower (also known as a downspray condenser or liquid-liquid exchange condenser or liquid/liquid heat exchanger), the diameter increases (e.g., to about 8 feet) to prevent material accumulation from occurring. A series of liquid nozzles are arranged in the quenching tower and are in an annular structure, and are downwards sprayed at the high position in the quenching tower to play two roles:

1. the hot hydrocarbon vapor entering the quench tower is cooled.

2. Some entrained char is removed from the vapor and deposited at the bottom of the quench tower.

In one exemplary embodiment, about 85 wt% of the condensable vapor is removed by spraying through a quench tower and the condensed vapor (also known as liquid hydrocarbon) is at about 121 ℃ in the quench tower. The top layer of condensate (at a distance from any char at the bottom) leaves the quench tower and is split, with one portion entering the raw synthetic oil tank and the other portion (slipstream) optionally being sent to a decanter centrifuge where it is cleaned. The slipstream washed in the decanter centrifuge is in continuous loop with the quench tower, resulting in improved quality of the synthetic crude over time (reduced particulate matter in the synthetic crude). As shown in fig. 1, element 146 is a spray element for cooling and removing particulate matter. Element 134b is optional; element 134b may also be combined with element 128, the combined stream being directed to element 160.

As shown, there may be two additional condensers (126 and 132) outside the first condensing device (122), which are shell-and-tube heat exchangers. The second condenser may use room temperature process water and the third condenser may use chilled water. The relative amounts captured may be: 85 wt% of quench tower, 10 wt% of first condenser and 5 wt% of second condenser. The second and third shell-and-tube condensers may include liquid spray systems to prevent tube fouling (tubes for product, shells for cooling water). The separator tank (optionally present) may capture additional condensable liquids. One may also (or instead) use a mist eliminator comprising a series of stainless steel pads that block the liquid path providing surface area for condensation.

Aspect 59. A method, the method comprising: passing a feed comprising vapor comprising pyrolysis oil products to a first condenser, optionally a downflow condenser; operating the first condenser so as to produce a first liquid comprising the pyrolysis oil product and a first overhead comprising the pyrolysis oil product; recycling at least some of the first liquid to the first condenser; passing the first overhead to a second condenser; operating the second condenser so as to produce a second liquid comprising the pyrolysis oil product and a second overhead comprising the pyrolysis oil product; passing the second overhead to a third condenser; and operating the third condenser to produce a third liquid comprising the pyrolysis oil product and a third overhead comprising uncondensed material.

Aspect 60 the method of aspect 59, further comprising recycling at least some of the first liquid back to the first condenser, and optionally cooling the first liquid.

Aspect 61 the method of aspect 60, further comprising contacting the recycled first liquid with the feed vapor.

Aspect 62 the method of any one of aspects 59-61, further comprising passing pyrolysis oil product to the first condenser.

Aspect 63. The method of any one of aspects 59-62, wherein the first condenser is configured to operate at about ambient temperature to about 204 ℃.

Aspect 64 the method of any one of aspects 59-63, wherein the second condenser is configured to operate at about 16 ℃ to about 54 ℃.

Aspect 65 the method of any one of aspects 59-64, wherein the third condenser is configured to operate at about 2 ℃ to about 21 ℃.

Aspect 66. The method of any one of aspects 59-64, wherein the third condenser is operated at sub-ambient conditions.

Aspect 67. The method of any one of aspects 59-66, further comprising: (a) Combusting the uncondensed material, (b) combusting the condensed material so as to heat a reactor train producing the first overhead, or both (a) and (b).

Aspect 68. The method of any one of aspects 59-67, wherein the first liquid comprises char.

Aspect 69 the method of any one of aspects 59-68, further comprising conveying any one or more of the first overhead, second overhead, and third overhead to a knock-out pot, a seal pot, or a mist eliminator.

Aspect 70. The method of any one of aspects 59-69, wherein the method is performed in a continuous manner.

Aspect 71, an isolated column set comprising: a separation module configured to receive a feed material comprising char and pyrolysis oil products, optionally from a condenser, the separation module operable to separate the char and pyrolysis oil from each other; a receiving line configured to receive pyrolysis oil products from the separation module.

Aspect 72. The separation train of aspect 71, wherein the separation module is characterized by a decanter centrifuge.

Aspect 73 the separation train of aspect 72, further comprising at least one filter configured to filter the feed material prior to the feed material entering the decanter centrifuge.

Aspect 74 the separation train of aspect 71, wherein the separation module is characterized by a multi-phase decanter centrifuge.

