WO2019226135A2

WO2019226135A2 - Pyrolysis reactor

Info

Publication number: WO2019226135A2
Application number: PCT/TR2019/050059
Authority: WO
Inventors: Ahmet Turhan URAL; Ragup SARIOGLU; Yusuf ULUDAG; Murat Kayhan URAL
Original assignee: M-D2 Muhendislik Danismanlik Insaat Taahhut Ic Ve Dis Ticaret Limited Sirketi
Priority date: 2018-02-01
Filing date: 2019-01-31
Publication date: 2019-11-28
Also published as: TR201801440A1; WO2019226135A3

Abstract

The present invention relates to a pyrolysis reactor (1) which obtains industrial raw materials, monomer or secondary products by means of pyrolysis process from domestic, industrial, medical and natural wastes by performing heating through induction.

Description

PYROLYSIS REACTOR Technical Field

The present invention relates to a pyrolysis reactor which obtains industrial raw materials, monomer or secondary products by means of pyrolysis process from domestic, industrial, medical and natural wastes by performing heating through induction.

Background of the Invention

Industrial and domestic wastes lead to a significant environmental problem upon rapid increase of population and urbanization and an important part of these wastes composes of wastes that can be converted into a product having commercial value, being recyclable and useable in industry. Success is achieved in sectors such as glass, paper, metal in recycling whereas the same success cannot be obtained in recycling of organic wastes. The fact that organic wastes have a wide variety and also suitable processes cannot always be economic has an effect as well.

Disposal of recyclable wastes by combustion cause drawback in two respects. The first of these is that products that can be returned to economy are lost and the second of these are environmental damages owing to the fact that gases occurring during combustion such as NO_x are discharged to the environment.

Converting domestic, industrial, medical and natural wastes having large molecule chains into gaseous, liquid and solid products upon being heated in an oxygen-free environment is a method which is called as pyrolysis and has been used for many years. Obtaining monomer and/or secondary products from plastic wastes are issued being studied in both academic and industrial aspect and different methods are used for heating wastes in an oxygen-free environment. One of the oldest methods being used is to obtain various organics by heating forest wastes.

Polymethyl methacrylate (PMMA) is a polymer with high commercial value. Unlike many other polymers, it is broken into methyl methacrylate (MMA) that is its monomer to a large extent when it is subjected to pyrolysis and the obtained monomer must be purified so as to be reused in production and the recycling process comprising pyrolysis and purification steps for MMA is applied in industrial and commercial aspect.

The most widely-used method for pyrolysis of MMA is depolymerisation in hot metal bath (dementi Process). Lead or tin is usually used as bat material [Newborough M., Highgate D., Vaughan P.; Thermal depolymerisation of scrap polymers; Applied Thermal Engineering, 22 (2002) 1875-1883 and Popescu V., et ah; The characterization of recycled PMMA; Journal of Alloys and Compounds, 483 (2009) 432-436] This method has many disadvantages such as adverse effect on environment. Apart from this, using lead -which is cheaper as bath material- causes major drawbacks in terms of working environment and the product comprises metal residue that is difficult to be separated from monomer by means of conventional methods. Due to these reasons, dementi Process is not preferred in many countries. Carbon/metal mixture layer occurring in time on metal surfaces of bath is another disadvantage of dementi Process. Energy efficiency of the system is low since it is required to remove this layer from the bath at short intervals and cool the bath before each cleaning.

The fact that dementi Process is still used in commercial aspect despite all its drawbacks results from that methods developed alternatively have not been able to reach adequate economic competence or they have not been established in industrial aspect yet. Systems that are closest to commercialization among processes developed alternatively are Auger and fluidized bed systems. Wastes can be fed into Auger type pyrolysis reactors alone as mentioned in the United States patent document no. US3959357 and they can also be fed together with hot sand as mentioned in the United States patent document no. US6769203. The fact that sand increases heat transfer surface is the most important advantage of feeding by hot sand.

In systems wherein waste polymer is fed directly, the heating surface is limited to the outer surface of the Auger reactor. Performance of the pyrolysis process is determined by rate and efficiency in heat transfer. The fact that surface area of heat transfer is low causes the amount of product that can be obtained from unit volume to decrease. Although increasing surface temperature of the reactor seems as a solution in order to overcome this problem, high surface temperature leads to increase of unrequested gas ratio within pyrolysis products.

