WO2013054334A2

WO2013054334A2 - Rotary reactor cum vaporizer

Info

Publication number: WO2013054334A2
Application number: PCT/IN2012/000141
Authority: WO
Inventors: Raghavendra Rao TURLAPATI
Original assignee: Turlapati Raghavendra Rao
Priority date: 2011-10-12
Filing date: 2012-02-29
Publication date: 2013-04-18
Also published as: WO2013054334A3

Abstract

The present invention discloses a device for vaporization of carbonaceous homogenous and heterogeneous, segregated or unsegregated, wet or dry input feed comprising of a rotary reactor cum vaporizer vessel system. In particular, the present invention discloses a rotary reactor cum vaporizer vessel system, having controls for temperature, rotational speed and inclination, and which avoids direct combustion of feed material inside the vessel at any given time. The present invention further discloses a rotary reactor cum vaporizer vessel system designed to provide a continuous vaporization process of carbonaceous input feed material into high molecular weight hydrocarbons in vapour state.

Description

ROTARY REACTOR CUM VAPORIZER

Field of Invention:

The present invention relates to a device for vaporization of carbonaceous homogenous and heterogeneous input feed comprising of a rotary reactor cum vaporizer vessel system. In particular, the present invention relates to rotary reactor cum vaporizer vessel system, having controls for temperature, rotational speed and inclination, and which avoids direct combustion of feed material inside the vessel at any given time. The present invention further relates to a rotary reactor cum vaporizer vessel system designed to provide a continuous vaporization process of carbonaceous input feed material into high molecular weight hydrocarbons in vapour state.

Background of Invention:

Renewable energy sources with sufficient capacity to supply for a significant share of energy demand are now being exploited increasingly. Various arenas of such renewable sources of energy are now being researched into in order to generate more and more options for reducing carbon footprints. Waste products resulting from, but not necessarily limited to, forestry and agricultural residues, animal wastes, bacterial sludge, sewage sludge, municipal solid waste, food wastes, animal bovine parts, industrial solid waste, petroleum coke, oil shale, waste oil, industrial liquid wastes, residuals from petroleum refining, electronic wastes etc. are contributing significantly to environmental pollution. Dumping of these wastes and its effective disposal has become widely challenging. Challenges such as these have compelled scientists to tap into the waste management processes as plausible renewable sources of energy. To overcome environmental hazards and to meet the ever increasing energy demand, efforts are now being directed to conversion of various waste materials into useful hydrocarbon fuels as energy resources.

Different forms of solid waste treatment technologies and facilities employed in waste management infrastructure include gasification, incineration, bio-drying, mechanical heat treatment, combustion of organic wastes, thermal cracking, plasma arc waste disposal etc. The technologies described therein are targeted to convert one or two limited feed stocks into end products, the processes require high temperatures, require relatively high voltage and thus high energy consumption. Certain processes cannot handle all kinds of heterogeneous mix of waste material. Therefore, pre-segregation of such material becomes necessary. The gases produced using heterogeneous wastes may further require cleaning and filtration to obtain useful hydrocarbons which can be used as fuel. Processes like gasification and subsequent post-processing methods on resultant vapours neither directly emit nor trap greenhouse gases such as carbon dioxide. Moreover, power consumption in gasification and syngas conversion is significantly higher and may indirectly cause additional C0₂ emissions.. Further, direct combustion of reactants such as in thermal cracking leads to non-uniform heating of the reactants. For such processes, to extract carbon and carbon fraction fuels, it may pose a particular challenge since such non-uniform heating of input source may lead to a less industrious yield composed of uneven amounts of carbon fractions.

A European Patent EP 1260599 discloses device for the pyro-metallurgical working up of waste material, e.g. household waste, broken road asphalt or shredder light fractions from the disposal of vehicles comprises a melting down oxidation reactor formed as a fluidized bed reactor connected to a tipping and/or oscillating drive. The reactor has nozzles for blowing in gases in the reactor wall, thus leading to direct combustion of the feed/reactants.