Aspect 75 the separation train of aspect 74, further comprising a separation liquid source configured to communicate with the multiphase decanter centrifuge. Such separation liquid may be, for example, water or other liquid that is not miscible with pyrolysis oil.

Aspect 76 the separation train of aspect 75, further comprising an outlet for separating liquid in communication with the multiphase decanter centrifuge.

Aspect 77 the separation train of any one of aspects 75-76, further comprising at least one filter configured to filter the feed material prior to the feed material entering the multi-phase decanter centrifuge.

Aspect 78 the separation train of any one of aspects 71-77, further comprising a char-receiving line configured to receive char from the centrifugal separator.

Aspect 79 the separation train of any one of aspects 71-78, wherein the receiving line is configured to place the separated pyrolysis oil product in fluid communication with a collection location.

Aspect 80. The separation train of any one of aspects 71-79, wherein the separation train is configured to recycle at least a portion of the feed material to the feed material source.

Decantation centrifuges are uniquely employed in pyrolysis applications; such devices are commonly used for food processing/separation, wastewater cleaning, fish meal and fish oil separation, chemical extraction, clay and mineral processing, oil dewatering, fertilizer processing, and the like. A decanter centrifuge for pyrolysis oil purification may use the second stream to increase separation efficiency. The char from the bottom of the quench tower may be sent as a slip stream to a decanter centrifuge. Water was added to separate oil and carbon particles. Slipstream feed methods can be used to remain within the limits of the recyclability of the device. The oil can be separated from the oily char by multiple recycles of the device, leaving a semi-solid component enriched in particulates. The particulate-rich semi-solid component is separated from the water stream and the hydrocarbon product stream. The semi-solid component has fuel value.

Aspect 81. A solid-liquid separation method, the method comprising: introducing a feed comprising pyrolysis oil product and char to a separation module, the pyrolysis oil product and char being fluidly separated from each other using the separation module; collecting the char; and collecting at least some of the pyrolysis oil product.

Aspect 82 the method of aspect 81, wherein the source of the feed is a condenser.

Aspect 83 the method of aspect 83, wherein the condenser is a downflow condenser.

Aspect 84 the method of any one of aspects 81-83, wherein a portion of the feed from the condenser is recycled back to the condenser.

Aspect 85 the method of any one of aspects 81-84, wherein the separation module is characterized by a decanter centrifuge.

Aspect 86 the method of aspect 85, further comprising filtering the feed material prior to the feed material entering the decanter centrifuge.

Aspect 87 the method of aspect 81, wherein the separation module is characterized by a multiphase decanter centrifuge.

Aspect 88 the method of aspect 87, further comprising delivering a separation liquid to the multiphase decanter centrifuge.

Aspect 89 the method of aspect 88, further comprising separating the separated liquid from pyrolysis oil and char transferred to the multiphase decanter centrifuge.

Aspect 90 the method of any one of aspects 81-89, wherein the method is performed in a continuous manner.

Aspect 91, an operation unit, comprising: a first compartment; a second compartment; a conduit extending through the first compartment and into the second compartment, the conduit being at least partially surrounded by a conduit jacket, the conduit jacket defining an outer diameter, the conduit fluidly connecting the second compartment with an environment outside the compartment, the second compartment comprising a wall facing the conduit jacket, and the second compartment being rotatable relative to the first compartment; a seal defining a boundary between the first compartment and the second compartment, the seal extending radially from a wall of the second compartment toward the conduit jacket, the seal comprising a first flange secured to and extending from a wall of the second compartment, the first flange defining an inner diameter, (a) the seal comprising a layered portion comprising a plurality of annular portions, at least one of the annular portions having an inner diameter less than an outer diameter of the conduit jacket such that the at least one annular portion rotatably abuts the conduit jacket, the outer diameter of the conduit jacket optionally being no more than about 1.25cm greater than the inner diameter of the at least one annular portion, or (b) the seal comprising a brush rotatably abutting the conduit jacket.

As described elsewhere herein, the second compartment may be a reactor or kiln, such as a rotatable drum or cylinder. In some cases, the first compartment may be considered a "catch basin" for byproducts or products such as wax and/or char produced in the second compartment that pass through the seal. As also described elsewhere herein, the first compartment may be pressurized to achieve a positive pressure on the material that may pass through the seal 204.

