WO2023166287A1

WO2023166287A1 - Helical screw reactor with means to feed or withdraw fluid arranged in the screw shaft

Info

Publication number: WO2023166287A1
Application number: PCT/GB2023/050464
Authority: WO
Inventors: Muhammad SAGHIR
Original assignee: Eco Research Limited
Priority date: 2022-03-01
Filing date: 2023-03-01
Publication date: 2023-09-07
Also published as: GB202202787D0

Abstract

A reactor (1), the reactor (1) comprises a first chamber (10), the first chamber (10) comprising: an elongate housing (110) having an inlet (113) located at or towards a first end (111) of the elongate housing for receipt of material to be treated and an outlet (114) located at or towards a second end (112) of the elongate housing; and a rotatable screw (120) located within the elongate housing (110), the rotatable screw (120) comprising a shaft (121) and a helical flight (122) provided therearound, the shaft (121) comprising an elongate internal passage (123) and one or more apertures (124) therethrough to provide fluid communication between the elongate housing (110) and the elongate internal passage (123), the elongate internal passage (123) having a first opening (125) at a first end, and a second opening (126) at a second end, the first and second openings (125, 126) being configured to supply fluid to the elongate housing (110) and/or withdraw fluid from the elongate housing (110) the elongate internal passage (123) having an occlusion(128) to define first and second passageways (123A, 123B).

Description

HELICAL SCREW REACTOR WITH MEANS TO FEED OR WITHDRAW FLUID ARRANGED IN THE SCREW SHAFT

This invention relates generally to a reactor. More specifically, although not exclusively, this invention relates to a reactor for treating waste material and a method for treating waste material.

Domestic and other wastes, for example including plastics waste material, may be traditionally delivered to landfill, for natural decomposition. However, such waste, especially many plastics waste material, may take a long time to naturally decompose, for example in the order of many hundreds of years. Further, the product of natural decomposition in land fill sites is often methane which typically vents to atmosphere.

Accordingly, there is a need to treat waste material, such that the waste material and/or the by-products thereof may find use. There is also a need to find sources of energy other from petrochemical or fossil sources. One such fuel source is biomass. For example, a substantial amount of latent energy and/or useful chemical components may be extracted from such waste which would otherwise not be used. Additionally, biomass is a useful energy and materials source.

Thermochemical conversion and activation of waste material/feedstock involves controlled heating and/or oxidation of the feedstock and covers a range of technologies including pyrolysis, gasification, carbonisation and combustion.

In gasification, feedstock is heated and broken down to synthesis gas (syngas). Syngas is a gaseous mixture primarily comprising carbon monoxide, hydrogen and methane (as well as other alkanes, alkenes and water vapour). The feedstock is first heated before being partially oxidised, or reformed with a gasifying agent (air, oxygen, or steam). The makeup of syngas varies due to the different types of feedstock, their moisture content, the type of gasifier used, the gasification agent, and the temperature and pressure in the gasifier. The generated syngas can then be sent on for further treatment.

Accordingly, the apparatus for treating feedstock/waste material is often relatively complex and requires a large quantity of energy which results in relatively high operating costs. Further, combustion reactors may burn the feedstock more than necessary, so it does not remain as a valuable material, and a large amount of harmful substances may accompany the combustion.

Activated carbon may be prepared from, say biomass, feedstock through (hydro)thermal processing followed by chemical and/or physical activation. During carbonisation, feedstock is thermally decomposed in an inert environment, at temperatures below 800 °C. During activation, the carbonised material, or char, is activated through oxidising the char at temperatures between 800-900 °C typically in the presence of air, carbon dioxide, or steam, to form porous activated carbon. However, the use of 800° C steam requires expensive equipment with high running costs.

Further, in the production process of activated carbon, the biomass needs to be dried. However, when using existing drying equipment, the biomass may remain stationary during the drying process which can lead to uneven heat transfer which can lead to portions of the treated material which is incompletely dried.

Methods using screw-type carbonisation apparatus are known. However, such methods require multiple devices such as a drying device, deodorisation reactor, carbonisation reactor and/or a carbide cooling device, which increases the cost of the apparatus.

It is therefore a first non-exclusive object of the invention to provide a reactor for treating waste material that overcomes one or more drawbacks of the prior art.

According to a first aspect of the invention, there is provided a reactor, the reactor comprising a first chamber, the first chamber comprising: an elongate housing located within the first chamber and having an inlet located at or towards a first end of the elongate housing for receipt of material to be treated and an outlet located at or towards a second end of the elongate housing; and a rotatable screw located within the elongate housing, the rotatable screw comprising a shaft and a helical flight provided therearound, the shaft comprising an elongate internal passage and one or more apertures therethrough to provide fluid communication between the elongate housing and the elongate internal passage, the elongate internal passage having a first opening at a first end, and a second opening at a second end, the first and second openings being configured to supply fluid to the elongate housing and/or withdraw fluid from the elongate housing.

It will be understood that the inlet and outlet to the elongate housing provide, respectively, an upstream and downstream portion of the reactor.

The shaft may be mounted on or be provided with a rotary coupling, for example at both ends, to allow rotation of the shaft and facilitate the introduction to and/or removal of fluids from the elongate housing.

One or both of the inlet and outlet may comprise flow sensors. Beneficially, each of the inlet and outlet comprise flow sensors. The provision of flow sensors allows for monitoring of the ingress and/or egress of material from the first elongate housing. Changes in flow may be indicative of blockages and/or progression of the reaction and may be used to control other aspects of operation, for example temperature, ingress of fluids to the elongate housing via the first shaft and/or egress of fluids from the elongate housing via the first shaft. The signals from the flow sensors may be received by a controller, the controller being operable to control the reactor, or at least aspects thereof such as temperature, flow (using valves and the like), material ingress, reactant ingress, product egress, byproduct egress and other process parameters.

The first and second openings of the elongate internal passage of the shaft allow for the entry and/or the exit of fluids, e.g. air, oxygen, nitrogen (or other non-oxidising gases) and/or steam, e.g. superheated steam. The one or more apertures allow for fluid communication between the elongate housing and the first and/or second openings, via the elongate internal passage.

Thus, advantageously, fluids may be introduced into the elongate housing and/or extracted from the elongate housing via one or both ends of the hollow shaft of the screw.

Accordingly, the direction of flow within the elongate internal passage may be co-current or counter-current, as compared to flow from the upstream to the downstream directions of the reactor. In some embodiments fluids may be introduced both co-currently and counter- currently, or gases may be removed both co-currently and counter-currently, or may be introduced or removed exclusively co-currently or counter-currently. In an embodiment the elongate internal passage of the shaft may be an uninterrupted elongate internal passage. Alternatively, the shaft (e.g. the elongate internal passage within the shaft) may have one or more occlusions, e.g. a separating plate, blockage, restriction, constriction or so on, therealong to separate the elongate internal passage into a first portion, second portion and so on. Advantageously, this allows for addition and/or withdrawal of different fluids at the first and second open ends of the shaft, or to limit or control flows to and/or from various portions of the chamber. Further advantageously, this allows control over the reactions occurring in the elongate housing of the first chamber, for example at different positions within the chamber.

The elongate internal passage may have one or more occlusions (e.g. a separating plate, blockage, restriction, constriction or so on) to define first a first passageway, a second passageway and so on.