Due to economic and ecological reasons, it is necessary to improve the existing technologies to reduce the energy consumption, to control the temperature of the reaction during direct heating of the input feed as highly exothermic reaction conditions lead to a possibility that all of the reaction mixture may be burnt or spent before the desired useful hydrocarbons are s obtained, to avoid catalyst damage in case of pyro catalytic cracking, to obtain optimal residence time to bring out the effective conversion of the feed material etc. As fluidized bed reactors are characterized by a high heat and mass transfer, the use of a rotary reactor promises the saving of thermal energy, the acceleration of removal processes and the material throughput.

It is seen that reactors for catalytic cracking, fluidized catalytic cracking for the conversion of biomass need pre-processed, cleaned, sorted and proportionately composed input feed for generating desired hydrocarbon fuel output. Such reactors have negligible tolerance for unwanted particles such as soot and other gaseous waste products since such impurities may clog outlets and increase the serviceability and maintenance requirement of the equipment. In absence of a uniformly pre-dried input feed, generated output is often contaminated with impurities. Managing rate of flow of reactants and an appropriate temperature range throughout the process play a crucial role in for consistent output quality and quantity. Further, this requires specially modified means to maintain the various specific parameters such as reaction time, temperature, residence time, flow rate etc. to bring about economical, efficiently functional and industrious continuous conversion of input feed in bulk quantities to useful hydrocarbons.

In the last few years, researchers have mainly focused on indirect rotary drum reactor technology for pyrolysis of waste material at ambient temperature and pressure, either in presence or absence of a catalyst along with the provisions for additional means of suitable heating, drying and vaporizing.

Japanese patent, JP 2208461, discloses a 'Rotary chemical heat pump' to obtain incremental heating by heat storage and release at each successive cell based on hydration and dehydration reactions induced by rotation of each rotary unit. The three rotary units, piled up in stages, comprise a cylindrical vessel, divided into plurality of fanwise distributed cells separated by radial partitions. Moreover, it is partitioned into an indoor chamber and an outdoor chamber with an arc-shaped partition wall provided with a ventilation port respectively. One chamber serves as a reactor, which induces a heat storage medium to perform hydration/ dehydration reactions, while the other chamber serves as a vaporizer and condenser which vaporizes and condenses water. The rotation of rotary units performs heat storage and radiation at each cell successively based on the hydration and dehydration reaction of the heat storage medium to obtain heating values which exceed introduced heating values consecutively, driving a rotary chemical pump. Such multi-chamber reactor arrangements often add on to the serviceability of the overall functioning of the plant and equipment.

Another US application, US 2009277090 titled 'Gas Distribution Arrangement for a Rotary Reactor' discloses a port assembly comprising a main conduit extending from front to the rear of a rotary kiln. The conduit is divided into four or more non- communicating sections for introducing gases such as air, oxygen and steam into the kiln at the locations inside the kiln coinciding with the specific sections of the conduit. Each section of the conduit communicates independently to the supply of reactant gases for that particular section. The amount of gas and the composition of gas supplied to each of the section is independently controlled to commensurate with the specific gas solid reaction requirement at a particular stage of reaction along the rotary kiln. The conduit is placed along the vertical axis of the rotary kiln and positioned such that the lower portion of the conduit is immersed in the layer of solids present at the bottom of the rotating kiln. Each section of the port assembly communicates with the kiln through the plurality of the nozzles drilled into each section of the port. The nozzles are confined to lower third circumference of the conduit to prevent escape of reactant gases into the main gas stream without having first contacted with the solids present in the rotary kiln. The immersion of the lower section of the conduit into the layer of solids residing on the bottom of the kiln promotes intimate mixing between the gas and solids and thereby accords first opportunity for reactant gases to react with solids prior to merging into main gas stream in the rotary kiln. The said assembly has multiple chambers which add to the complexity of the equipment, there is direct contact of the gases with the input feed (solids) which leads to direct combustion and hence impacts the yield and purity of the product.