Aspect 92 the operating unit of aspect 91, wherein the first flange comprises a plurality of portions. Without being limited to any particular theory or implementation, the first flange may be formed from a single material portion (e.g., a ring), but this is not required. In some cases, the first flange may be formed of multiple material portions, for example, to allow the flange to be configured within the operating unit in a "ship in bottle" manner. As just one example, the flange extending inwardly from the wall of the second compartment (which may be, for example, a kiln) may comprise several curved sections which are circumferentially arranged around the inner wall of the kiln and which are welded to the inner wall of the kiln and also welded/sealed to each other.

Aspect 93 the operational unit of any one of aspects 91-92, wherein the layered portion is attached to the first flange.

Aspect 94 the operating unit of any one of aspects 91-92, further comprising a first gasket attached to the first flange. The first gasket may comprise metal or other refractory material.

Aspect 95. The operating unit of aspect 94, wherein the layered portion is attached to the first face of the first gasket.

Aspect 96 the operating unit of aspect 95, further comprising a second gasket attached to the second face of the first gasket.

Aspect 97 the operating unit of aspect 96, further comprising a fastener extending at least partially through the first washer, layered portion, and second washer.

Aspect 98 the operating unit of any one of aspects 91-97, wherein the annular portion comprises steel, aluminum, brass, bronze, copper, carbon fiber, glass-loaded vermiculite, or any combination thereof. The annular portion may comprise one or more woven or knit structures.

Aspect 99. The operating unit according to any one of aspects 91 to 98, wherein the layered portions comprise an alternating arrangement of annular portions.

Aspect 100. The operating unit according to any one of aspects 91-98, wherein the layered portion comprises a periodic arrangement of annular portions.

Aspect 101. The operating unit according to any one of aspects 91-100, wherein the layered portion comprises at least two annular portions having different moduli. In this way, the seal may exhibit desirable mechanical properties such as stiffness, elasticity, and flexibility. The layered portion of the seal may have multiple portions that may be stacked together. The portions may be arranged in ase:Sub>A periodic or repeating fashion, for example, in an ase:Sub>A-B-ase:Sub>A-B fashion, ase:Sub>A-ase:Sub>A-B fashion, or other arrangement as appropriate to the needs of the user.

It will be appreciated that the annular portions of the layered portions may have the same dimensions (e.g. the same inner diameter and the same outer diameter), but this is not required, as the different annular portions of the layered portions themselves may also have different dimensions. The portions may be arranged such that the portions exhibit a gradient within the thickness of the layered portion, e.g. a first annular portion facing the second compartment may have a higher porosity than a second annular portion immediately adjacent to the first annular portion, and so on.

Without being limited by any particular theory, a seal according to the present disclosure may operate such that if there is extensive blockage (i.e., percent open area or reciprocal of POA) of the annular portion of the seal (which may be stacked) and a multi-layer configuration is used, byproducts (e.g., wax and char) that impinge on the face of the seal facing the second compartment (as shown in fig. 1 and 2) act to seal the seal. In this way, the by-product may act to enhance the seal performance. Again without being limited by any particular theory, in certain embodiments the final structure may be characterized as having less than about 10POA.

Aspect 102 the operating unit of any one of aspects 91-101, further comprising a source of pressurized fluid in fluid communication with the second compartment. The pressurized fluid source may be configured to cause byproducts generated in the second compartment to remain in the second compartment. The pressurized fluid may be delivered through a hose, conduit or manifold.

The operating device may also include a source of pressurized fluid (e.g., nitrogen) configured to create a positive pressure in the first compartment (element 220 in fig. 2 and 3). Such positive pressure may thus prevent byproduct material from the second compartment from passing through the seal 204 and then into the first compartment 204.

Aspect 103. The operating unit of aspect 102, wherein the fluid comprises an inert gas. Argon and helium are considered particularly suitable.

Aspect 104. The operating unit of aspect 102, wherein the fluid comprises nitrogen. The fluid may also include hydrocarbon-containing vapor.

Aspect 105 the operating unit of any one of aspects 91-104, further comprising a pressure sensor configured to detect a pressure within the first compartment.

Aspect 106. The operating unit according to any one of aspects 91-105, further comprising a pressure sensor configured to detect a pressure within the second compartment. Without being limited by any particular theory, a pressure sensor may be used as part of a pressure maintenance bank that may create a positive pressure in the first compartment that may (as explained elsewhere herein) prevent byproduct material from the second compartment from passing through the seal 204 and then into the first compartment 204. The pressure sensor may also monitor the pressure in the second compartment and the readings from such pressure sensor may in turn be used to adjust the pressure in the second compartment, for example by opening a valve and/or activating a pump to reduce the pressure in the second compartment.