The first portion may be the first passageway, the second portion may be the second passageway and so on.

The first portion or passageway of the elongate internal passage may be fluidly discrete from the second portion of the elongate internal passage.

A first portion of the elongate internal passage may be fluidly sealed from a second portion of the elongate internal passage to create fluidly distinct first and second portions of the elongate internal passage.

The first portion of the elongate internal passage may extend from a first open end of the shaft to the occlusion (e.g. separating plate, blockage, restriction, constriction or so on). The second portion of the elongate internal passage may extend from a second open end of the shaft to the occlusion (e.g. separating plate, blockage, restriction, constriction or so on).

The first portion may be fluidly connected to the first opening and the second portion may be fluidly connected to the second opening, whereby fluid may be introducible to/or removable from the reactor, e.g. the elongate internal passage or the chamber, e.g. the first chamber, via the first opening and/or fluid may be introducible to and/or removable from the reactor, e.g. the elongate internal passage or the chamber, e.g. the first chamber, via the second opening.

The occlusion (e.g. separating plate, blockage, restriction, which may be located therein or formed on or in the shaft, or so on) may be located centrally within the elongate internal passage, i.e. the first and second portions of the elongate internal passage may be equal in length. Alternatively, the occlusion (e.g. separating plate, blockage, restriction or so on) may be located off-centre, i.e. towards the first or second open end of the shaft, e.g. such that the first and second portions of the elongate internal passage are different lengths.

In an embodiment, more than one occlusion (e.g. separating plate, blockage, restriction or so on) is present. For example, two occlusions (e.g. separating plates, blockages, restrictions or so on) may be present. The two occlusions (e.g. separating plates, blockages, restrictions or so on) may together define a third portion of the elongate internal passage. The third portion of the elongate internal passage may be located between, e.g. sandwiched between, i.e. separate from, the first and second portions.

The first portion and/or the second portion and/or the third portion may be fluidly connected to a first end and/or a second end of the passageway extending along the shaft.

In an embodiment, only a section of the elongate internal passage, e.g. the first and/or second portions of the elongate internal passage, i.e. the portions of the elongate internal passage in fluid communication with the first and/or second open ends of the shaft, comprise apertures therethrough.

Additionally or alternatively, the shaft may have one or more restrictions therealong, for example to change the flow rate along the elongate passageway.

The elongate internal passage may comprise more than two distinct portions to allow fluid flows from and/or two more than two regions of the chamber. This may be employed to introduce (or remove) a first species to (from) the chamber in a first region thereof and introduce (or remove) a second species (or a different amount of a first species) to (from) the chamber ish a second region thereof and so on in a third or further region. In this way the reactions and processes occurring within and/or throughout the chamber can be controlled. The reactor may comprise a steam delivery system for delivery of steam, e.g. superheated steam, to the first and/or second openings.

The reactor may comprise a control means, e.g. one or more valves, to control the flow of gases (e.g. air and/or steam and/or nitrogen or other non-oxidising gases) into the first chamber, e.g. through the first and/or second openings.

The first and/or second openings may be external to the first chamber and/or the elongate housing. Advantageously, this allows for fluid to enter and/or exit the first and/or second opening of the shaft at ends which are outside of the first chamber and/or elongate housing.

The elongate housing may be substantially cylindrical. The first chamber may comprise a peripheral wall. The peripheral wall may be substantially cylindrical.

There may be a single inlet and/or a single outlet or there may be a plurality of inlets and/or outlets. The inlet(s) and/or outlet(s) may upstand from the elongate housing. The inlet(s) and/or outlet(s) may depend from the elongate housing. For example, an inlet may upstand from the elongate housing while an outlet depends from the elongate housing.

The or each inlet and/or the or each outlet may extend from the elongate housing and through the first chamber. The inlet and/or the outlet may extend from the elongate housing and through the or a peripheral wall of the first chamber.

The helical flight may comprise through holes to allow fluid communication in an axial direction of the elongate housing. Such through holes may be advantageous to allow the elongate passage of syngas or other fluids within the elongate housing and/or to maximise contact of introduced fluids with solids and/or to reduce blockages or at least to mitigate the effect of blockages. Further, depending on the direction of addition and/or withdrawal of fluids from the elongate internal passage of the shaft, introduced (or removed) fluids can be introduced (or removed) co-currently or counter-currently with respect to the direction of travel of solids within the elongate housing.

The helical flight may have a variable pitch along its length. For example, the flight pitch at the inlet end of the elongate housing may be larger than the flight pitch at the outlet end of the elongate housing. The one or more apertures of the shaft (for example the, one or some apertures) may be located in a region of relatively small pitch (for example at or towards the outlet). By locating the at least one aperture or, for example, at least some of the apertures, at or towards the outlet where the pitch size is relatively reduced will increase contact with the solids in the elongate housing, which are concentrated as a result of the reduced pitch. This may lead to localised oxidation reactions with gasifying agents towards the outlet end.

The pitch may change gradually or may alter in a stepped fashion, for example having, in a direction from inlet to outlet, a first pitch portion of pitch P1 and succeeding pitch portion of pitch P2 and a succeeding third portion of pitch P3 and, wherein, for example, P3<P1 , and/or P2 may be less than P1 and/or wherein P3 may be less than P2.

In an embodiment the density of apertures may increase from the inlet to the outlet, e.g. the number of apertures per linear length may increase in a direction along the shaft. Alternatively the density of apertures may remain constant from the inlet to the outlet.

Advantageously, the apertures in the shaft and the apertures through the flight may together insure increased contact with the solids and a reduction of blockages, especially at a or the relatively small pitch portion of the helical flight.

One, some or each of the apertures may be shaped to provide a first path and a second path. The first path and the second path may be non-colinear.

The reactor may comprise one or more nozzles. One, some or each of the apertures may have a nozzle provided therein. The one or more nozzles may form the first and second path.

The one or more nozzles may be secured to the shaft of the rotatable screw. For example, the one or more nozzles or a portion thereof may be welded or threaded onto the shaft of the rotatable screw, or the one or more nozzles, or a portion thereof, may be fitted as a sliding arrangement onto the shaft of the rotatable screw.

The one or more nozzles may have a first and second nozzle portion extending at an angle therebetween. The first and second nozzle portion may form the first and second path of the aperture. For example a first nozzle portion may extend at an angle of from 30 to 135° or 30 to 120°, say 40 to 110° or 45 to 110°, and in some embodiments 70 to 110°, with respect to the second nozzle portion, in an embodiment the nozzles may be L-shaped, e.g. about 90°.

The first path or first nozzle portion or a part of the first path or first nozzle portion, e.g. the first nozzle open end, may be located in the elongate internal passage of the rotatable screw. The second path or second nozzle portion or a part of the second path or second nozzle portion, e.g. the second nozzle open end, may be located in the elongate housing of the first chamber.

Advantageously, the provision of angled, e.g. L-shaped, nozzles located in the one or more apertures avoids or at least prevents or inhibits solids in the elongate housing of the first chamber from blocking the one or more apertures. For example, with a shaft of a nozzle extending along the shaft of the screw there is less likelihood of solids within the chamber occluding the aperture of the nozzle. The shaft of the nozzle may extend in a direction counter to the flow of material within the chamber or co-current with the flow of material within the chamber. In the first instance, mixing may be improved (where the nozzle is used to introduce fluids into the chamber), although occlusion may be impaired and vice versa with respect to the second instance. If the nozzle is used to remove fluids from the chamber it may not matter if the shaft of the nozzle extends counter or co-current to the flow of material within the chamber, although we prefer that the nozzle extends counter current.