Adding hot sand to Auger reactor before polymer eliminates limitation of heat transfer surface area. Each of sand particles heated over pyrolysis temperature composes heat transfer surface area. Each particle meeting with plastic waste lose heat and get cold rapidly. Surfaces of plastic pieces contacting with hot sand particles melt and become sticky. The plastic surface is covered with sand particles in a short time and sand particles lower the pyrolysis rate by creating an insulation layer in terms of heat transfer. Another disadvantage of the method is that the sand must be transferred to a furnace or a combustion chamber with fluidized bed in order to be heated. Sand/plastic ratio is maintained about 10 so as to compensate for the temperature loss of sand particles meeting with plastics and keep the average temperature over pyrolysis temperature throughout the reactor (US 6,469,203 Bl) and this necessitates that a large amount of sand must be moved and burnt continuously. Fluidized bed systems can be separated into two groups; namely, systems which are fluidized by hot gas and systems which are fluidized mechanically. Because it does not react in systems which are fluidized by hot gas, usually nitrogen is used [Kaminsky W.; Recycling of polymers by pyrolysis; Journal de Physique, Vol. 3 Nov. 1993, Kang B.S., Kim S.G, Kim J.S.; Thermal degradation of poly(methyl methacrylate) polymers: Kinetics and recovery of monomers using a fluidized bed reactor and Vaughan P.W., Highgate J.D.; Depolymerisation; US 5,663,420] Due to the fact that homogeneous bed temperature can be obtained easily and the resulting pyrolysis products leave the reactor fast with this method, yield of targeted product becomes too high. For example, MMA is obtained in the ratio of 97% in PMMA pyrolysis [Kaminsky W.; Recycling of polymers by pyrolysis; Journal de Physique, Vol. 3 Nov.1993 and Kang B.S., Kim S.G, Kim J.S.; Thermal degradation of poly(methyl methacrylate) polymers: Kinetics and recovery of monomers using a fluidized bed reactor].

The most important disadvantage of this method is that energy efficiency is low. The hot gas used for fluidizing the bed leaves the reactor together with pyrolysis products and it is also required to cool the gas under dew point in order to recover pyrolysis products through the gas. The same gas is reheated and used for fluidizing the bed; sequential heating and cooling leads to decrease of energy efficiency. Energy consumption does not fall below MMA level of 10-13 MJ/kg despite the measures taken for increasing energy efficiency and although hot sand is circulated between two fluidized beds [Sasaki A., Tsuji T.; Poly(methyl methacrylate) pyrolysis by tow fluidized bed process; The 5^th ISFR, October 11- 14, 2009, Chengdu, China] It is determined that pyrolysis energy of PMMA particles heated up to the pyrolysis temperature by means of radiation and convection methods is in the range of 1.3-1.7 MJ/kg MMA (by radiation heating) and in the range of 2.5-2.7 MJ/kg MMA (by convection heating) respectively [De Wilde J.P; The heat of gasification of polyethylene and polymethylmethacrylate; Memorandum M-593, SFCC Publication No:53, September 1988] Therefore, energy efficiency in fluidized bed is under 30%. The second negative aspect of this method is that a pyrolysis product -at the least- remains inside the bed after cooling the gas used for fluidizing the bed. Due to the fact that these products are broken into smaller molecules when they are reheated, this leads to loss of product.

The third negative aspect of this method is that the polymer pieces fed into the reactor create large lumps and damage the fluidity characteristic of the bed. Major decreases may occur at heat transfer and pyrolysis rate because large lumps don’t move.

An important part of the above-mentioned problems could be solved in mechanically fluidized beds [Newborough M., Highgate D., Vaughan P.; Thermal depolymerisation of scrap polymers; Applied Thermal Engineering, 22 (2002) 1875-1883; Newborough M., Highgate D., Matcham T; Thermal depolymerisation of poly-methyl-methacrylate using mechanically fluidised beds; Grause G., Predel M., Kaminsky W., Monomer recovery from aluminum hydroxide high filled poly(methyl methacrylate) in a fluidized bed reactor; J. Ana. Appl. Pyrolysis, 75 (2006) 236-239 and Sasaki A. et ah; Recovery method of pyrolysis product of resin; US 8,304,573 B2] Agglomeration problem still continues in vibrationally fluidized beds and energy efficiencies of mechanically fluidized beds are high. There is no gas that must be heated, cooled continuously in such reactors. Efficiency of heat transfer of the sand, which is used within the bed, to the polymer pieces is high. Polymer pieces are subjected to pyrolysis quickly within the bed that is increased over the pyrolysis temperature. However, since these particles are stable, they can be heated from the outer surface of the reactor and in some geometries, by means of heaters that are put inside thereof as well. These heaters cannot be used inside a reactor abundantly because they impair fluidity and create extreme hot surfaces. The fact that outer surface area is also limited restricts the production capacity of such reactors. Stirring the bed continuously by a mixer ensures that the agglomeration problem does not affect the entire process and the lumps formed can be broken quickly [Sasaki A. et al.; Recovery method of pyrolysis product of resin; US 8,304,573 B2] In such reactors, the bed is fed by hot sand continuously and the sand getting cold is removed in order to be heated from beneath the bed. Therefore, the disadvantage existing in Auger reactors is also valid for such reactors.