Aspect 107 the operating unit of any one of aspects 91-106, further comprising a pump configured to reduce pressure within the second compartment.

Aspect 108 the operating unit of any one of aspects 91-107, further comprising a motor configured to rotate the second compartment.

Aspect 109 the operating unit of any one of aspects 91-92, further comprising a circumferentially rotatable joint configured to support rotation of the second compartment. Without being limited to any particular theory, such a joint may be a rotatable face-to-face double O-ring joint. In some cases, the joint may include a bearing.

Also not to be limited by any particular theory or implementation, the operating unit may include a source of pressurized fluid (e.g., nitrogen) configured to be applied to the joint such that the pressurized fluid prevents leakage through the rotatable joint.

Aspect 110 the operating unit of aspect 109, further comprising a source of pressurized fluid in fluid communication with the circumferentially rotatable joint.

Aspect 111 the operating unit of aspect 110, wherein the fluid comprises an inert gas.

Aspect 112 the operating unit of aspect 110, wherein the fluid comprises nitrogen. The fluid may also comprise hydrocarbon-containing vapor.

Aspect 113 the operating unit according to any one of aspects 91-112, wherein the second compartment is configured as a rotary kiln reactor.

Aspect 114 the operating unit of aspect 113, wherein the second compartment comprises one or more chains, lifters or helical flights.

Aspect 115 the operating unit of any one of aspects 91-114, wherein the seal comprises a layered portion comprising a plurality of annular portions, at least one of the annular portions having an inner diameter that is smaller than an outer diameter of the catheter jacket such that the at least one annular portion rotatably abuts the catheter jacket.

Aspect 116 the operating unit of any one of aspects 91-115, wherein the first compartment is defined by an interference fit joint that is expandable in response to a temperature within the first compartment, a temperature within the second compartment, or both. As shown in fig. 1, the interference fit joint 226 may accommodate temperature-dependent expansion by constituting one or both surfaces of the joint. In this way, leakage associated with temperature induced joint expansion can be mitigated, as the joint retains at least some of its sealing ability even in the face of temperature expansion. By having a housing arrangement that accommodates thermal expansion, the disclosed operating unit can operate at industrial temperatures without compromising performance or exhibiting undesirable levels of leakage.

Aspect 117 the operational unit according to any one of aspects 91-116, further comprising a fabric portion (which may be referred to as a "bellows") at least partially surrounding the first compartment. As shown in fig. 2, the fabric 228 may at least partially surround the first compartment 220. The fabric may be permeable, but this is not required. In some cases, the fabric may be removable so that byproducts that have passed through the seal 204 and accumulated within the first compartment 220 and/or in the seal 204 may be collected and the fabric (or a replacement fabric) may be reinstalled. Alternatively, the user may clean the bellows on a schedule or periodically as desired.

Aspect 118 a method comprising operating the operating unit according to any one of aspects 91-117.

Aspect 119. The method of aspect 118, wherein the operation is performed to pyrolyze a hydrocarbonaceous material. Such a material may be, for example, plastic, rubber, etc.

Claims

1. A system for converting an organic polymeric material to a hydrocarbonaceous material, the system comprising:

a thermal cracking group of the column,

the thermal cracking train is configured to molecularly crack polymeric material fed to the thermal cracking train;

A condensing group column is arranged in the way,

the condensing train is configured to receive thermal cracking products from the thermal cracking train and condense at least a portion of the thermal cracking products to produce pyrolysis oil products from the thermal cracking products; and

the array of the groups is separated,

the separation train is configured to receive a first liquid comprising solid material and the pyrolysis oil product from the condensation train,

the separation train is configured to separate at least some of the pyrolysis oil product from the first liquid.

2. The system of claim 1, wherein the thermal cracking train is configured to expose the polymeric material to a plurality of temperature zones.

3. The system of any of claims 1-2, further comprising a supply of at least one inorganic additive for communication with the thermal cracking train.

4. The system of any of claims 1-2, wherein the thermal cracking train is configured to devolatilize char derived from cracking of the polymeric material.

5. The system of any of claims 1-2, wherein the thermal cracking train comprises a reactor defining a reaction compartment having a length and operable to have a plurality of temperature zones along the length of the reaction compartment.

6. The system of any of claims 1-2, wherein the condensing train comprises a first condenser in fluid communication with the thermal cracking train,

the first condenser is optionally configured as a direct contact condenser, and

the first condenser is configured to receive a thermal cracking feed from the thermal cracking train.