The first nozzle portion may have a first nozzle open end. The second nozzle portion may have a second nozzle open end.

The one or more nozzles, e.g. the first and/or second nozzle open ends, may have an end cap located thereon. Advantageously, provision of an end cap prevents solid ingression when there is no flow, e.g. fluid flow, through the nozzle.

Introduced (or removed) fluids can be introduced (or removed) from the elongate internal passage of the shaft co-currently or counter-currently with respect to the direction of travel of material, e.g. solids, within the elongate housing. In an embodiment, the one or more nozzles or a portion thereof, e.g. the second nozzle portion (e.g. the second nozzle open end) may be oriented in a direction parallel to the shaft of the rotatable screw. In an embodiment, the one or more nozzles or a portion thereof, e.g. the second nozzle portion (e.g. the second nozzle open end) may introduce or withdraw fluid parallel to the direction of solid flow. Advantageously, this prevents the one or more nozzles from becoming blocked by solid ingression when the fluid flow is reduced or stopped.

The one or more nozzles or a portion thereof, e.g. the second nozzle portion, may face in the same direction as the flow of material, e.g. solids (in the elongate housing of the first chamber).

The one or more nozzles or a portion thereof, e.g. the second nozzle portion, may face in the opposite direction to the flow of material, e.g. solids (in the elongate housing of the first chamber).

Whilst the nozzles are usually fixed, they may be movable to allow for optimal conformability of the reactor.

The apertures in the shaft allow for additions to and extraction from the chamber. By combining with nozzles, and preferably directional nozzles, and an at least partially segregated (/.e. at leats partially fluidly distinct) first and second portion of the elongate internal passage, optimum reaction conditions can be deployed.

By having directional control of the flow of materials into and out of the elongate internal passage, coupled together with the one or more occlusions within the elongate internal passage of the shaft (e.g. a separating plate, blockage, restriction, constriction or so on), the reactor of the invention allows or at least provide for greater control over the interaction between inflow and outflow fluids and materials, e.g. solids, within the chamber.

Advantageously, the provision of one or more occlusions and the shape of the aperture, e.g. the angle of the nozzle ( e.g. the first and second nozzle portions), allows further control over the chamber, e.g. allows the directional flow of materials to be altered. The reactor may further comprise a heater or heating means arranged to heat the first chamber. For example, the first chamber may comprise, be provided with, or be contained within a heater or heating means. The heat may be produced by combustion or partial combustion of volatile gases. In some embodiments the heater or heating means comprises one or more heaters, e.g. combustion heaters such as gas burners. The heater or heating means (e.g. one or more burners) may be provided in the first chamber in which the elongate housing is located. Alternatively, the heater or heating means may comprise a heating jacket.

The heater or heating means may heat the reactor, e.g. the first chamber in which the elongate housing is provided, to a temperature above 400 °C, e.g. above 405, 410, 415, 420, 425, 450, 475, 500, 550, 600, 650, 700, 750 or above 800 °C. That is, one or more of the reactions, e.g. pyrolysis, combustion, gasification or drying, involved in the thermochemical conversion and activation of waste material/feedstock may be undertaken at a temperature above 400 °C, e.g. above 405, 410, 415, 420, 425, 450, 475, 500, 550, 600, 650, 700, 750 or above 800 °C.

The reactor, for example the heater or heating means, may comprise one or more nozzles for air/oxygen/steam injection, to mix or create a swirl effect within the first and/or second chamber, i.e. to ensure the system is adhering to the waste incineration directive to have a minimum >850 Celsius at a dwell time of 2 sec.

The heater or heating means may heat the inlet and/or outlet

In some embodiments, the fuel used by the heater or heating means, e.g. one or more heaters, may be provided partly, mostly or entirely by generated gas, e.g. synthesis gas.

In embodiments, the generated synthesis gas (or at least a portion thereof) may be treated prior to being supplied to the heater or heating means, e.g. one or more heaters. For example, one or more components (for example hydrogen) of the generated synthesis gas may be removed prior to supply to the heater or heating means, e.g. one or more heaters.

The first chamber may further comprise an egress or vent, e.g. a combustion egress. The elongate housing is preferably sealed from the first chamber, that is there is no fluid communication between the first chamber and the elongate housing.

The rotatable screw may be formed of any suitable material, such as metal, plastic or ceramic material. In some embodiments the rotatable screw is formed of ceramic or metal material. Advantageously, ceramic or metal material is compatible with a high temperature environment. Ceramic materials may be useful because of a low coefficient of thermal expansion, when compared to metals.

The cross-sectional shape of the shaft may be a hex shape, or the cross-sectional shape of the shaft may be in another suitable connecting configuration. For example, the cross- sectional shape of the shaft may be triangular, square, round, e.g. with a keyway, heptagonal, octagonal, splined or any other conventional shape.

The shaft may be used to supply hot gases such as flue gases to come into contact with solids in the first chamber, e.g. in drying, combustion, carbonisation or gasification modes.

The shaft may be used to remove fluids from the first chamber, e.g. remove any heavy/light or long/short chain hydrocarbons from the reactor depending on the size of the one or more apertures in the shaft.

The one or more apertures may be on or along a major or minor portion of the shaft.

In some embodiments a plurality of apertures is provided. Some or all of the apertures may be the same size or some or all of the apertures may be different sizes. Some or all of the nozzles may be the same size or some or all of the nozzles may be different sizes, such that the nozzles fit within the apertures.

The apertures may be provided along the full length of the shaft. For example, the apertures may be equally spaced from each other along the length of the shaft. Alternatively, the one or more apertures may be provided at or towards only one end (portion) of the shaft. For example, the plurality of apertures may be distributed towards a downstream end of the shaft, or towards an upstream end of the shaft. For example, the plurality of apertures may be provided in only a portion of the shaft, e.g. the passageway of the shaft, that is fluidly connected to the first end opening and/or the second end opening of the passageway. A heat resistant (e.g. insulating) material may be provided on the shaft (i.e. on the exterior of the shaft). The heat resistant material may be located between the first chamber and the first and/or second opening, i.e. the heat resistant material may be external to the elongate housing.

The heat resistant material may extend partially or fully around the shaft. The heat resistant material may be between 1 and 15 inches in diameter. For example, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12,13, 14 or 15 inches in diameter. For larger scale reactors the heat resistant material may be even larger in diameter.

Advantageously, the heat resistant material may insulate other components of the reactor from the first chamber, which may in use become very hot by virtue of the heating means.

One or more bearings may be provided to facilitate rotation of the rotatable screw. The or each bearing may be located in a bearing housing. Advantageously the bearing housing may protrude beyond the first chamber to help distance the bearing from the first chamber.

The heat resistant material may be provided on or about the shaft either side of the first chamber. In other words, a heat resistant material may be located between the first chamber and the first opening, and also between the first chamber and the second opening of the shaft. Alternatively, the heat resistant material may be provided on the shaft on only one side of the first chamber (i.e. between the first chamber and the first or second opening).