A German application DE 3503069 discloses a rotary-drum reactor, which is indirectly heated by means of a flowing heat transfer medium, comprising a rotatably mounted, driveable shell tube and a plurality of tubes or tube sections arranged within the shell tube in which, the tubes or tube sections arranged in the interior of the shell tube are designed as material tubes for the throughput of the material to be reacted. The material tubes can be heated indirectly and individually by means of liquid heat transfer media, and the outer wall of the shell tube does not come into contact with the heat transfer medium. Each of the plurality of material tubes preferably is covered with the heating coils and is heated indirectly. The reactor is preferably used for pyrolysis. Further, the process is characterised in that the indirect heating is accomplished by using a salt melt as the heat transfer medium. Such a construction envisages a multi-chamber reactor system, wherein maintaining reaction constraints over the distributed material tubes may pose an additional challenge of serviceability, also due to multiple material tubes it leads to additional reactant losses thereby minimising the yield while incurring additional operational expenditure costs. As seen through various prior arts herein above, known rotary drum reactors embodying fluid bed reactors, employing multiple cylindrical or barrel like or curved drum-like or tube-like chambers for reaction are complicated, are not capable of handling all kinds of heterogeneous feed input, requires frequent maintenance and serviceability thus adding to the capital and operational costs etc. Moreover, the prior art reactors do not specifically relate to controlled vaporization of the input feed into high molecular weight gases which can be further reformed to low molecular weight hydrocarbon products due to which the operational temperature remains high for the conversion process thus making the process uneconomical.

There is thus an obvious need for an equipment that is compact, integrated and comprises heating, drying, reacting and vaporizing of the input feed all in one, enabled to carry out the controlled vaporization process of all kinds of homogenous and heterogeneous waste material feed in to high molecular weight hydrocarbons, in a continuous manner, for subsequent conversion to useful hydrocarbon fuels through catalytic cracking or any such suitable conversion process thereof. The present invention targets at achieving this objective.

Brief Description of Drawings:

Figure 1 : illustrates the rotary reactor cum vaporizer (RRV) as seen in its front view and right hand side view.

Figure 2: illustrates the RRV system when inclined.

Figure 3a: illustrates a gas fired burner with infra-red emitter.

Figure 3b: illustrates the gas fired burners with infra-red emitter and the heating system in the outer stationary combustion chamber

Figure 4: illustrates the Reactor Vaporizer (RV).

Detailed Description of Invention:

The invention will now be described in detail in connection with certain preferred and optional embodiments, so that various aspects thereof may be more fully understood and appreciated. The present invention relates to a rotary reactor cum vaporizer vessel system, having controls for temperature, rotational speed and inclination, and which avoids direct combustion of feed material inside the vessel at any given time. The instant invention further relates to a rotary reactor cum vaporizer vessel system that carries out controlled vaporization of the homogenous and/or heterogeneous carbonaceous, segregated or un- segregated, wet or dry feed material in to high molecular weight hydrocarbons in a continuous manner, thereby allowing the process to carry out from ambient to the vaporization temperature of the input feed material.

In view of overcoming the drawbacks seen in the prior arts for chemical conversion of the feed material into useful hydrocarbon vapour fractions/ combustible fuels, the inventor has focussed on the use of an improved rotary reactor chamber wherein heating, drying, reacting and vaporizing of the input feed material into the high molecular weight gases, which can further be decomposed into useful hydrocarbon fractions, occurs all in a single chamber. The improvised rotary drum reactor can adapt to all kinds of homogeneous and heterogeneous carbonaceous waste material in any form and which can be vaporized at optimum temperature of the feed material and wherein the vapours so formed are optimized in hydrocarbon content thus ensuring a refined input for further conversion into useful low hydrocarbon fuels.