7. The system of claim 6, wherein the first condenser effects contact between (1) and (2) below, (1) a first liquid recycled from the separation train to the first condenser, (2) a thermal cracking feed received by the first condenser from the thermal cracking train.

8. The system of claim 6, wherein the condensing train comprises a second condenser,

the second condenser is configured to receive the first overhead from the first condenser, and

the second condenser is configured to produce a condensed pyrolysis oil product and an uncondensed second overhead from the first overhead.

9. The system of claim 8, wherein the condensing train comprises a third condenser configured to receive an uncondensed second overhead from the second condenser, and the third condenser is configured to produce an uncondensed product and a condensed light product from the uncondensed second overhead.

10. The system of claim 9, wherein the thermal cracking train is configured to combust the uncondensed products to produce heat for use in the thermal cracking train.

11. The system of claim 9, further comprising a flare stack configured to combust the uncondensed products.

12. The system of any of claims 1-2, wherein the system is configured to send at least some of the first liquid exiting the condensing-bank back to the condensing-bank.

13. A process comprising operating the system of any one of claims 21-22 to convert a polymeric material to char, gas, and pyrolysis oil products, the process optionally being carried out continuously.

14. The method of claim 13, wherein the pyrolysis oil product has a boiling range of about 27 ℃ to about 704 ℃.

15. The method of claim 13, wherein the pyrolysis oil product comprises from about 10 wt% to about 70 wt% olefins.

16. The method of claim 15, wherein the pyrolysis oil product comprises from about 20 wt% to about 45 wt% olefins.

17. A method, the method comprising:

Thermal cracking of the polymeric material is effected to produce thermal cracking products and char;

optionally devolatilizing and collecting at least some of the char;

condensing at least a portion of the thermal cracking product to produce (1) a first liquid comprising at least some of the char and pyrolysis oil products, and (2) a first overhead comprising at least some of the pyrolysis oil products;

separating at least some of the pyrolysis oil product from the first liquid;

condensing a portion of the first overhead to produce (1) a second liquid comprising the pyrolysis oil product, and (2) a second overhead; and

collecting the second liquid.

18. The method of claim 17, further comprising contacting at least some of the first liquid with the thermal cracking product.

19. The method of any one of claims 17-18, wherein separating at least some of the pyrolysis oil product from the first liquid is performed by centrifugation.

20. The method of any of claims 17-18, further comprising condensing at least a portion of the second overhead product to produce syngas and a light product output.

21. The method of any one of claims 17-18, wherein the method is performed in a continuous manner.

22. A separation set of columns, comprising:

the separation module is arranged to separate the modules,

the separation module is configured to optionally receive feed material comprising char and pyrolysis oil products from the condenser,

the separation module is operable to separate the char and pyrolysis oil from each other;

a receiving line configured to receive pyrolysis oil products from the separation module.

23. The separation train of claim 22, wherein the separation module is characterized by a decanter centrifuge.

24. The separation train of claim 23, further comprising at least one filter configured to filter the feed material prior to the feed material entering the decanter centrifuge.

25. The separation train of claim 23, wherein the separation module is characterized by a multiphase decanter centrifuge.

26. The separation train of claim 25, further comprising a separation liquid source configured to communicate with the multiphase decanter centrifuge.

27. The separation train of claim 26, further comprising an outlet for separated liquid in communication with the multi-phase decanter centrifuge.

28. The separation train of any one of claims 26-27, further comprising at least one filter configured to filter the feed material prior to the feed material entering the multi-phase decanter centrifuge.

29. The separation train of any one of claims 23-27, further comprising a char-receiving line configured to receive char from the decanter centrifuge.

30. The separation train of any one of claims 22-27, wherein the receiving line is configured to place the separated pyrolysis oil product in fluid communication with a collection location.

31. The separation train of any one of claims 22-27, wherein the separation train is configured to recycle at least a portion of the feed material to the feed material source.

32. A solid-liquid separation method, the method comprising:

a feed comprising pyrolysis oil products and char is introduced to a separation module,

using the separation module to effect separation of the pyrolysis oil product and char fluid from each other;

collecting the char; and

at least some of the pyrolysis oil product is collected.

33. The method of claim 32, wherein the source of the feed is a condenser.

34. The method of claim 33, wherein the condenser is a downflow condenser.

35. The method of any of claims 32-34, wherein a portion of the feed from the condenser is recycled back to the condenser.