In some embodiments, the heat resistant material is located between the first chamber and the or each bearing to protect the bearing. Additionally or alternatively, the bearing housing may be provided with a cooling jacket, for example a water cooling jacket, to limit the temperature to which the bearing is exposed.

Advantageously, by locating the bearing away from the hottest part of the first chamber, and/or insulating and/or actively cooling the bearing means that the reactor can be run at hotter temperatures and/or for longer times than might otherwise be possible. The reactor may comprise a controller, for example electrical circuitry to control operation of one or more features of the reactor. For example, the controller may be operably connected to one or more of the flow sensors, temperature sensors, pressure sensors, control means, means to control the flow of fluids into and/or out from the elongate passage, rotation rate of the shaft of the elongate housing and so on.

For example the controller may be operable to monitor the temperature in the reactor, for example the first chamber and/or the elongate housing and/or the shaft, via one or more temperature sensors and may be operable to control the heater to alter the temperature. Additionally or alternatively, the controller may be operable to monitor the or each flow sensor to determine material flow rates within the reactor, for example to ensure correct operation and/or to notify incorrect operation, for example a blockage. The controller may be operable to monitor the output of the reactor, for example via one or more chemical (e.g. gas sensors) to alter control parameters for example one or more of temperature, fluid addition via the shaft, fluid removal via the shaft and so on.

The reactor may further comprise a second chamber for receiving a product of the first chamber. The second chamber may be identical to the first chamber or the second chamber may be different to the first chamber.

The second chamber is preferably located exterior to the first chamber.

The second chamber may comprise an elongate housing. The elongate housing may be substantially cylindrical. The elongate housing of the second chamber may have an inlet port located at or towards a first end thereof for receipt of the product of the first chamber. The elongate housing of the second chamber may have an outlet or discharge port located at or towards a second end of the elongate housing of the second chamber.

The first chamber may be located above or adjacent the second chamber. The outlet of the first chamber may be in fluid communication with the inlet port of the second chamber. Thus, in some embodiments the outlet of the elongate housing of the first chamber provides a conduit which extends through the elongate housing of the second chamber, thereby providing fluid communication between the first and second chambers. The elongate housing of the second chamber may be smaller than the elongate housing of the first chamber.

The reactor may further comprise a cooling means, e.g. a coolant, arranged to cool the second chamber. For example, the second chamber may comprise, be provided with, or be contained within a cooling means. The cooling means may be a cooling chamber or a cooling tunnel in which the second chamber is located. Alternatively, the cooling means may be a cooling jacket. The cooling jacket may be fitted around the second chamber. This enables the product of the first chamber to be cooled within the second chamber prior to its discharge. The cooling means may comprise one or more ports for entry and/or exit of coolant into and/or out of the cooling means.

The second chamber may comprise a rotatable screw. The rotatable screw may be located within the elongate housing of the second chamber. The rotatable screw may comprise a second shaft with a helical flight provided therearound.

The second shaft may project, e.g. protrude, from the elongate housing of the second chamber, e.g. from one or both ends of the elongate housing of the second chamber.

The cross-sectional shape of the second shaft may be of a hex shape, or the cross-sectional shape of the second shaft may be in another suitable connecting configuration. For example, the cross-sectional shape of the shaft may be triangular, square, round, e.g. with a keyway, heptagonal, octagonal, splined or any other conventional shape.

The second shaft may comprise an elongate internal passage. The second shaft may comprise an opening and an outlet. The reactor may further comprise fluid flow means (e.g. a fluid flowing apparatus) to cause fluid to flow along the shaft. The fluid flowing along the second shaft may be in heat exchange relations with material within the second chamber, for example via the walls of the shaft. The fluid may be water. Steam, for example low pressure steam, may be generated at the outlet of the second shaft. Advantageously, any so-generated steam may be used in the elongate housing of the first reactor, for example it may be fed to the elongate internal passage of the elongate housing or the first chamber. The fluid may flow or be arranged or configured to flow in a counter current direction to materiel passing through the second chamber. Such fluid flow may be used to cool the contents of the second chamber. In an embodiment the shaft may have an uninterrupted elongate passageway. Alternatively, the shaft may have one or more occlusions (e.g. a separating plate, blockage, restriction or so on) therealong to separate the elongate passageway into a first portion, second portion and so on, as described above with respect to the first shaft.

Additionally or alternatively the second shaft may comprises one or more apertures to provide fluid communication between the second shaft and the elongate housing, for example to introduce fluids to the second elongate housing or withdraw fluids therefrom.

The one or more nozzles may be secured to the second shaft of the rotatable screw. For example, the one or more nozzles or a portion thereof may be welded or threaded onto the second shaft of the rotatable screw, or the one or more nozzles, or a portion thereof, may be fitted as a sliding arrangement onto the second shaft of the rotatable screw.

The one or more nozzles may have a first and second nozzle portion extending at an angle therebetween. The first and second nozzle portion may form the first and second path of the aperture. For example a first nozzle portion may extend at an angle of from 30 to 135° or 30 to 120°, say 40 to 110° or 45 to 110, and in some embodiments 70 to 110°, with respect to the second nozzle portion, in an embodiment the nozzles may be L-shaped, e.g. about 90°.

The one or more nozzles may be a nozzle as described above with respect to the first shaft.

The diameter of the first and/or second chamber may converge, e.g. reduce in diameter, along its length.

The first and/or second chamber may be tilted, e.g. the first and/or second chamber may have an angle of incline to encourage the material/product to move along the first and/or second chamber, e.g. by gravity. The controller may be operable to control operation of the second chamber.

The discharge port of the second chamber may depend from the elongate housing of the second chamber. The discharge port may be or connect to a residue removal system. The residue removal system may be arranged to receive residue from the second chamber. The residue removal system may be configured to transport the residue to a residue processing system for further processing.

The reactor may further comprise a drive mechanism. The drive mechanism may comprise a direct drive, a mechanical drive chain and a motor, e.g. a variable speed drive motor. The mechanical drive chain may link the motor to one or both of the rotatable screws.

The drive mechanism may further comprise one or more discs. The one or more discs may be located on one or both ends of the shaft of the fits and/or second chamber. The discs may comprise teeth, e.g. around all or part of the outer perimeter to engage the mechanical drive chain.

In use, activation of the motor may cause the mechanical drive chain to move and, hence cause rotatable screw in the first and/or second chamber to rotate.

The reactor may further comprise one or more supply lines for transporting the product of the second chamber away from the second chamber. For example, a supply line may be provided for extracting the product (e.g. syngas) from the reactor. In some embodiments, a supply line may be configured to direct at least a portion of the product (e.g. generated synthesis gas) to the first chamber, for example the heating means. In some embodiments, a further supply line may be configured to direct at least a portion of any product discharged from the second chamber (e.g. cooled synthesis gas), back to the first chamber.

The supply line(s) may each comprise valves, e.g. check valves, to control the flow of fluid within the supply line. The flow of the fluid within the supply line may be controlled by opening and/or closing the valves. Supply to the first chamber, e.g. to the heating means, may be controlled by operation of a first, second, third valve. For example one or more valves may be opened to allow a larger or smaller amount of product to flow to the first chamber.