All the above-mentioned pyrolysis methods are the methods wherein wastes are heated indirectly. Therefore, rate and efficiency of heat transfer is of critical importance in these processes. Microwave-based pyrolysis is a method wherein wastes are heated directly. The microwave generated in the microwave generator reaches the reactor by passing through the transfer channel and it is absorbed by the waste (usually polymer) here. The pyrolysis process starts when the absorbed microwave energy increases the temperature of the waste to the pyrolysis temperature. This method has an obvious superiority in comparison with other methods in terms of energy efficiency. Pyrolysis energy of PMMA was determined as 2.5-2.7 MJ/kg [De Wilde J.P; The heat of gasification of polyethylene and polymethylmethacrylate; Memorandum M-593, SFCC Publication No:53, September 1988] In microwave-based pyrolysis process, consumption of energy was measured as 2.5 MJ/kg [Poree I.D. et al. Process for Decomposing a polymer to its monomer or monomers US 6,160,031] These results indicate that the energy provided to the system is used in the pyrolysis process to a large extent. At the same time, purity of product is also quite high in microwave-based pyrolysis process as well. It was measured that there is MMA in the ratio of 97% within non-purified product obtained from PMMA Pyrolysis [Poree I.D. et al. Process for Decomposing a polymer to its monomer or monomers US 6,160,031]

The fact that the system is quite complex and the risks encountered during operation are the most important disadvantages of microwave-based systems. Particularly, a fire outbreak is in question in the event that organic vapours penetrate the microwave channel or microwave generator [Poree I.D. et al. Process for Decomposing a polymer to its monomer or monomers US 6,160,031] It is required to take precaution specifically for protecting these lines and to perform nitrogen feed to the microwave line continuously. It is very important to prevent arc formation in microwave heating [Hemmings J., Pinto T., Sharivker V., Method and apparatus for microwave depolymerization of hydrocarbon feedstocks; US 8,466,332 B 1] Pyrolysis is a process wherein combustible gases occur naturally. Probability of arc occurrence and risk of fire in the system are the most important obstacles in common use of this method.

Another disadvantage is that microwave absorptions of wastes are different because their dielectric features are different. Microwave absorption of some polymers such as PET is very low and during pyrolysis of such polymers, it is required to add materials with high dielectric loss to the reactor such as carbon black. Materials with high dielectric loss transmit the absorbed energy to the waste indirectly.

Dielectric loss of some polymers such as PMMA increase by heat. These need to be subjected to pre-heating in order to be pyrolyzed efficiently in microwave reactor. Pre-heating the material adds a complexity to the process and this creates an additional disadvantage in terms of microwave-based pyrolysis process.

Another disadvantage is that carbon residues occurring during pyrolysis absorb the microwave energy excessively. There is risk that reactor temperature may exceed the pyrolysis temperature due to excessive absorption. It is important to control the microwave generator continuously and adjust it according to the changing reactor composition.

A further disadvantage of this method is that it is not possible to direct the microwave entering the reactor. Although the purpose is to direct the entire wave to the waste, there is always a probability that a part of it reaches the inlet opening and melt the polymer present here. Because the polymer melting in the inlet opening will close the opening, it will cause the process to stop.

Heating the reactor by means of induction method used as a heat transfer method is disclosed in patent documents no. US 8668810 Bl and WO 94/24837 in the prior art. In the United States patent document no. US 8668810 Bl, steel reactor is heated by the coil around thereof. The induction current occurring in the steel reactor enables the body to get heated and when the body reaches the pyrolysis temperature, molecular degradation of the wastes start. This method can be used not only in pyrolysis processes of wastes but also for degradation of smaller molecules such as dioxin at high temperatures [Cheon J.D.; Incinerating apparatus using low and high frequency induction heating; WO 02/33320 Al]

The fact that such system can be used for all types of wastes and produced in different sizes are its important advantages. Since there is no physical contact between induction generator and reactor, there is no risk for pyrolysis products to reach the generator contrary to systems wherein microwave is used energy efficiency is high in comparison with indirect heating methods such as heating reactor circumference by hot gas, because the heat occurs around or inside the reactor.

It is not possible to heat non-conductive materials by means of induction heating method directly. Heating plastics, ceramics, glass, mica, etc. materials by means of induction heating is only possible by mixing them with conductive materials such as metal [Monovoukas Y., El Camina R.; Induction heating of loaded materials; WO 94/24837] Conductors exhibiting magnetic characteristics such as iron, ferritic steel, nickel get heated much faster than the ones which are not austenitic steel, aluminum, copper. Geometry and size of a material are also factors affecting the heating speed as well [Monovoukas Y., El Camina R.; Induction heating of loaded materials; WO 94/24837] Disadvantage of the system which is developed for the purpose of pyrolysis in the United States patent document no. US 8668810 B1 is that heating is performed by means of reactor body. Induction enables the body to get heated and wastes contacting the body at high temperature are subjected to degradation. Therefore, only wastes contacting the body are subjected to pyrolysis and this limits the pyrolysis rate due to the fact that surface area of the heat transfer is limited with the body.

