WO2023167581A1 - A thermal decomposition reactor for decomposing waste material and a thermal decomposition system - Google Patents

A thermal decomposition reactor for decomposing waste material and a thermal decomposition system Download PDF

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Publication number
WO2023167581A1
WO2023167581A1 PCT/MY2023/050013 MY2023050013W WO2023167581A1 WO 2023167581 A1 WO2023167581 A1 WO 2023167581A1 MY 2023050013 W MY2023050013 W MY 2023050013W WO 2023167581 A1 WO2023167581 A1 WO 2023167581A1
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Prior art keywords
chamber
thermal decomposition
exhaust gas
waste material
purification unit
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PCT/MY2023/050013
Other languages
French (fr)
Inventor
Chee Seng Tee
Chan Kit TEE
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Nano Silver Manufacturing Sdn Bhd
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Publication of WO2023167581A1 publication Critical patent/WO2023167581A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/08—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F23G5/0276—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage using direct heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/08—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating
    • F23G5/14—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating including secondary combustion
    • F23G5/16—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating including secondary combustion in a separate combustion chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/50—Control or safety arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
    • F23G7/061—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases with supplementary heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • F23J15/04—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material using washing fluids
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D47/00—Separating dispersed particles from gases, air or vapours by liquid as separating agent
    • B01D47/02—Separating dispersed particles from gases, air or vapours by liquid as separating agent by passing the gas or air or vapour over or through a liquid bath
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D47/00—Separating dispersed particles from gases, air or vapours by liquid as separating agent
    • B01D47/06—Spray cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D50/00—Combinations of methods or devices for separating particles from gases or vapours
    • B01D50/60—Combinations of devices covered by groups B01D46/00 and B01D47/00
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2202/00—Combustion
    • F23G2202/10—Combustion in two or more stages
    • F23G2202/103—Combustion in two or more stages in separate chambers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2204/00—Supplementary heating arrangements
    • F23G2204/20—Supplementary heating arrangements using electric energy
    • F23G2204/201—Plasma
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/08—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating
    • F23G5/085—High-temperature heating means, e.g. plasma, for partly melting the waste
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2215/00—Preventing emissions
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00—Measuring
    • F23N2225/08—Measuring temperature
    • F23N2225/16—Measuring temperature burner temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2239/00—Fuels
    • F23N2239/02—Solid fuels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2241/00—Applications
    • F23N2241/18—Incinerating apparatus

Definitions

  • the present invention relates to the field of waste treatment technology. More particularly, the present invention relates to a thermal decomposition reactor for decomposing waste material and a thermal decomposition system.
  • Solid waste treatment via thermal decomposition has been subjected to stringent regulation due to public health and environmental concerns.
  • Exhaust gas produced from thermal decomposition contains harmful particles such as carbon dioxide, carbon monoxide, heavy metals such as lead and mercury, acid gases, volatile chlorinated organic compounds, dioxins, and furans.
  • the exhaust gas may contain hazardous particles especially when the solid waste treatment involves scheduled wastes or medical wastes. The hazardous particles may not be completely decomposed before being discharged to the environment.
  • a medical incinerator requires two chambers in which a first chamber is provided for decomposing solid wastes, whereas a second chamber operating at 850 °C is provided to destroy hazardous particles.
  • the first chamber is required to be operated at more than 850 °C
  • the second chamber is required to be operated at more than 1100 °C when hazardous wastes are involved.
  • China Patent Number CN106949480A discloses a pyrolysis incinerator comprising a first combustion chamber, a second combustion chamber, and an exhaust gas purification device.
  • the second combustion chamber is configured to operate at a higher temperature as compared to the first combustion chamber.
  • the second combustion chamber is configured to operate continuously by adjusting air intake to maintain the temperature therein.
  • China Patent Number CN105333440A discloses an incinerator comprising a first combustion chamber equipped with at least one first burner and a second combustion chamber equipped with a second burner. The generated combustible gas in the first chamber is sent to the second chamber for further combustion at a higher temperature that meets the regulatory requirement.
  • the aforementioned incinerators comprise a burner in the second chamber that is configured to operate continuously to provide heat thereto. This imposes a relatively high operating cost due to the continuous fuel consumption by the burner such that the temperature therein is maintained at a temperature that is higher than that of the first chamber. Therefore, it is desirable to provide a thermal decomposition reactor and system for decomposing waste material in a more efficient and effective way thereby reducing the operating cost.
  • the present invention provides a solution to the problem.
  • One aspect of the present invention is to provide a thermal decomposition reactor for decomposing a waste material and then further reducing or eliminating hazardous particles in exhaust gas produced from the decomposed waste material at a reduced operating cost. This can be achieved by providing a thermal decomposition reactor having a first chamber for decomposing the waste material and a second chamber in fluid communication with the first chamber for burning exhaust gas produced therein using a burner, wherein the burner activates only when the temperature in the second chamber drops below a certain temperature.