In its various embodiments as disclosed herein below, the present invention relates to the reactor cum vaporizer (RV) vessel system or a rotary reactor cum vaporizer (RRV) vessel system to carry out the vaporization of the said feed material.

In an embodiment, the present invention discloses a Rotary Reactor cum Vaporizer (RRV) vessel system comprises;

• A rotary cylindrical vessel system, having inner rotary reactor and outer stationary combustion chamber arranged in a concentric/ jacketed fashion, wherein, the inner rotary reactor chamber, accepting the input feed, is enclosed in the stationary outer combustion chamber separated by an air gap ;

• Heating means to generate heat flux in the said gap between the inner rotary reactor chamber and outer stationary combustion chamber;

• A Means for controlling inclination; • A Means for controlling rotational speed of the RRV;

• A Means for temperature control.

In a preferred embodiment, as illustrated in Fig. 1, the rotary reactor cum vaporizer system comprises a cylindrical vessel system, having an inner rotary reactor chamber (10) and outer stationary combustion chamber (09) arranged in a concentric/ jacketed fashion. The inner rotary reactor chamber (10), accepting the input feed, is enclosed in the stationary outer combustion chamber (09) separated by an air gap. The said inner rotary reactor chamber (10) is heated by said heating mechanism comprising a gas header (1 1 ) for gas fired burners with infrared emitters (12) generating heat flux in the said air gap to indirectly heat the carbonaceous input feed in the inner rotary reaction chamber (10). The said air gap between the inner rotary reactor chamber (10) and outer stationary combustion chamber (09) is sealed by an air tight seal ⁵(21 ) to prevent loss of heat flux. The outer stationary combustion chamber (09) is covered by insulation (22) to prevent outward loss of heat flux and conserve energy. A separate air tight sealing mechanism (02) prevents the ambient atmospheric air from entering the entire vessel system with the help of a damper unit (20). The inner rotary chamber (10) is mounted on a driving gear mechanism (13) controlled by drive gear (03) and driven by a motor ( 19), to achieve said rotary motion supported by the rubber support system (07). A gas piping (06) from a combustible gas storage tank (05) provides the gas supply to the gas fired burners with infrared emitters (12). The gas flow to the gas fired burners. with infrared emitters ( 12) is controlled by the PLC controlled gas regulatory valve ( 15).The entire RRV system is mounted on a hydraulic/ pneumatic/ motorised jack (04) and a pivot system ( 17) to achieve and maintain a suitable inclination as required for the reaction and vaporization of the said input feed. An expansion bellow (14) accommodates the varying inclination of the rotary reactor cum vaporizer system with respect to the gas regulatory valve (15) and the gas piping (06).

The rotary reactor and vaporizer system takes the said input feed material from a retractable shredder (01) at its input end. The output end comprises multiple outlets such as gas outlet (08) to the field replaceable multifunctional cartridge system and outlet for residue recovery system (16). The non-condensable gaseous hydrocarbons coming out of the field replaceable multifunctional cartridge system are passed into the burner gas storage tank (05) through burner gas storage tank inlet (18). .

The material to be heated is fed into the RRV vessel through the retractable shredder (01). The RRV vessel is a controlled reaction vessel having the controls of temperature, rotational speed and inclination. Between managing the 3 parameters, the material to be heated is subjected to a heat flux for a set duration. The duration of input feed residence time is controlled by the inclination of the vessel controlled and maintained by hydraulic/ pneumatic/ motorised jack (04) and a pivot system (17). The expansion bellow (14) accommodates the varying inclination of the RRV system with respect to the PLC (programming logic controller) controlled gas regulatory valve (15) and the gas piping (06) thus acting as a buffer to prevent accidental damage to the gas piping (06) . The inclination of the RRV is maintained in the range 0° to 45°; preferably at 0° to 20° to ensure continuous optimum flow of feed material.