The International patent document no. W094/24837 discloses heating plastic pieces by means of metal materials placed into thereof. Induction heating enables to heat a thin shell on material. Thickness of this shell depends upon the type of material and the induction frequency used. It is aimed to heat plastic materials in a short time without creating a change in their general characteristics in the International patent document no. W094/24837.

Summary of the Invention

An objective of the present invention is to realize a pyrolysis reactor which uses heating process by induction, without a physical contact, and which is used for obtaining industrial raw materials, monomer or secondary products by means of pyrolysis method from medical, natural wastes.

Another objective of the present invention is to realize a pyrolysis reactor wherein polymeric materials and domestic wastes are broken into small molecules in an oxygen-free environment by means of induction heating.

Another objective of the present invention is to realize a pyrolysis reactor which is made of a material whose outer circumference has no electrical and magnetic feature, and the outer periphery of which does not get heated as a result of heating by induction. Another objective of the present invention is to realize a pyrolysis reactor wherein the heat required for pyrolysis is transferred to wastes by its contact with the particles and/or the powders that are located within the body having a periphery with no electrical and magnetic feature and that have electrical and magnetic conductivity.

Another objective of the present invention is to realize a pyrolysis reactor wherein a homogeneous temperature distribution is obtained within the body by continuously mixing the particles and/or the powders that are located within the body having a periphery with no electrical and magnetic feature and that have electrical and magnetic conductivity, and the interior part of the body is fluidized mechanically.

Another objective of the present invention is to realize a pyrolysis reactor wherein pyrolysis is carried out at low temperature without causing loss in production due to the fact that the particles and/or the powders that are located within the body having a periphery with no electrical and magnetic feature and that have electrical and magnetic conductivity provide a very large surface area.

Another objective of the present invention is to realize a pyrolysis reactor wherein heat transfer surface area is determined by the surface area of the particles and/or the powders that are located within the body without being limited to the body periphery due to the body with no electrical and magnetic feature and the particles and/or the powders that have electrical and magnetic conductivity located within the body.

Another objective of the present invention is to realize a pyrolysis reactor wherein the temperature within the body that has the periphery with no electrical and magnetic feature is controlled automatically and precisely. Another objective of the present invention is to realize a pyrolysis reactor wherein the particles and/or the powders that have electrical and magnetic conductivity are selected depending on decomposition temperature of the material to be pyrolyzed and auto-control of the highest temperature to be reached within the body is provided upon being determined by Curie temperature of the particles and/or the powders.

Another objective of the present invention is to realize a pyrolysis reactor wherein heating is realized quickly by selecting particle and/or powder suitable for the pyrolysis temperature of the wastes to be pyrolyzed, and overheating is avoided.

Another objective of the present invention is to realize a pyrolysis reactor wherein the mixer, which moves the particles and/or the powders that have electrical and magnetic conductivity continuously and enables to realize the pyrolysis in the fluidized bed, is coated with a material suitable for the Curie temperature and the decomposition temperature of the material to be pyrolyzed.

Another objective of the present invention is to realize a pyrolysis reactor wherein nickel is used as the particle and/or the powder that have electrical and magnetic conductivity within the body having no electrical and magnetic feature for PMMA (Polymethyl methacrylate) and/or the mixer is coated with nickel.

Another objective of the present invention is to realize a pyrolysis reactor wherein heat is transferred to the waste quickly due to large surface area of the particles and/or the powders that have electrical and magnetic conductivity, pyrolysis is realized at low temperature and the particles and/or the powders quickly recover the heat lost without contacting the body periphery through induction heating.

Another objective of the present invention is to realize a pyrolysis reactor wherein decomposition is realized at small volumes due to the fact that no hot gas generator is needed by performing heating directly. Detailed Description of the Invention

“A pyrolysis reactor” realized to fulfil the objectives of the present invention is shown in the figures attached, in which:

Figure 1 is a view of the inventive pyrolysis reactor together with a feeding bunker and a condenser.

Figure 2 is a front view of the inventive pyrolysis reactor as sectioned. Figure 3 is a front view of a condenser used in the inventive pyrolysis reactor.

The components illustrated in the figure are individually numbered, where the numbers refer to the following:

1. Pyrolysis reactor

2. Body

3. Feeding opening

4. Outlet pipe

5. Heater

6. Mixer

7. Engine

8. Insulation

9. Area enhancer

10. Sealing gasket

11. Mechanical seal

12. Feeding bunker

13. Feeding valve

14. Gas inlet valve

15. Gas outlet valve

16. Vibration engine 17. Condenser

18. Condenser connection

19. Inlet opening

20. Pump

21. Outlet opening

22. Liquid outlet

23. Tower

24. Cooling coil

25. Outlet valve

The inventive pyrolysis reactor (1) wherein pyrolysis process is applied to wastes in an oxygen-free environment, at high temperatures comprises:

- at least one body (2) wherein pyrolysis process is realized and which has at least one feeding opening (3) where the wastes enter and at least one outlet pipe (4) where the arising pyrolysis gases exit;

- at least one heater (5) which is located outside the body (2) and used for heating the wastes within the body (2) by induction; and

- at least one mixer (6) which activates the wastes inside the body (2) in order that they are heated homogeneously during heating process by the heater (5) and which is triggered by an engine.