36. The method of any of claims 32-34, wherein the separation module is characterized by a decanter centrifuge.

37. The method of claim 36, further comprising filtering the feed material prior to the feed material entering the decanter centrifuge.

38. The method of claim 36, wherein the separation module is characterized by a multiphase decanter centrifuge.

39. The method of claim 38, further comprising routing a separation liquid to the multiphase decanter centrifuge.

40. The method of claim 39, further comprising separating the separated liquid from pyrolysis oil and char transferred to the multiphase decanter centrifuge.

41. The method of any one of claims 32-34, wherein the method is performed in a continuous manner.

42. A thermal cracking process train, comprising:

a rotary kiln reactor;

The rotary kiln reactor is configured to receive a polymer feed material,

the rotary kiln reactor defines at least one interior wall defining an interior volume of the rotary kiln reactor,

the internal volume defines an inlet and an outlet along the direction of travel of the feed material,

the rotary kiln reactor comprises a section containing one or more purging features configured to purge a portion of the at least one inner wall as the defined kiln rotates,

the rotary kiln includes a section containing one or more lifting features extending from the at least one inner wall and configured to cause material disposed on the one or more features to fall into an interior volume of the interior of the rotary kiln as the rotary kiln rotates;

a burner configured to provide heated gas to the rotary kiln reactor,

the combustor is optionally configured to receive and combust uncondensed hydrocarbon-containing vapors; and

the array of devolatilizing elements is arranged in a row,

the devolatilization packet train optionally comprises a first valve, a holding chamber, and a second valve, the first valve configured to interrupt fluid communication between the internal volume of the rotary kiln reactor and the holding chamber, and

The second valve is configured to interrupt fluid communication between the holding chamber and an environment outside the holding chamber.

43. The thermal cracking train of claim 42, further comprising an auger configured to convey material into, along, or out of an interior volume of the rotary kiln.

44. The thermal cracking train of claim 43, wherein the screw conveyor is configured to convey material out of an outlet of the interior volume of the rotary kiln.

45. The thermal cracking train of any one of claims 42-44, further comprising a gas delivery train configured to deliver gas to the holding chamber.

46. The thermal cracking train of any one of claims 42-44, further comprising a gas delivery device configured to deliver gas to an interior volume of the rotary kiln reactor.

47. The thermal cracking train of any one of claims 45-44, wherein the gas is nitrogen.

48. The thermal cracking train of any one of claims 42-44, wherein the rotary kiln reactor defines one or more compartments disposed about an interior volume of the rotary kiln reactor, the one or more compartments configured to receive heating fluid from the burner.

49. The thermal cracking train of claim 48, wherein the rotary kiln reactor comprises one or more baffles configured to regulate an amount of heating fluid distributed to the one or more compartments.

50. The thermal cracking train of claim 48, wherein the one or more compartments receive an amount of heating fluid that achieves regions of different temperatures along the direction of material travel.

51. The thermal cracking train of any one of claims 42-44, wherein the rotary kiln reactor is configured to define a plurality of temperature zones of different temperatures along a direction of material travel.

52. The thermal cracking train of claim 51, wherein the rotary kiln reactor is configured to define at least a first temperature zone and a second temperature zone, the first temperature zone having a temperature different than a temperature of the second temperature zone.

53. The thermal cracking train of claim 51, wherein the rotary kiln reactor comprises one or more sections of refractory material defining a plurality of temperature zones of different temperatures along a direction of material travel.

54. The thermal cracking train of claim 51, wherein the one or more cleaning elements comprise a chain.

55. The thermal cracking train of claim 51, wherein the one or more lifting features comprise a flange, a ridge, or any combination thereof.

56. The thermal cracking train of claim 55, wherein the one or more lifting features are oriented generally parallel to a direction of feed material travel.

57. The thermal cracking train of any one of claims 42-44, comprising a supply of at least one inorganic additive in communication with the extruder.

58. A method, the method comprising: operating the thermal cracking train of any one of claims 42-44 to produce thermal cracking products and char, optionally removing volatile components and collecting at least some of the char, and optionally passing the cracking products to one or more condensers.

59. A method, the method comprising:

the transfer of polymer feed material within a rotary kiln reactor having at least one inner wall is effected,

exposing the polymeric feed material to two or more regions of different temperatures within the rotary kiln reactor,

at least one of the two regions of different temperature thermally cracking the polymer feed material into (1) a thermal cracking product comprising pyrolysis oil products and (2) char;

At least partially devolatilizing the char to produce a first devolatilized char;

collecting at least some of the first devolatilized char in a holding chamber;

optionally interrupting fluid communication between the holding chamber and the rotary kiln reactor;

further devolatilizing at least some of the first devolatilized char in the holding chamber to produce a second devolatilized char;

collecting the char of the second devolatilization component.