  • Another aspect of the present invention is to provide a thermal decomposition system comprising the thermal decomposition reactor and at least one purification unit for removing hazardous particles from the exhaust gas.
  • the embodiment of the present invention describes a thermal decomposition reactor (100) comprising (a) a first chamber (102) for decomposing the waste material, wherein the first chamber (102) comprises a feed inlet (104) for feeding the first chamber (102) with the waste material, means for supplying magnetized air (106) into the first chamber (102), and means for receiving an ignition source (108) such that the ignition source ignites the magnetized air during a start-up phase of the thermal decomposition to heat the first chamber (102) to a first predetermined temperature for decomposing the waste material; and (b) a second chamber (110) in fluid communication with the first chamber (102) for burning exhaust gas produced therein thereby reducing or eliminating hazardous particles in the exhaust gas, wherein the second chamber (110) comprises a burner (112) for heating the second chamber (110), a temperature sensor (not shown) for detecting temperature in the second chamber (110), the arrangement being such that the burner (112) is activated when the temperature in the second chamber (110) drops below
  • the first chamber (102) further comprises plasma generation means (116) for accelerating the heating process during the start-up phase.
  • the first chamber (102) further comprises a residue collector (118) for collecting residues produced from the thermal decomposition, and means for removing the residues (120) from the first chamber (102).
  • the thermal decomposition reactor (100) further comprises a feed processing unit (200) connected to the feed inlet (104), wherein the feed processing unit (200) comprises shredding means (202) for reducing size of the waste material.
  • the feeding means (206) is a hydraulic feed cylinder or a pneumatic feed cylinder.
  • thermal decomposition system comprising a thermal decomposition reactor (100) as hereinbefore described and further comprising a first purification unit (302) in fluid communication with the second chamber (110), wherein the first purification unit (302) is configured with means for mixing the exhaust gas with a scrubbing medium (304) so as to reduce temperature of the exhaust gas and remove hazardous particles therefrom.
  • the thermal decomposition system (300) further comprises a second purification unit (306) in fluid communication with the first purification unit (302), wherein the second purification unit (306) comprises a plurality of spray nozzles (308) for spraying mist to wash down hazardous particles from the exhaust gas.
  • the second purification unit (306) comprises a plurality of spray nozzles (308) for spraying mist to wash down hazardous particles from the exhaust gas.
  • the thermal decomposition system (300) further comprises a second filtration unit (312) in fluid communication with the second purification unit (306) for filtering the exhaust gas prior to discharge thereof.
  • a second filtration unit (312) in fluid communication with the second purification unit (306) for filtering the exhaust gas prior to discharge thereof.
  • Figure 1 shows a thermal decomposition reactor (100).
  • Figure 2 shows a thermal decomposition reactor (100) comprising a feed processing unit (200).
  • the thermal decomposition reactor (100) comprises a first chamber (102) for decomposing the waste material.
  • the first chamber (102) comprises a feed inlet (104) for feeding the first chamber (102) with waste material, means for supplying magnetized air (106) into the first chamber (102), and means for receiving an ignition source (108) such that the ignition source ignites the magnetized air during a start-up phase of the thermal decomposition to heat the first chamber (102) to a first predetermined temperature for decomposing the waste material.
  • the means for supplying magnetized air (106) may comprise an air suction unit and a permanent magnet or an electromagnet located in the air suction unit.
  • the magnet magnetizes the air provided through the air suction unit.
  • the means for supplying magnetized air (106) is disposed at exterior of the first chamber (102) at a suitable distance therefrom to avoid heat from the first chamber (102) to adversely affect the magnetism of the magnet housed in the means for supplying magnetized air (106).
  • the means for supplying magnetized air (106) can be housed in a heat-insulated housing or covered by a layer of heat insulating material.
  • the means for receiving an ignition source (108) is disposed at lower section of the first chamber (102) for the ease of access by a user.
  • the means for receiving an ignition source (108) is an opening disposed at a side wall of the first chamber (102), in which the opening is configured with a hinged cover.
  • the ignition source may be an ignition tool such as a lighter or a burner.
  • the first predetermined temperature can be selected based on the type of waste material.
  • the first predetermined temperature is preferably at about 1100 °C to about 1300 °C when the waste material comprises a scheduled waste, a medical waste, or a combination thereof.
  • the first predetermined temperature can be at a lower temperature of about 800 °C to about 1100 °C when the waste material is municipal solid waste.
  • the thermal decomposition reactor (100) comprises a second chamber (110) in fluid communication with the first chamber (102) for burning exhaust gas produced therein.