In a preferred embodiment of the invention, the body (2) is made of a material having no conductive and/or magnetic feature. The body (2) is cylindrical; the feeding opening (3) is located on one end while the outlet pipe (4) is located on the other end thereof. The heater (5), which surrounds the periphery and is a coil, is located in the section remaining in between the feeding opening (3) and the outlet pipe (4) of the body (2). In a preferred embodiment, the insulation (8) is located around the body (2) in order that a substantial part of heat can be used for pyrolysis reaction. In the inventive pyrolysis reactor (1), the body (2) has a permeable feature against the magnetic field occurring as a result of the induction current. The body (2) is permeable against the magnetic field and made of any material resistant to pyrolysis temperature. In a preferred embodiment, the body (2) is made of glass or ceramic material. In another preferred embodiment, the body (2) is made of materials such as alumina, aluminium silicate, silicon carbide graphite or specific mixtures used in induction pots. The body (2) is made of a material and/or materials which is/are permeable against the magnetic field occurring as a result of the induction, maintain/s the mechanical strength at pyrolysis temperatures and can resist to wearing created by the metal sphere or the powder moving in thereof continuously.

In a preferred embodiment of the invention, material is selected in the body (2) depending on pyrolysis temperature of the waste to be processed in thereof. For example, pyrolysis of PMMA occurs under 450°C. Since borosilicate glasses can operate easily up to 400°C, the reactor body (2) can be made of borosilicate glass for pyrolysis of PMMA. In another example, the body (2) is made of ceramic or different durable material because temperatures over 700°C are needed for PE (polyethylene) pyrolysis.

In the inventive pyrolysis reactor (1), the body (2) comprises a plurality of area enhancers (9) which are used for increasing the heat transfer surface area wherein there is powder and/or particle. The occupancy ratio of the interior of the body (2) can be between 5% to %80, preferably l0%-70% and the most preferred occupancy ratio is between %30-50. The area enhancers (9) included inside the body (2) can be metal sphere. In case where the area enhancers (9) are metal sphere, their diameters are between 1-10 mm, preferably between 2-6mm. Metal powders can be used as the area enhancers (9) inside the body (2). In case where the area enhancers (9) are metal powder, their sizes vary between 250-1000 microns. The area enhancers (9) which are included inside the body (2) and which are metal sphere and/or powders can be heated by means of induction field and they have electrical conductivity and high magnetic feature. In a preferred embodiment of the invention, magnetic metals such as ferritic steels such as iron, nickel or SS 420 are used as the area enhancer (9). In a preferred embodiment, the area enhancer (9) can be homogeneous or it may have a heterogeneous structure as well. Nickel plated iron spheres can be cited as a heterogeneous material. Also, metal spheres coated with coating materials exhibiting magnetic feature can be used as the area enhancer (9) for a similar purpose.

In a preferred embodiment of the invention, a wide heat transfer area is obtained because the surface area volume ratio increases as the area enhancers (9) which enhance the heat transfer surface area inside the body (2) decrease. For example, heat transfer surface area of a body (2) filled in the ratio of 50% with a 6mm diameter sphere as the area enhancer (9) is 300 m²/m³.

In a preferred embodiment of the invention, the body (2) consists of three sections; namely, the section where the feeding opening (3) is located, the section where the outlet pipe (4) is located and the section remaining between the feeding opening (3) and the outlet pipe (4).

The feeding opening (3) and the outlet pipe (4) are preferably made of stainless steel that will not show an adverse effect for the pyrolysis process. In a preferred embodiment, the feeding opening (3) and the outlet pipe (4) are manufactured from a steel comprising high chrome and nickel, preferably SS 316. In the inventive pyrolysis reactor (1), the feeding opening (3) and the outlet pipe (4) should not get heated by induction besides their chemical property. Particularly, because wastes melt and become sticky when they encounter with a hot environment, the waste may melt and stick to the feeding opening (3) for example in the event that the feeding section is too hot. Similarly, the fact that the outlet pipe (4) where the gas exits is too hot may cause secondary degradation of pyrolysis gases. Stainless steel is one of the most suitable materials for the feeding opening (3) and the outlet pipe (4) because it does not exhibit SS 316 magnetic feature and does not affect the pyrolysis process affect in a negative way chemically.