Similarly, the temperature is controlled by an electronically controlled PLC system (not shown in the Figure) which is controlled by an on-board micro-processor. The temperature of the RRV is maintained between the room temperature and vaporisation temperature i.e. approximately -5°C to 450°C, depending on geographical variations in room temperature and requirement of the input feed composition. The thermal sensors (placed suitably as required) located inside the RRV vessel send the temperature signals to the PLC and the burners are automatically switched on or off depending upon the temperature inside the RRV vessel.

The rotational speed is controlled by the driving gear mechanism (13) controlled by drive gear (03) and driven by a motor (19), to achieve said rotary motion supported by the rubber support system (07). The rotational speed of the RRV varies between 10 rpm to 120rpm preferably between 10-60 rpm keeping in mind the nature and composition of the input feed material.

As illustrated in figure 2, the inclination of the RRV vessel is controlled and maintained by hydraulic/ pneumatic/ motorised jack (04) and a pivot system (17). The expansion bellow (14) accommodates the varying inclination of the RRV system with respect to the PLC controlled gas regulatory valve (15) and the gas piping (06) thus acting as a buffer to prevent accidental damage to the gas piping (06).

The purpose of maintaining the inclination of the RRV at a suitable angle is to enable smooth and uniform transfer of the input feed material from input end to output end of the RRV by mobilizing the feed under gravitational pull, thus ensuring an optimal residence time in the vessel.

The temperature in the RRV ranges from the ambient to the vaporization temperature (- 5°C - 450° C) of the input feed material. The input material reaches the vaporization temperature and by the time it reaches the end of the RRV vessel, vaporization is completed and only dry, powdery carbon remains are available for discharge. Thus the process is designed as a continuous feed process. The vapours coming out of the RRV vessel, from the gas outlet (08), are further passed in to a field replaceable multifunctional cartridge system for catalytic cracking into useful hydrocarbons. Subsequently, the non- condensable gaseous combustible gases are sent to the combustible gas storage tank (05) to be reutilised for the heating process. The residual discharge from the RRV is discharged into the residue recovery system through outlet ( 16).

As illustrated in Figure 3a, the gas fired burners with infrared emitters (12) comprise of infrared emitters mounted over a combustion chamber. The combustible gases from the combustible gas storage tank (05) are sent into the said combustion chamber through gas inlet header. Further, as seen in Figure 3b, the gas infra-red mantle heater, made of an alloy steel fabric or any similar temperature resistant material, is embodied on the inner surface of the outer stationary combustion chamber to generate heat flux from the infrared heat waves arising from the emitters of the gas fired burners with infrared emitters (12) that impinge on the said gas infra-red mantle heater. Thus, the total heat imparted by the gas burners with IR emitter's infrared emitters (12) is due to part convection and part radiation. The hot gases of combustion escaping from the combustion chamber of the gas burners with infrared emitters (12) carry convection heat which is then transferred to the outer surface of the inner rotary reactor chamber (10). The direct flame of combustion inside the combustion chamber of the burner heats the steel mantle which becomes red hot and starts emitting infrared radiation. Thus the radiation from the emitter impinges on to heating surface of the outer combustion chamber (10). Thereafter, the exhaust gases from the air gap are drawn into a scrubber to be released into the atmosphere. Thus the RRV is not in direct contact with the heater but heated by Infrared rays causing the RRV to heat up uniformly along its length and circumference.

The Retractable shredder (01) which is connected at the input end of the RRV vessel is a movable inlet system which is mounted on a trolley. The Breaching is insulated and made gas tight.

In an embodiment, the vapours obtained from the RRV system may further be cracked/ converted into useful hydrocarbon fuels and hydrogen in a converter in presence of a catalyst. The catalyst is a single or multi-layered bed of agglomerated nano catalyst. The agglomerated nano catalyst is a metal, metal oxide, metal hydroxide optionally in combination with the binder or montmorillonate clay selected from the transition metals of group IV, the lanthanides or actinides either alone or combination thereof. The process of conversion of the vapours into useful hydrocarbons may further be carried out either by pyrolytic or by thermal process. The intermediate vapors obtained comprise a mixture of high molecular weight hydrocarbons with a carbon chain length upto C40, hydrogen and others.