60. A method as set forth in claim 59 further comprising delivering gas to the holding chamber so as to reduce vapor ingress from the rotary kiln reactor into the holding chamber.

61. The method of any one of claims 59-60, further comprising delivering a gas to remove material accumulation on the at least one inner wall.

62. The method of any of claims 59-60, wherein the polymer feed material is exposed to two to about six different temperature zones within the rotary kiln reactor.

63. The method of claim 62, wherein the polymer feed material is exposed to four different temperature zones within the rotary kiln reactor.

64. The method of any one of claims 59-60, wherein the method is performed in a continuous manner.

65. A condensing train, comprising:

a first condenser configured to condense a first liquid comprising pyrolysis oil products from feed vapor provided to the first condenser,

the first condenser is optionally configured as a downflow condenser;

a second condenser in fluid communication with the first condenser,

the second condenser is configured to receive the first overhead from the first condenser,

the second condenser is configured to condense a second liquid comprising the pyrolysis oil product from the first overhead; and

an optional third condenser in fluid communication with the second condenser,

the third condenser is configured to receive the second overhead from the second condenser,

the third condenser is configured to condense a third liquid comprising pyrolysis oil products from the second overhead.

66. The condensing array according to claim 65, wherein said first condenser is configured as a downspray condenser.

67. The condensing train of any one of claims 65-66, further comprising a flare train configured to combust uncondensed products from the third condenser.

68. The condensing bank column of any of claims 65-66, further comprising a fluid circuit configured to transfer a first liquid to the first condenser.

69. The condensing array according to claim 68, wherein said fluid circuit includes an adjustable diverter configured to divert at least some of said first fluid to said first condenser.

70. The condensing train of claim 68, wherein the first condenser is configured to contact the feed vapor with pyrolysis oil products delivered to the first condenser.

71. The condensing train of any one of claims 65-66, further comprising a gas delivery train configured to deliver gas to the first condenser, the gas delivery train optionally comprising a transfer tube.

72. The condensing array according to claim 71, wherein said gas is nitrogen.

73. The condensing bank according to any of claims 65-66, wherein the first condenser is configured to operate at about ambient temperature to about 204 ℃.

74. The condensing bank according to any of claims 65-66, wherein the second condenser is configured to operate at about 16 ℃ to about 54 ℃.

75. The condensing bank according to any of claims 65-66, wherein the third condenser is configured to operate at about 2 ℃ to about 21 ℃.

76. The condensing bank according to any of claims 65-66, wherein the third condenser operates at a sub-ambient temperature.

77. The condensing train of any of claims 65-66, further comprising at least one of a knock-out pot, a single seal pot, or a mist eliminator.

78. The condensing train of claim 77, comprising a knock-out pot.

79. A method, the method comprising:

a feed comprising vapor comprising pyrolysis oil products is passed to a first condenser,

the first condenser is optionally a downflow condenser;

operating the first condenser so as to produce a first liquid comprising the pyrolysis oil product and a first overhead comprising the pyrolysis oil product;

recycling at least some of the first liquid to the first condenser;

passing the first overhead to a second condenser;

operating the second condenser so as to produce a second liquid comprising the pyrolysis oil product and a second overhead comprising the pyrolysis oil product;

Passing the second overhead to a third condenser; and

the third condenser is operated so as to produce a third liquid comprising the pyrolysis oil product and a third overhead comprising uncondensed material.

80. The method of claim 79, further comprising recycling at least some of the first liquid back to the first condenser, and optionally cooling the first liquid.

81. The method of claim 79, further comprising contacting the recycled first liquid with the feed vapor.

82. The method of any one of claims 79-81, further comprising passing pyrolysis oil product to the first condenser.

83. The method of any of claims 79-81, wherein the first condenser is configured to operate at about ambient temperature to about 204 ℃.

84. The method of any of claims 79-81, wherein the second condenser is configured to operate at about 16 ℃ to about 54 ℃.

85. The method of any of claims 79-81, wherein the third condenser is configured to operate at about 2 ℃ to about 21 ℃.

86. The method of any of claims 79-81, wherein the third condenser is operated at sub-ambient conditions.

87. The method of any one of claims 79-81, further comprising: (a) Combusting the uncondensed material, (b) combusting the condensed material so as to heat a reactor train producing the first overhead, or both (a) and (b).