In the inventive pyrolysis reactor (1), the sealing gaskets (10) which are preferably heat-resistant are located between the middle part of the body (2) and the ends of the outlet pipe (4). Thereby, impermeability of the sealing gaskets (10) is ensured when vacuum is applied. In addition, the middle part of the sealing gaskets (10) and the body (2) -which gets heated and expands under the influence of heat- move among the sealing gaskets (10) and prevent stress formation. Thus, long-term strength of the body (2) made of fragile materials such as ceramic is ensured.

In the inventive pyrolysis reactor (1), the outlet pipe (4) is used for the pyrolysis gases to leave the body (2) shortly afterwards they are formed by means of the vacuum applied to the body (2). Thereby, secondary degradation of pyrolysis gases are avoided when they remain inside.

In the inventive pyrolysis reactor (1), the heater (5) is a coil which surrounds the body (2) and enables to heat the powders and/or the particles inside the body (2) by receiving the current coming from an induction current generator. Thus, the wastes encountering with the hot powders and/or the particles are subjected to pyrolysis inside the body (2) and leave the body (2) from the outlet pipe (4). In a preferred embodiment of the invention, the middle part of the body (2) remaining between the feeding opening (3) and the outlet pipe (4) is surrounded by the heaters (5) wherefrom the induction current passes and that are coils.

In a preferred embodiment of the invention, the mixer (6) ensures that the wastes fed to the body (2) are pyrolyzed (degraded) inside a fluidized bed by continuously moving the powders and/or the particles inside the body (2) through the rotational motion that it receives from an actuator which is the engine (7). The mixer (6) is a ribbon type mixer, moves the wastes throughout the body (2) together with the powders and/or the particles and fluidize the waste/metal mixture mechanically. In a preferred embodiment, the mixer (6) moves the mixture close to the surface in the body (2) towards the feeding opening (3) whereas it moves the mixture away from the surface towards section from the feeding opening (3) towards the outlet pipe (4). The mixer (6) rotates 5-120 revolutions per minute and in a preferred embodiment of the invention, 20-40 revolutions per minute. The powders and/or the particles passing through the middle part of the body (2) are heated by the mixer (6).

In a preferred embodiment of the invention, the mechanical seals (11) are located in the inlet and outlet sections where the mixer (6) is bedded to the body (2). In a preferred embodiment, the mechanical seals (11) are resistant to pyrolysis temperature.

The inventive pyrolysis reactor (1) also comprises at least one feeding bunker (12) wherein the wastes to be fed to the body (2) are located. There is at least one feeding valve (13) between the feeding bunker (12) and the body (2) which controls the flow from the feeding bunkers (12) to the body (2). On the feeding bunker (12), there is also at least one gas inlet valve (14) where a gas such as nitrogen enters and at least one gas outlet valve (15) where a gas exits. Upon the feeding bunker (12) is filled; a cover owned by thereof is closed, the gas outlet valve (15) where there is nitrogen and then the gas inlet valve (14) is opened and it is ensured that the air/nitrogen mixture leaves the gas outlet valve (15) by sweeping the air inside the feeding bunker (12). Thereby, the oxygen ratio is reduced inside the feeding bunker (12). Before the feeding bunker (12) feeds waste to the body (2), the body (2) and the heater (5) are expected to reach the pyrolysis temperature of the area enhancers such as metal sphere and/or powders inside thereof. In the feeding bunker (12), after the feeding valve (13) reaches the desired temperature it is opened preferably 25%. The feeding bunker (12) also comprises at least one vibration engine (16) in order that the wastes can be fed to the body (2) continuously under a certain control. The inventive pyrolysis reactor (1) also comprises at least one condenser (17) wherein the pyrolysis gases exiting the body (2) over the outlet pipe (4) are condensed. There is at least one condenser connection (18) where the gas passes between the body (2) and the condenser (17). The condenser (17) is the section where the pyrolysis gases coming from the body (2) are washed with the cooled liquid and condensed. The condenser (17) comprises at least one inlet opening (19) where the gas enters. The condenser (17) comprises at least one pump (20) which is used for conveying the gas entering from the inlet opening (19) to the lower part of the condenser (17) and for pumping it upwards after being cooled. The condenser (17) also comprises at least one outlet opening (21) where the gases being pumped to the top of the condenser (17) by means of the pump (20) and being not condensed exit. Thereby, the gases are removed quickly for environmental safety.

In a preferred embodiment of the invention, the condenser (17) comprises at least one liquid outlet (22) where cold water exits in the form of shower upon the gas enters. Thereby, the gas encounters with the cold water exiting the liquid outlet (22) in the form of shower as soon as the gas enters the condenser (17) from the inlet opening (19). The pyrolysis gases being met by cold liquid in the condenser (17), pass through the tower (23) together with the cold liquid and they drop below the condenser (17). The condenser (17) comprises at least one cooling coil (24) wherein cooled water is passed in order to cool the liquid in the lower part thereof. In a preferred embodiment, the cooling water passing through the cooling coil (24) is sent to chiller.