The high molecular weight hydrocarbons after vaporisation are then passed into field replaceable multifunctional cartridge system wherein the multifunctional cartridge system is loaded with the agglomerated nano catalyst for pyrolytic or by thermal cracking. The vapours are broken down to low molecular weight hydrocarbons with a carbon chain length upto C40 along with other gases which is discharged through outlet (16). The low molecular weight hydrocarbons are passed into the condensers and the non-condensed combustible gases are passed into the combustible gas storage tank (05) through inlet (18).

The analysis of intermediate vapours obtained during vaporization in the said RRV system from various dry and wet waste feed material is given below in the examples. The data indicates that the wet feed material produces hydrocarbon vapours of good calorific value than the dry waste feed material.

Alternately, the present invention relates to a vertical reactor cum vaporizer vessel (RV) system, as illustrated in Figure 4, that has vaporization of reactants as a main body of process equipment, comprising;

• The drum assembly (concentric/jacketing manner);

• External Heating assembly;

• A temperature distribution and flow rate modulation mechanism

The reactor cum vaporizer vessel (RV vessel) (09) is a vertical, cylindrical vessel heated indirectly using electrical band heaters or induction heating or Infra- Red heating using indirect gas/liquid fuel combustion or any other heating system. The RV Vessel (09) is heated from outside and the material to be heated is placed inside the RV Vessel. Thus, there is no direct combustion of the material inside the RV vessel at any given time. The heat flux received by the vessel is conveyed to the material inside. As the temperature inside the vessel rises, the material inside the RV vessel begins vaporizing at a temperature range between 80° - 450° C, depending upon the material that is being heated. The heat flux in the RV Vessel is a variable system and the temperature can be set to meet the specific melting points of various kinds of feed material or specific vaporization temperatures of the input feed. Advantageously, the Vertical RV vessel is a thin film evaporator having a distributor specifically designed for the purpose of viscous flowing materials such as rubber, plastics and other polymers. The high molecular weight gaseous hydrocarbons extracted from the RV vessel (09) are then passed into the field replaceable multifunctional cartridge system and subsequently condensed in the condenser. The non-condensed gases are then stored in the combustible gas storage tank (05) as shown in Figure 1.

In an embodiment, individual homogenous waste streams or a heterogeneous mixture of co-mingled, un-segregated, moist, dirty, contaminated waste materials containing hydrogen and carbon in their chemical structure can be vaporized in the RV system or RRV system of the instant invention. Such waste materials include and are not limited to; Municipal Solid waste, waste plastics including halogenated plastics and high temperature resistant industrial plastics, e-waste, waste rubber tyres, Styrofoam or thermocol and other rubber materials, organic waste , polymer waste, agro waste such as sugar cane bagasse, edible and non-edible seeds, grass, bamboo, empty fruit bunch from palm oil extraction, bio-solids from oil seed wastes, de-oiled cakes from the extraction of edible oils like coconut, peanut, mustard, castor and other oils, waste lubricating oil from automobiles, automobile fluff, bio-solids from sewage treatment plants, vegetable fats, animal fats, used cooking oil, Jathropha and other oil bearing seeds, refinery waste products such as tank bottom sludge, vacuum residue, off-spec oils and lubricants, residual oils from oil tankers, soil contaminated with hydrocarbons, any hydrocarbon product, fibrous materials such as coconut fibre, coconut shells, any other vegetable plant based product including trimmings, leaves, stem, branches, roots, algae, water hyacinth and other aquatic plants, any polymeric material containing hydrogen-carbon bonds within its molecular structure, any organic material containing hydrogen-carbon bonds within their molecular structure.