For example, a first and second supply line or conduit may communicate with the outlet port of the second chamber, each controlled by a respective valve. Control of the valve may allow gaseous product to flow from the second chamber to the heating means of the first chamber. The conduits or supply lines may terminate in one or more nozzles. For example the first conduit or supply line may terminate in one or more first supply line nozzles and the second supply line may terminate in one or more second supply line nozzles. The nozzles may be located within the first chamber and may provide the heater or heating means. Additional oxygen or air may be fed to the conduit or supply lines and/or the nozzles. A pilot flame, spark ignition device or similar may be provided to allow or cause gas issuing from the nozzles to combust. As stated above the conduits or supply lines may further comprise one or more treatment stages, for example to filter the gas from the outlet port of the second chamber and/or to remove some or all of a component of the gas issuing from the outlet port.

Of course, there may be further conduits or supply lines, or indeed fewer.

The heating mans may further comprise a gas supply line and a further set of one or more nozzles. The gas supply line will preferably communicate with a store of combustible gas. In operation, the gas supply line may be used to supply gas to generate heat within the first chamber, for example during start-up procedures or whilst insufficient gas is being generated by the reactor.

The reactor, for example the first and/or second chamber may further comprise insulation, for example a refractory lining for insulation. Insultation may be located inside and/or outside of the first and/or second chamber. The elongate housing may comprise insulation for example a refractory lining for insulation. Insultation may be located inside and/or outside of the elongate housing.

The first chamber of the reactor may further comprise one or more baffles for heat distribution. The first chamber may be at least partially filled with a material to help retain heat. The first chamber may comprise one or more visualisation ports. The visualisation ports may allow sight of the heater or heating means within the first chamber to allow for a visual check to be provided of the functioning of the heater or heating means.

The outlet of the first chamber and/or the outlet/discharge port of the second chamber may be provided with a filter, e.g. a cyclone filter which works by centrifugal force or a ceramic filter.

The product of the first and/or second chamber, e.g. synthesis gas, may enter the filter through the inlet. The filter may be shaped to force the material and/or fluid to swirl and create a vortex. The vortex may allow the clean fluid, e.g. air and/or synthesis gas or flue gas, to exit via the outlet, leaving behind particles, e.g. dust particles in the lower portion.

The reactor may comprise one or more temperature sensors for determining the temperature within the first and/or second chamber.

The first and or second shaft may be provided with temperature sensors. In an embodiment the temperature sensors may be thermocouples.

The reactor may comprise one or more pressure sensors for determining the pressure within the first and/or second chamber.

The heating chamber may be located on a support. The support may comprise one or more stands, e.g. 1 , 2, 3, 4, 5, 6, 7, 8, 9 or 10 stands. The support or the or each stand may comprise a recessed portion for receiving the first chamber. The second chamber may be mounted on the same stand(s) or on a dedicated stand. The or each stand may be substantially triangular or substantially rectangular, i.e. the outer shape of the stand may be substantially triangular or substantially rectangular.

The first chamber of the reactor may be for drying or pyrolysis/gasification or for manufacture of activated carbon.

The second chamber of the reactor may be for cooling the product which leaves the first chamber and/or for secondary gasification or pyrolysis. In use, activation of the driving means, for example the variable speed drive motor causes the driving means to move and hence causes the rotatable screws in the first and/or second chamber to rotate.

Material to be treated may be fed into the first chamber through the inlet. The material may be transported along the elongate housing by the rotatable screw.

The driving mechanism may be activated before the material to be treated is added through the inlet or after the material to be treated is added through the inlet.

Additionally or alternatively, the first and/or second chamber may be inclined, to encourage the material to move along the first and/or second chamber, e.g. by gravity.

In both carbon activation, pyrolysis and gasification modes, heat may be supplied by a or the heating means, e.g. a heating jacket or one or more heaters, e.g. combustion heaters such as gas burners, to heat the first chamber. Additionally or alternatively, the heat may be produced by combustion or partial combustion of volatile gases within the first chamber.

The heater or heating means may heat the reactor, e.g. the first chamber in which the elongate housing is provided, to a temperature above 400 °C, e.g. above 405, 410, 415, 420, 425, 450, 475, 500, 550, 600, 650, 700, 750 or above 800 °C.

Depending on the mode of action (e.g. gasification, pyrolysis or activated carbon generation by carbonisation), fluid, e.g. air, nitrogen and/or steam, e.g. superheated steam, may be introduced to and/or withdrawn from first chamber via the first and second openings. That is, the first chamber may be in fluid communication with the openings via the apertures provided in the elongate internal passage.

Depending on the location and/or number of apertures and/or the location or number of occlusions (e.g. separating plates, blockages, restrictions or so on), the fluid, e.g. air and/or steam, may be supplied only in one portion of the first chamber, e.g. towards the first or second end of the elongate housing. The movement of fluids into and/or out of the first chamber may be based on differential pressure. The reactor may be designed to be below 500 bar to avoid pressure equipment directive compliance.

Fluids, e.g. evaporated water, may be withdrawn from the first chamber via the one or more apertures in the shaft. The size of the one or more apertures in the shaft may increase across the whole or part of the length of shaft, to increase the total surface area.

The product of the first chamber may then exit the first chamber via the outlet and enter the second chamber.

The second chamber may be cooled by a fluid, e.g. coolant, which may be supplied to the cooling means, e.g. the cooling chamber or a cooling jacket which surrounds the second chamber.

The product of the first chamber may then be transported along the second chamber at least in part by the rotatable screw. Residue from the second chamber may be removed from the reactor by a residual removal system. The residue removal system may be configured to transport the residue to a residue processing system for further processing.

At least a portion of the product (e.g. generated synthesis gas) may be recycled. That is, at least a portion of the generated synthesis gas may be directed by the supply line to the heating means, in order to heat the first chamber. The flow of synthesis gas may be controlled by opening one or more of the one or more valves in the supply line.

Advantageously, the reactors of the invention can be interchangeably used for activated carbon production or for producing syngas from biomass and waste residues of synthetic origin and can be used for biooil condensation from pyrolysis gas. The pyrolysis gas can be used directly in a furnace and/or can be further refined, for example to remove tars.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms “may”, “and/or”, “e.g.”, “for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is a schematic perspective view of a reactor according to an embodiment of the invention;

Figure 2 is a schematic view of a first side of the reactor of Figure 1 ;

Figure 3 is a schematic view of a second side of the reactor of Figure 1 ;

Figure 4 is a schematic view of a first end of the reactor of Figure 1 ;

Figure 5 is a schematic view of a second end of the reactor of Figure 1 ;

Figure 6 is a schematic top view of the reactor of Figure 1 ;

Figure 7 is a section view of the reactor of Figure 6 along the line A-A’;

Figures 8A to 8C show a filter according to an embodiment of the invention;

Figures 9A to 9E show rotatable screws according to embodiments of the invention; and

Figures 10A and 10B are schematic perspective views of a reactor according to a further embodiment of the invention.

Referring now to Figures 1 to 7, there is shown a reactor 1 according to an embodiment of the invention.

The reactor 1 comprises a first chamber 10 and a second chamber 20.

The first chamber comprises a heating chamber 107 in which is located an elongate housing 110. The heating chamber comprises plural observation portions 101a to allow a view of the internal space defined by the heating chamber 107. Three are shown but there might be more or fewer. All first chambers 10 may be provided with observation ports 101a. In this embodiment the heating chamber 107 is substantially cylindrical.