In the inventive pyrolysis reactor (1), since all of pyrolysis products are not condensed in the condenser (17), a part of them goes out from the outlet opening (21). In a preferred embodiment, the outlet opening (21) is connected to a suction member and it is ensured that the feeding bunker (12) and the body (2) operate under a certain vacuum. The condenser (17) also comprises at least one outlet valve (25) where a condensed product is received.

In another preferred embodiment of the invention, water is used in the lower part of the condenser (17) instead of pyrolysis product. Thereby, an important function is obtained in pyrolysis of materials such as PET created by water and acidic products. Since water solubility of acids are high, the acid occurring in the pyrolysis passes to the water that it contacts during the condensation. When the water is contacted to a material such as limestone (calcium carbonate) that reacts with the acid and enables neutralization of the water, it is ensured that the acid is eliminated inside the mixture.

In another preferred embodiment of the invention, the pyrolysis product which accumulates when the level of pyrolysis product inside the condenser (17) exceeds over a certain level by connecting to a suction pump to the outlet valve (25), is removed from the condenser (17). Thereby, it is ensured that the condenser (17) as well as the body (2) operate.

In another preferred embodiment of the invention, absorption of cooled liquid gases entering the injector is provided by sending the pyrolysis gases entering from the inlet opening (19) to an injector and it is ensured that the gas and the cooled liquid (or water) gases which are mixed inside the injector effectively condense quickly.

In the inventive pyrolysis reactor (1), before wastes are fed to the body (2) they are heated by induction up to the pyrolysis temperature and it is ensured that the metal spheres and/or the powders included in thereof are heated. It is ensured that the temperature inside the body (2) is maintained in a homogeneous value by the heat transfer among the spheres during mixing by mixing the metal inside the body (2) continuously via the ribbon type mixer (6) within the body (2). When the body (2) reaches the desired temperature, it is started to feed the waste to the body (2) from the feeding bunker (12). The gas exiting the body (2) is collected and it is gathered to be condensed and purified in the condenser (17).

Polymers such as polymethyl methacrylate (PMMA), polytetra fluoro ethylene (PTFE), polystyrene, polyethylene terephthalate (PET) which can be broken into their monomer or monomers at high temperature and medical or domestic wastes and wastes such as car tire which can be used as input in industry at high temperature can be recovered with the inventive pyrolysis reactor (1). Within these basic concepts; it is possible to develop various embodiments of the inventive pyrolysis reactor (1); the invention cannot be limited to examples disclosed herein and it is essentially according to claims.

Claims

1. A pyrolysis reactor (1) wherein pyrolysis process is applied to wastes in oxygen-free environment at high temperatures; comprising

- at least one mixer (6) which activates the wastes inside the body (2) in order that they are heated homogeneously during heating process by the heater (5) and which is triggered by an engine;

characterized by

- the body (2) which is made of a material having no conductive and/or magnetic feature.

2. A pyrolysis reactor (1) according to Claim 1; characterized by the body (2) which is cylindrical and wherein the feeding opening (3) is located on one end while the outlet pipe (4) is located on the other end thereof.

3. A pyrolysis reactor (1) according to Claim 1 or 2; characterized by the body (2) around which the insulation (8) is located in order that a substantial part of heat can be used for pyrolysis reaction.

4. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the body (2) which is permeable against the magnetic field and made of any material resistant to pyrolysis temperature.

5. A pyrolysis reactor (1) according to Claim 4; characterized by the body (2) which is made of glass or ceramic material.

6. A pyrolysis reactor (1) according to Claim 4; characterized by the body (2) which is made of materials such as alumina, aluminium silicate, silicon carbide graphite or specific mixtures used in induction pots.

7. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the body (2) which is made of a material and/or materials which is/are permeable against the magnetic field occurring as a result of induction, maintain/s the mechanical strength at pyrolysis temperatures and can resist to wearing created by the metal sphere or the powder moving in thereof continuously.

8. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the body (2) in which a plurality of area enhancers (9) used for increasing the heat transfer surface area wherein there is powder and/or particle, are located.

9. A pyrolysis reactor (1) according to Claim 8; characterized by the body (2) wherein the occupancy ratio of its interior is between 5% to %80, preferably l0%-70% and the most preferred occupancy ratio is between %30-50.

10. A pyrolysis reactor (1) according to Claim 8 or 9; characterized by the body (2) wherein the area enhancers (9) included inside it can be metal sphere.

11. A pyrolysis reactor (1) according to Claim 10; characterized by the area enhancers (9) wherein their diameters are between 1-10 mm, preferably between 2-6mm.

12. A pyrolysis reactor (1) according to any of Claim 8 to 11; characterized by the body (2) wherein metal powders can be used as the area enhancer (9).

13. A pyrolysis reactor (1) according to Claim 12; characterized by the area enhancer (9) sizes of which vary between 250-1000 microns.