In yet another embodiment, the present invention provides a method for continuous vaporisation of wet or dry, homogenous or heterogeneous, segregated or unsegregated carbonaceous input feed to obtain intermediate high molecular weight hydrocarbons composed of carbon chains up to C-40 in a Rotary Reactor Vaporizer (RRV).

In another embodiment, the invention relates to the use of Rotary Reactor Vaporizer (RRV) for continuous vaporisation of wet or dry, homogenous or heterogeneous, segregated or unsegregated carbonaceous input feed to obtain intermediate high molecular weight hydrocarbons composed of carbon chains up to C-40.

Advantages:

• Can efficiently process all kinds of homogenous, heterogeneous, dry, moist, segregated, non-segregated feed in bulk quantities.

• Works as a continuous process with no down time between processing of input feed going in and output being discharged out unlike batch-processing.

• Can optimally extract/vaporize hydrocarbon content from all kinds input feed, irrespective of its original, individual hydrocarbon composition,

• Inner chamber of the rotary drum reactor cum vaporizer manages heating, drying, reacting, vaporizing as a single pot process, thus avoiding complicated servicing and maintenance. • Enclosed heating mechanism prevents accidental hazards.

• Parameters of the reaction are easily maintainable.

• Equipment to maintain reaction parameters and constraints are constructed to be simple, efficient and easy to operate.

The following examples, which include preferred embodiments, will serve to illustrate the practise of this invention, it being understood that the particulars shown are by way of examples and for purpose of illustrative discussion of preferred embodiments of the invention only and are not limiting the scope of the invention.

Example: Analysis of the intermediate hydrocarbon vapours obtained from various wet and dry feed material using the RRV (pyro catalytic, thermal reaction) system:

Example 1: Analysis of the vapours formed from waste plastics.

The waste plastic is shredded and passed into the RRV system and vaporized at a temperature 450C. The intermediate vaporized hydrocarbons obtained are given below in

Table 1.

Example 2: Analysis of the intermediate vapors from dry organic matter

Components Cone Yield

C1-C5 15.83 %(v/v)

C6-C9 0.926 %(v/v) Hydrogen 6.03 %(v/v)

OTHERS 77.214 %(v/v)

Superior (gross) calorific 15.6424 MJ/m3 value

Inferior (net) calorific value 14.6462 MJ/m3

Example 3: Analysis of the intermediate vapors from wet organic matter

Component Cone yield

C 1-C5 21.73 %(v/v)

C6-C9 1.38 %(v/v)

Hydrogen 18.5 %(v/v) others 58.39 %(v/v)

Superior (gross) calorific 20.9543 MJ/m3 value

Inferior (net) calorific value 19.231 MJ/m3

Claims

I Claim,

1. A Rotary Reactor Vaporizer (RRV) for continuous vaporization of homogenous or heterogeneous carbonaceous input feed, wherein said rotary reactor vaporizer, having simultaneously operating components, comprises:

• a rotary cylindrical vessel arrangement, having inner rotary reactor and outer stationary combustion chamber arranged in a concentric/ jacketed fashion, wherein, the inner rotary reactor chamber, accepting the input feed, is enclosed in the stationary outer combustion chamber separated by an air gap ;

• a heating means to generate heat flux in the said air gap between the inner rotary reactor chamber and outer stationary combustion chamber;

• a means for controlling rotational speed of the inner rotary reactor chamber;

• a means for controlling inclination of the cylindrical vessel arrangement; and

• a means for controlling the temperature in the cylindrical vessel arrangement;

wherein, said RRV takes shredded waste material as input feed and discharges intermediate vapours of high molecular weight hydrocarbons, hydrogen for further cracking.

2. The Rotary Reactor Vaporizer as claimed in claim 1 , wherein the Rotary Reactor Vaporizer is provided with at least two outlets, one for releasing intermediate high molecular weight hydrocarbons and hydrogen for further cracking while another to discharge non vaporized residue into a residue recovery system.