The elongate housing 110 has a first end 111 and a second end 112. In this embodiment the elongate housing 110 is substantially cylindrical.

An inlet 113, for receipt of material to be treated, is located towards the first end 111 of the elongate housing 110. An outlet 114 is located towards the second end 112 of the elongate housing 110. In this embodiment, the outlet 114 depends from the elongate housing 110 and the inlet 113 upstands from the elongate housing 110 and each extend from the elongate housing 110 through the wall of the heating chamber 107, as may be best seen in Figure 7.

Located within the elongate housing 110 is a rotatable screw 120. The rotatable screw 120 comprises a shaft 121 and a helical flight 122 provided therearound. The shaft 121 is hollow, comprising an elongate internal passage 123 and apertures 124 therethrough to provide fluid communication between the elongate housing 110 and the elongate internal passage 123. The apertures 124 may be continuously spaced along the length of shaft 121 , or they may be located in different portions of the shaft 121 .

The rotatable screw 120, specifically the shaft 121 is provided with a rotary coupling (not shown) to allow engagement of a supply conduit and/or withdrawal conduit for the introduction and removal of fluids to the elongate internal passage 123.

The first chamber 10 may comprise, be provided with, or be contained within a heating means which is arranged to heat the first chamber 10. In the embodiment shown, the elongate housing 110 is located within a heating chamber 107. The heating chamber 107 comprises a plurality of heaters 108, e.g. combustion heaters such as gas burners. Alternatively, the heating means may comprise a heating jacket which may be provided around the first chamber.

The inlet 113 extends through the heating chamber 107, and into communication with the elongate housing 110. A first end 113a of the inlet 113 is external to the heating chamber 107 and a second end 113b of the inlet 113 is received within the first chamber 10, to allow material to be treated to be introduced into the elongate housing 110. The outlet 114 also extends through the heating chamber 107. A first end 114a of the outlet 114 is received in communication with the elongate housing 110 and a second end 114b of the outlet 114 is received in communication with the second chamber 20, thereby providing fluid communication between the first and second chambers 10, 20 and specifically fluid communication between the elongate housing 110 and the second chamber 20, thereby providing a continuous fluid passage from the first end 113a or the inlet 113 to the outlet port 200a of the second chamber 20.

In the embodiment shown, the heating chamber 107 is located on a support 160 which comprises three stands 161 , 162, 163. The stands 161 to 163 are substantially triangular, having a recessed portion for receiving the heating chamber 107. The second chamber 20 may be supported on the same stands 161 , 162, 163 or on a dedicated support.

A first plate 101 having a flange 102 seals against a corresponding flange 103 on one end of the heating chamber 107, and a second plate 104 having a flange 105 seals against a corresponding flange 106 on the opposing end of heating chamber 107, thereby sealing the heating chamber 107. The heating chamber 107 further comprises an egress or vent 130, e.g. a combustion egress.

The first plate 101 and second plate 104 substantially seal a first end 111 and second end 112 of the elongate housing 110 to fluidly isolate the elongate housing 110 from the heating chamber 107. The walls of the elongate housing 110 are made of a material to allow heat transfer therethrough such that the internal volume of the elongate housing 110 is heatable by heat generated in the heating chamber 107.

The shaft 121 , e.g. the elongate internal passage 123, has a first open end 125 and a second open end 126. The shaft 121 projects, e.g. protrudes, from first and second ends 111 , 112 of the elongate housing 110, and from the first and second ends of the heating chamber 107. In this embodiment the shaft 121 extends through an aperture (not shown) in the first and second plates 101 , 104 such that the open ends 125, 126 of the shaft 121 are external to the heating chamber 107. The first and second open ends 125, 126 of the shaft 121 , e.g. the elongate internal passage 123 of the shaft, allow for entry and/or exit of fluids, e.g. air, nitrogen and/or steam. In this embodiment the elongate internal passage 123 is split into three portions 123A-C. The first portion 123A is located between the first open end 125 and a first occlusion (e.g. separating plate) 128A. The second portion 123B is located between the second open end 126 and a second occlusion (e.g. separating plate) 128B. The third portion is located between the two occlusions (e.g. separating plates) 128A, 128B. The third portion 123C separates the first and second portions 123A, 123B.

In an embodiment, the first portion 123A, second portion 123B and/or third portion 123C have apertures 124 provided therethrough.

The reactor 1 may further comprise a control means, e.g. valves, to control the flow of air and/or steam into the elongate housing 110, e.g. through the first and/or second open ends 125, 126.

A heat resistant material (e.g. an insulating material) 115 is located towards the second open end 126 of the shaft 121 , outside of the heating chamber 107 and abutting the plate 104. A heat resistant material 116 is located towards the first open end of the shaft 121 , outside of the heating chamber 107 and abutting plate 101 . The heat resistant material 115, 116 serves to insulate other components of the reactor from the heat of the first chamber 10 and heating means. In the embodiment shown, the heat resistant material 115, 116 insulates a bearing that turns the shaft 121 from the heat of the heating chamber 107 so as to extend the lifespan of the bearing. The bearing 115b (only shown on one end in Figure 7, although one is preferably located at each end of the shaft 121) is preferably located in a bearing assembly which also houses heat resistant material 115. Additionally or alternatively, a cooling jacket may be provided on or within the housing 115h

The second chamber 20 comprises an elongate housing 210 having a first end 211 and a second end 212. In this embodiment the elongate housing 210 of the second chamber 20 is substantially cylindrical. In the embodiment shown, the elongate housing 210 of the second chamber 20 is smaller than the elongate housing 110 of the first chamber 10.

The second chamber 20 may comprise or be provided with a cooling means which is arranged to cool the second chamber 20. In the embodiment shown, the second chamber 20 is located within a cooling chamber 207. In some embodiments the cooling means may be a cooling jacket. The cooling chamber 207 of this embodiment comprises ports 200a, 200b configured to supply fluid, e.g. coolant, to the cooling chamber 207 and/or withdraw fluid, e.g. coolant, from the cooling chamber.

The second chamber 20 further comprises a rotatable screw 220 located within the elongate housing 210. The rotatable screw 220 comprises a shaft 221 and a helical flight 222 provided therearound.

The shaft 221 may be hollow and may have a inlet and outlet for flowing cooling fluid therealong.

The shaft 221 projects, e.g. protrudes, from the first and second ends 211 , 212 of the second chamber 20.

The reactor 1 further comprises a driving mechanism 140. The driving mechanism 140 comprises a mechanical drive chain 141 and a variable speed drive motor 142. The mechanical drive chain 141 links the variable speed drive motor 142 to the shafts 121 , 221 of the rotatable screws 120, 220. In use, activation of the variable speed drive motor 142 causes the mechanical drive chain 141 to move and hence causes the rotatable screws 120, 220 to rotate.

The reactor 1 further comprises a supply line 150 configured to remove at least a portion of the generated product (e.g. syngas). In the embodiment shown, the supply line 150 is configured to direct at least a portion of the generated product back to the heating chamber 107. The supply line 150 further comprises valves 151 , e.g. check valves, to control the flow of fluid within the supply line.

In this embodiment there is a first supply line 150a having a first valve 151a and a second supply line 150b having a second valve 151b.