14. A pyrolysis reactor (1) according to Claim 12 or 13; characterized by the area enhancers (9) which are included inside the body (2), can be heated by means of induction field and which are metal spheres and/or powders that have electrical conductivity and high magnetic feature.

15. A pyrolysis reactor (1) according to any of Claim 8 to 14; characterized by the area enhancer (9) wherein magnetic metals such as ferritic steels such as iron, nickel or SS 420 are used.

16. A pyrolysis reactor (1) according to any of Claim 8 to 15; characterized by the area enhancer (9) which can be homogeneous or may have a heterogeneous structure as well.

17. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the body (2) which consists of three sections; namely, the section where the feeding opening (3) is located, the section where the outlet pipe (4) is located and the section remaining between the feeding opening (3) and the outlet pipe (4).

18. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the feeding opening (3) and the outlet pipe (4) which are preferably made of stainless steel that will not show an adverse effect for the pyrolysis process.

19. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the feeding opening (3) and the outlet pipe (4) which are manufactured from a steel comprising high chrome and nickel, preferably SS 316.

20. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the body (2) wherein the sealing gaskets (10) which are preferably heat-resistant are located between the middle part thereof and the ends of the outlet pipe (4).

21. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the outlet pipe (4) which is used for the pyrolysis gases to leave the body (2) shortly afterwards they are formed by means of the vacuum applied to the body (2).

22. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the heater (5) is a coil which surrounds the body (2) and enables to heat the powders and/or the particles inside the body (2) by receiving the current coming from an induction current generator.

23. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the body (2) the middle part of which remaining between the feeding opening (3) and the outlet pipe (4) is surrounded by the heaters (5) wherefrom the induction current passes and that are coils.

24. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the mixer (6) which ensures that the wastes fed to the body (2) are pyrolyzed (degraded) inside a fluidized bed by continuously moving the powders and/or the particles inside the body (2) through the rotational motion that it receives from an actuator which is the engine (7).

25. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the mixer (6) which is a ribbon type mixer, moves the wastes throughout the body (2) together with the powders and/or the particles and fluidize the waste/metal mixture mechanically.

26. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the mixer (6) which moves the mixture close to the surface in the body (2) towards the feeding opening (3) whereas moves the mixture away from the surface towards section from the feeding opening (3) towards the outlet pipe (4).

27. A pyrolysis reactor (1) according to any of the preceding claims; characterized by the mechanical seals (11) which are located in the inlet and outlet sections where the mixer (6) is bedded to the body (2).

28. A pyrolysis reactor (1) according to any of the preceding claims; characterized by at least one feeding bunker (12) wherein the wastes to be fed to the body (2) are located.

29. A pyrolysis reactor (1) according to Claim 28; characterized by at least one feeding valve (13) which is located between the feeding bunker (12) and the body (2) and controls the flow from the feeding bunkers (12) to the body (2).

30. A pyrolysis reactor (1) according to Claim 28 or 29; characterized by the feeding bunker (12) on which there is also at least one gas inlet valve (14) where a gas such as nitrogen enters and at least one gas outlet valve (15) where a gas exits.

31. A pyrolysis reactor (1) according to any of Claim 28 to 30; characterized by the feeding bunker (12) which also comprises at least one vibration engine (16) in order that the wastes can be fed to the body (2) continuously under a certain control.

32. A pyrolysis reactor (1) according to any of the preceding claims; characterized by at least one condenser (17) wherein the pyrolysis gases exiting the body (2) over the outlet pipe (4) are condensed.

33. A pyrolysis reactor (1) according to Claim 32; characterized by at least one condenser connection (18) where the gas passes between the body (2) and the condenser (17).

34. A pyrolysis reactor (1) according to Claim 32 or 33; characterized by the condenser (17) where the pyrolysis gases coming from the body (2) are washed with the cooled liquid and condensed.

35. A pyrolysis reactor (1) according to any of Claim 32 to 34; characterized by the condenser (17) which comprises at least one inlet opening (19) where the gas enters.

36. A pyrolysis reactor (1) according to Claim 35; characterized by at least one pump (20) which is used for conveying the gas entering from the inlet opening (19) to the lower part of the condenser (17) and for pumping it upwards after being cooled.

37. A pyrolysis reactor (1) according to Claim 36; characterized by the condenser (17) which also comprises at least one outlet opening (21) where the gases being pumped to the top of the condenser (17) by means of the pump (20) and being not condensed exit.

38. A pyrolysis reactor (1) according to any of Claim 32 to 37; characterized by the condenser (17) which comprises at least one liquid outlet (22) where cold water exits in the form of shower upon the gas enters.

39. A pyrolysis reactor (1) according to any of Claim 32 to 38; characterized by the condenser (17) which comprises at least one cooling coil (24) wherein cooled water is passed in order to cool the liquid in the lower part thereof.