3. The Rotary Reactor Vaporizer as claimed in claim 1 and 2, wherein the said intermediate high molecular weight hydrocarbons are composed of carbon chains up to C-40.

4. The Rotary Reactor Vaporizer as claimed in claim 1, wherein the said heating means to generate heat flux in the said air gap further comprises gas fired infrared emitters and heaters which are fueled by stored combustible gas stored in a combustible gas storage tank.

5. The Rotary Reactor Vaporizer as claimed in claim 1 , wherein the said means for controlling rotation of the inner rotary reactor chamber further comprises a driving gear mechanism, a single drive gear or plurality of drive gears and a driving motor along with a driving support system.

6. The Rotary Reactor Vaporizer as claimed in claim 1, wherein the said means for controlling inclination of the cylindrical vessel arrangement further comprises jacks and pivot system along with expansion bellows. .

7. The Rotary Reactor Vaporizer as claimed in claim 6, wherein the means of operating the jack comprises hydraulic or pneumatic or electrical system.

8. The Rotary Reactor Vaporizer as claimed in claims 1, 2 and 4, wherein the said expansion bellows are enabled to accommodate the varying inclination of the cylindrical vessel arrangement in order to prevent any accidental damage to the gas piping.

9. The Rotary Reactor Vaporizer as claimed in claims 1, 3 and 4, wherein the said means for controlling rotation of the rotary reactor chamber and the said means for controlling inclination of the cylindrical vessel arrangement, together, control the rate of flow of input feed inside the rotary reaction chamber, maintain uniform distribution of temperature throughout said feed and determine and control the residence duration of the said feed inside the said Rotary Reactor Vaporizer.

10. The Rotary Reactor Vaporizer as claimed in claim 8, wherein the parameters being controlled by temperature sensors at logical locations to trigger a PLC system for various parameter changes.

1 1. The Rotary Reactor Vaporizer as claimed in claim 1, wherein the rotary reactor vaporizer is inclined at a higher inclination and rotated at higher rotational speed for input feed that needs less residence time in the said rotary reactor vaporizer.

12. The Rotary Reactor Vaporizer as claimed in claim 1, wherein the rotational speed of the RRV varies in the range of 10-120rpm.

13. The Rotary Reactor Vaporizer as claimed in claim 1 , wherein the rotary reactor vaporizer is inclined in the range of 0°-45° depending on the mixture and composition of the input feed material.

14. The Rotary Reactor Vaporizer as claimed in claim 1, wherein the temperature in the said rotary reactor vaporizer ranges between geographically varying room temperature to 450°C i.e. -5°C and 450°C.

15. The Rotary Reactor Vaporizer as claimed in claim 1 , wherein the indirect heating is achieved by a combination of convection heating of the combustible gases in the gas fired burners and radiation heating of the impinging Infra -red rays between infrared emitters and heaters.

16. The Rotary Reactor Vaporizer as claimed in claim 13, wherein the flow of gas for combustion is controlled by the temperature sensors logically located in the RRV, wherein the sensors trigger a PLC system to operate a gas flow valve as well as a sparking mechanism to combust the gas as required. o

1 7. The Rotary Reactor Vaporizer as claimed in claim 1 , wherein homogenous or heterogeneous carbonaceous input feed mixture comprises un-segregated or segregated, wet or dry, dirty, contaminated waste materials containing hydrogen and carbon in their chemical structure.

18. A method for continuous vaporization of wet or dry, segregated or unsegregated, homogenous or heterogeneous carbonaceous input feed to obtain intermediate high molecular weight hydrocarbons of carbon chains up to C-40, comprising vaporization of the same in a Rotary Reactor Vaporizer (RRV).

19. Use of the Rotary Reactor Vaporizer (RRV) for continuous vaporisation of wet or dry, segregated or unsegregated homogenous or heterogeneous carbonaceous input feed to obtain intermediate high molecular weight hydrocarbons comprising of carbon chains up to C-40.