88. The method of any one of claims 79-81, wherein the first liquid comprises char.

89. The method of any one of claims 79-81, further comprising passing any one or more of the first, second, and third overheads to a knock-out pot, a seal pot, or a mist eliminator.

90. The method of any one of claims 79-81, wherein the method is performed in a continuous manner.

91. An operating unit, comprising:

a first compartment;

a second compartment;

a conduit extending through the first compartment and into the second compartment,

the conduit is at least partially surrounded by a conduit jacket,

the conduit jacket defines an outer diameter,

the conduit places the second compartment in fluid communication with an environment outside the compartment,

the second compartment comprises a wall facing the conduit jacket, and

the second compartment is rotatable relative to the first compartment;

A seal defining a boundary between the first compartment and the second compartment,

the seal extends radially from the wall of the second compartment toward the conduit jacket,

the seal includes a first flange secured to and extending from a wall of the second compartment, the first flange defining an inner diameter,

(a) The seal includes a layered portion including a plurality of annular portions,

at least one of the annular portions has an inner diameter less than an outer diameter of the conduit jacket such that the at least one annular portion rotatably abuts the conduit jacket, the outer diameter of the conduit jacket optionally being no more than about 1.25cm greater than the inner diameter of the at least one annular portion, or

(b) The seal includes a brush rotatably abutted against the catheter jacket.

92. The operating unit of claim 91, wherein the first flange includes a plurality of portions.

93. The operating unit of any one of claims 91-92, wherein the layered portion is attached to the first flange.

94. The operating unit of any one of claims 91-92, further comprising a first gasket attached to the first flange.

95. The operating unit of claim 94, wherein the layered portion is attached to the first face of the first gasket.

96. The operating unit of claim 95, further comprising a second gasket attached to a second face of the first gasket.

97. The operating unit of claim 96, further comprising a fastener extending at least partially through the first washer, layered portion, and second washer.

98. The operating unit of any one of claims 91-92, wherein the annular portion comprises steel, aluminum, brass, bronze, copper, carbon fiber, glass-loaded vermiculite, or any combination thereof.

99. The operating unit of any one of claims 91-92, wherein the layered portions comprise an alternating arrangement of annular portions.

100. The operating unit of any one of claims 91-92, wherein the layered portion comprises a periodic arrangement of annular portions.

101. The operating unit of any one of claims 91-82, wherein the layered portion comprises at least two annular portions having different moduli.

102. The operating unit of any one of claims 91-92, further comprising a source of pressurized fluid in fluid communication with the second compartment.

103. The operating unit of claim 102, wherein the fluid comprises a non-reactive fluid.

104. The operating unit of claim 102, wherein the fluid comprises nitrogen.

105. The operating unit of any one of claims 91-92, further comprising a pressure sensor configured to detect pressure within the first compartment.

106. The operating unit of any one of claims 91-92, further comprising a pressure sensor configured to detect pressure within the second compartment.

107. The operating unit of any one of claims 91-92, further comprising a pump configured to reduce pressure within the second compartment.

108. The operating unit of any one of claims 91-92, further comprising a motor configured to rotate the second compartment.

109. The operating unit of any one of claims 91-92, further comprising a circumferentially rotatable joint configured to support rotation of the second compartment.

110. The operating unit of claim 109, further comprising a source of pressurized fluid in fluid communication with the circumferentially rotatable joint.

111. The operating unit of claim 110, wherein the fluid comprises an inert gas.

112. The operating unit of claim 110, wherein the fluid comprises nitrogen.

113. The operating unit of any one of claims 91-92, wherein the second compartment is configured as a rotary kiln reactor.

114. The operating unit of claim 113, wherein the second compartment includes one or more chains, lifters, or helical flights.

115. The operating unit of any one of claims 91-92, wherein the seal comprises a layered portion comprising a plurality of annular portions, at least one of the annular portions having an inner diameter that is smaller than an outer diameter of the conduit jacket such that the at least one annular portion rotatably abuts the conduit jacket.

116. The operating unit of any one of claims 91-92, wherein the first compartment is defined by an interference fit joint that is expandable in response to a temperature within the first compartment, a temperature within a second compartment, or both.

117. The operating unit of any one of claims 91-92, further comprising a fabric portion at least partially surrounding the first compartment.

118. A method comprising operating an operating unit according to any one of claims 91-92.

119. The method of claim 118, wherein the operation is performed to pyrolyze hydrocarbonaceous material.