The reactor 1 may further comprise a filter 3 as shown in Figures 8A to 8D.

The filter 3 is preferably a cyclone filter which works by centrifugal force.

The filter 3 comprises a body 30 having an upper portion 31 and a lower potion 32. The filter 3 further comprises an inlet 33 and an outlet 34. The filter 3 may be located on a first or second end 114a, 114b of the outlet 114.

Material enters the filter 3 through the inlet 33. The shape of the filter 3 forces the material and air to swirl and create a vortex. This vortex allows the air to exit via the outlet 34, leaving behind particles, e.g. dust particles in the lower portion 32.

Turning now to Figure 9A there is shown a portion of a rotatable screw 120 according to an embodiment of the invention.

The section of the rotatable screw 120 differs from the rotatable screw of Figure 7 in that it has a nozzle 127 provided in the aperture 124. The nozzle 127 has a first and second nozzle portion angled to form an L-shape. The nozzle 127 is positioned such that the first open nozzle end 127A (of the first nozzle portion) is located in the elongate internal passage 123 of the rotatable screw 120 and the second open nozzle end 127B (of the second nozzle portion) is located in the elongate housing of the first chamber. The second nozzle portion, which includes the second open nozzle end 127B, is oriented in a direction parallel to the shaft 121 of the rotatable screw 120.

Turning now to Figures 9B to 9E, there is shown rotatable screws 120 according to embodiments of the invention.

The occlusion (e.g. separating plate) 128 of Figure 9B is located centrally within the elongate internal passage 123, separating it into two portions 123A, 123B of equal length.

The occlusion (e.g. separating plate) 128 of Figures 9C and 9D are located off-centre, i.e. towards a first open end 125 or a second open end 126 of the shaft 121 , i.e. such that the first and second portions 123A, 123B of the elongate internal passage are different lengths.

Turning to Figure 9E, the elongate internal passage 123 is split into three portions 123A-C. The first portion 123A is located between the first open end 125 and a first occlusion (e.g. separating plate) 128A. The second portion 123B is located between the second open end 126 and a second occlusion (e.g. separating plate) 128B. The third portion 123C is located between the two occlusions (e.g. separating plates) 128A, 128B. The third portion 123C separates the first and second portions 123A, 123B. In an embodiment, the first, second and/or third portions, 123A-C have apertures provided therethrough.

Turning now to Figures 10A and 10B, there is shown a reactor T according to a further embodiment of the invention.

The reactor T of Figures 10A and 10B is similar to the reactor 1 of Figures 1 to 7. Like features are denoted with like reference numerals, except followed by a prime, and will not be described further herein.

The diameter of the heating chamber 107’ converges, e.g. reduces, along its length although it may diverge or have a constant size.

The inlet 113’ and outlet 114’ is provided with flow sensors 180’ to monitor the flow of materials within the inlet 113’ and outlet 114’. By monitoring the flow it is possible to detect blockages and/or to control process characteristics, for example heat to be applied, gas to be introduced via the shaft 12T or gas to be removed via the shaft 12T. Conveniently, the flow sensors may be rotary paddle sensors. The output of the flow sensors 180’ may be continuously or intermittently monitored. In an embodiment, the output from the flow sensor may be monitored to determine residence time within the elongate housing 110. Beneficially by knowing he rotation rate of the elongate shaft within the elongate housing 110 and the output of the flow sensors it is possible to carefully control the operational parameters and to avoid blockages.

These flow sensors may be provided on all embodiments.

The inlet 113’ and outlet 114’ may also be provided with cleaning ports 190’ to facilitate cleaning of the inlets and/or outlets 114’ in the event of a blockage. Additionally or alternatively, the inlet 113’ and outlet 114’ may be provided with observation portions to allow visualisation of material flowing through the inlet 113’ and/or outlet 114’. These cleaning and/or visualisation ports may be provided on all embodiments.

The heating chamber 107’ is located on a support 160’. In this embodiment the support 160’ comprises three stands 16T, 162’, 163’. The stands 16T to 163’ are substantially rectangular, having a recessed portion for receiving the heating chamber 107’. In this embodiment, the reactor T is absent the supply line 150. Gas for a heater may be supplied from a gas store. Additionally or alternatively, gas may be supplied via a gas supply line as in the first embodiment.

Accordingly, in each embodiment a heater may be supplied within the heating chamber 107, 107’ which is supplied by a gas supply line from a gas store and a supply line 150 from the second chamber 20, 20’. Supply of gas from the second chamber 20, 20’ to the heating chamber 107, 107’ may be controlled by operation of valves operably connected to one or more supply lines 150, for example to allow a larger or smaller amount of product to flow to the heater chamber 107, 107’.

The gas supply may feed the gas supply line to generate heat within the heating chamber 107, 107’, for example during start-up procedures or whilst insufficient gas is being generated by the reactor 1 , T.

In the second embodiment, the driving mechanism 140’ comprises a first gear 143’ provided on a first end of the shaft 22T and a second gear 144’ provided on a second end of the shaft 22T. The gears 143’ 144’ comprise teeth around the outer edge to engage the mechanical drive chain (not shown).

The first chamber 10 of the reactor 1 , T may be used for drying or pyrolysis/gasification or for manufacture of activated carbon.

The second chamber 20 of the reactor 1 , T may be for cooling a product discharged from the first chamber 10.

In use, activation of the variable speed drive motor 142 causes the mechanical drive chain 141 to move and hence causes the rotatable screws 120, 220 to rotate.

Material to be treated is then fed into the first chamber 10 of the reactor 1 , T, through the inlet 113, 113’. The material is transported along the first chamber 10 by the rotatable screw 120. In both activation and gasification modes, heat may be supplied by a heating means. In these embodiments, the heating chamber 107, 107’ comprises a plurality of heaters 108, e.g., combustion heaters such as gas burners, to heat the heating chamber 107, 107’ and thus the elongate housing 110, and thus the material to be treated. Alternatively, the heating means may comprise a heating jacket.

Depending on the mode of action (e.g. gasification or activated carbon), fluid, e.g. air, nitrogen and/or steam, may be introduced and/or withdrawn from the elongate housing 110 via the first and second open ends 125, 125’, 126, 126’ of the shaft 121 , 121’. That is, the elongate housing is in fluid communication with the first and second open ends 125, 125’, 126, 126’ of the shaft 121 , 12T via the apertures 124 provided in the elongate internal passage 123.

For example, in drying (activated carbon) mode, hot air may be introduced into the first chamber 10 under positive pressure.

Depending on the location and/or number of apertures 124, the fluid, e.g. air and/or steam, may be supplied only in or towards one end of the first chamber 10, e.g. only in or towards the second end 112 of the first chamber 10.

The movement of fluids into and/or out of the first chamber 10 may be based on differential pressure. The reactor 1 , T may be designed to be below 500 barg to avoid pressure equipment directive compliance.

Fluids, e.g. evaporated water, may be withdrawn from the first chamber 10 via the one or more apertures 124 in the shaft 121 , 12T. The size of the one or more apertures 124 in the shaft 121 , 12T may be increased across the whole or part of the length of shaft 121 , 12T, to increase the total surface area.

The product of the first chamber 10 exits the first chamber 10 via the outlet 114, 114’ and enters the second chamber 20.

In the second chamber 20, fluid, e.g. coolant, may be supplied to the cooling means, e.g. the cooling chamber 207, 207’ via port 200a, 200b, to cool the second chamber 20. The product of the first chamber 10 is transported along the second chamber 20 by the rotatable screw 220. Residue from the second chamber 20 may then be removed from the reactor 1 , T, e.g. by a residue removal system. The residue removal system may be configured to transport the residue to a residue processing system for further processing.

At least a portion of the product (e.g. generated synthesis gas) may be recycled. That is, at least a portion of the product (e.g. generated synthesis gas) may be directed by the supply line 150 to the heating means, in order to heat the first chamber 10. The flow of synthesis gas may be controlled by opening one or more of the one or more valves 151.

Advantageously, the reactors 1 , T of the invention can be interchangeably used for activated carbon production or for producing synthesis gas from biomass and waste resides of synthetic origin.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention.

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

CLAIMS A reactor, the reactor comprising a first chamber, the first chamber comprising: an elongate housing having an inlet located at or towards a first end of the elongate housing for receipt of material to be treated and an outlet located at or towards a second end of the elongate housing; and a rotatable screw located within the elongate housing, the rotatable screw comprising a shaft and a helical flight provided therearound, the shaft comprising an elongate internal passage and one or more apertures therethrough to provide fluid communication between the elongate housing and the elongate internal passage, the elongate internal passage having a first opening at a first end, and a second opening at a second end, the first and second openings being configured to supply fluid to the elongate housing and/or withdraw fluid from the elongate housing, the elongate internal passage having an occlusion to define first and second passageways. The reactor according to Claim 1 , comprising plural occlusions. The reactor according to Claim 2, wherein the or an occlusion is located centrally within the elongate internal passage. The reactor according to any of Claims 1 to 3, wherein the or an occlusion is located off-centre within the elongate internal passage, e.g. towards the first opening at the first end of the elongate internal passage, or towards the second opening at the second end of the elongate internal passage. A reactor according to any preceding Claim, wherein the one or more apertures are shaped to provide a first path and a second path, wherein the first path and the second path are non-colinear A reactor according to Claim 5, wherein one, some or each of the apertures have a nozzle provided therein.

7. A reactor, the reactor comprising a first chamber, the first chamber comprising: an elongate housing having an inlet located at or towards a first end of the elongate housing for receipt of material to be treated and an outlet located at or towards a second end of the elongate housing; and a rotatable screw located within the elongate housing, the rotatable screw comprising a shaft and a helical flight provided therearound, the shaft comprising an elongate internal passage and one or more apertures therethrough to provide fluid communication between the elongate housing and the elongate internal passage, the elongate internal passage having a first opening at a first end, and a second opening at a second end, the first and second openings being configured to supply fluid to the elongate housing and/or withdraw fluid from the elongate housing, wherein the one or more apertures are shaped to provide a first path and a second path, wherein the first path and the second path are non-colinear.

8. The reactor according to Claim 7, wherein one, some or each of the apertures have a nozzle provided therein.

9. The reactor according to Claim 6 or 8, wherein the or each nozzle has a first and second nozzle portion extending at an angle therebetween, for example a first nozzle portion may extend at an angle of from 30 to 135° or 30 to 120° or 40 to 110° or 45 to 110° or 70 to 110°, with respect to the second nozzle portion.

10. The reactor according to Claim 6, 8 or 9, wherein the or each nozzle or a portion thereof, e.g. the second nozzle portion, faces in the opposite direction to the flow of material, e.g. solids in the elongate housing of the first chamber.

11 . The reactor according to Claim 6, 8, 9 or 10, wherein the nozzles or a portion thereof, e.g. the second nozzle portion, are oriented in a direction parallel to the shaft of the rotatable screw.

12. A reactor according to any of Claims 7 to 11 , wherein the elongate internal passage has one or more occlusions therealong.

13. A reactor according to Claims 1 to 6 or 12, wherein a first portion of the elongate internal passage is fluidly discrete from a second portion of the elongate internal passage.

14. A reactor according to Claim 13, wherein the first portion is fluidly connected to the first opening and the second portion is fluidly connected to the second opening, whereby fluid is introducible to/or removable from the chamber via the first opening and/or fluid is introducible to and/or removable from the chamber via the second opening.

15. The reactor of any preceding Claim, wherein the first and second openings are external to the elongate housing.

16. The reactor of any preceding Claim, wherein the reactor further comprises a heating means arranged to heat the first chamber, e.g. to a temperature above 400 °C, e.g. above 405, 410, 415, 420, 425, 450, 475, 500, 550, 600, 650, 700, 750 or 800 °C.

17. A reactor according to Claim 16, wherein the heating means comprises one or more heaters, e.g. combustion heaters such as gas burners, or wherein the heating means comprises a heating jacket.

18. The reactor of any preceding Claim, wherein a heat resistant material is provided on the shaft, between the first chamber and the first and/or second openings.

19. The reactor of any preceding Claim, further comprising a second chamber for receiving a product of the first chamber, the second chamber comprising: an elongate housing having an inlet at or towards a first end thereof for receipt of the product of the first chamber.

20. The reactor of Claim 19, wherein the second chamber further comprises a discharge port at or towards a second end of the elongate housing of the second chamber.

21. The reactor of Claim 19 or 20, wherein the second chamber further comprises a rotatable screw located within the elongate housing of the second chamber, the rotatable screw comprising a shaft and a helical flight provided therearound. 2. The reactor of and one of Claims 19, 20, 21 , wherein the shaft protrudes from one or both ends of the elongate housing of the second chamber.

23. The reactor of any one of Claims 19 to 22, further comprising a cooling means arranged to cool the second chamber. 4. The reactor of Claim 23, wherein the cooling means is a cooling jacket provided around the second chamber. 5. The reactor of any preceding Claim, further comprising one or more conduits. 6. The reactor of Claim 25, wherein at least one conduit is configured to transport a product away from the discharge port of the second chamber (where present) or away from the outlet of the first chamber. 7. The reactor of Claim 25 or 26, wherein at least one conduit is configured to direct at least a portion of any product from the discharge port of a or the second chamber to the heating means. 8. The reactor of Claim 25, wherein at least one conduit is configured to direct at least a portion of any product from the discharge port of a or the second chamber back to the first chamber. 9. The reactor of any one of Claims 25 to 28, wherein the or each conduit comprises a valve to control the flow of fluid therealong. 0. The reactor according to any preceding Claim, wherein the outlet of the first chamber and/or the discharge port of the second chamber (where present) is provided with a filter. 1. The reactor according to any preceding Claim, further comprising one or more pressure sensors. The reactor according to any preceding Claim, further comprising one or more temperature sensors. The reactor according to any preceding Claim, comprising one or more flow sensors. The reactor according to Claim 34, wherein the reactor comprises a first flow sensor for detecting flow along the inlet. The reactor according to Claim 33 or 34, wherein the reactor comprises a second flow sensor for detecting flow along the outlet. The reactor according to any preceding Claim, comprising a controller, the controller preferably being operable to control flow as a response to a signal received from the first flow sensor and/or a or the second flow sensor. The reactor according to any preceding Claim, wherein the first chamber comprises one or more viewing ports through which the interior of the first chamber is viewable.