  • the first chamber (102) and the second chamber (110) are connected via a pipe such that the exhaust gas produced in the first chamber (102) travels to the second chamber (110) therethrough.
  • the movement of exhaust gas from the first chamber (102) to the second chamber (110) is the due to difference in pressure within these chambers (102, 110).
  • the burner (112) does not operate continuously to burn the exhaust gas produced in the first chamber (102). This reduces operating cost of the thermal decomposition reactor (100).
  • the burner (112) only activates when the temperature in the second chamber (102) drops below a second predetermined temperature.
  • the second predetermined temperature can be selected based on the local regulatory requirement where the thermal decomposition reactor (100) is being deployed.
  • the second predetermined temperature is about 800 °C to about 1300 °C, more preferably at about 1100 °C.
  • the regulatory requirement in Malaysia for this particular chamber is 1100 °C with a retention time of 2 seconds.
  • the first predetermined temperature in the first chamber (102) is higher than the second predetermined temperature in the second chamber (110) to further reduce the need of operating the burner (112).
  • the heat in the first chamber (102) can be provided by the incineration of magnetized air provided by the means for supplying magnetized air (106). This approach is more effective for heating the first chamber (102) as compared to a conventional burner or a conventional pyrolysis as described in prior art.
  • the temperature in the first chamber (102) may change during thermal decomposition due to various factors such as inconsistent waste material feed rate and presence of different ingredients in the waste material. These will affect the thermal decomposition thereby resulting in a change in the temperature in the first chamber (102).
  • the first chamber (102) further comprises plasma generation means (116) for accelerating the heating process during the start-up phase.
  • plasma generation means (116) together with the means for supplying magnetized air (106) can produce a high temperature of about 1300 °C to about 1600 °C in the first chamber (102).
  • the thermal decomposition reactor (100) further comprises a feed processing unit (200) connected to the feed inlet (104).
  • the feed processing unit (200) comprises shredding means (202) for reducing size of the waste material thereby improving the thermal decomposition thereof.
  • the shredding means (202) is a shredder.
  • the shredder may be driven by electric or hydraulic motor.
  • the feed processing unit (200) comprises a storage facility (204) connected to the shredding means (202) for storing the shredded waste material.
  • the feed processing unit (200) comprises feeding means (206) connected to the storage facility for supplying the shredded waste material from the storage facility (204) to the first chamber (102) via the feed inlet (104).
  • the feeding means (206) is a hydraulic feed cylinder or a pneumatic feed cylinder.
  • the present invention further provides a thermal decomposition system (300) as illustrated in Figure 3.
  • the thermal decomposition system (300) comprises athermal decomposition reactor (100) as hereinbefore described and further comprising a first purification unit (302) in fluid communication with the second chamber (110).
  • the first purification unit (302) can be configured with means for mixing the exhaust gas with a scrubbing medium (304) so as to reduce temperature of the exhaust gas and remove hazardous particles therefrom.
  • the means for mixing the exhaust gas with a scrubbing medium (304) can be a stirrer, whereas the scrubbing medium Is preferably water.
  • the temperature of the exhaust gas can be reduced by adjusting stirring speed of the stirrer or retention time of the exhaust gas in the first purification unit (302).
  • the thermal decomposition system (300) further comprises a second purification unit (306) in fluid communication with the first purification unit (302).
  • the first purification unit (302) and the second purification unit (306) are connected via another pipe such that purified exhaust gas in the first purification unit (302) travels to the second purification unit (306) therethrough.
  • the movement of purified exhaust gas from the first purification unit (302) to the second purification unit (306) is due to the difference in pressure within these purification units (302, 206).
  • the second purification unit (306) can be configured with a plurality of spray nozzles (308) for spraying mist to wash down hazardous particles from the exhaust gas.
  • the combined use of the first purification unit (302) and the second purification unit (306) improves removal of the hazardous particles from the exhaust gas. This is because hazardous particles with higher temperature are more difficult to be removed via water mist spraying.
  • the thermal decomposition system (300) further comprises a first filtration unit (310) disposed between the first purification unit (302) and the second purification unit (306) for separating hazardous particles from the exhaust gas.
  • the thermal decomposition system (300) further comprises a second filtration unit (312) in fluid communication with the second purification unit (306) for filtering the exhaust gas prior to discharge thereof.
  • the filtration units (310, 312) may be a plurality of filtration trays stacked on top of one another or arranged in a series.
  • each filtration tray contains carbon material such activated carbon to remove heavy metal particles from the exhaust gas and to decolorize the exhaust gas.
  • the activated carbon can be mixed with powder derived from coconut shell or further impregnated with minerals for improved filtration performance.
  • carbon nanotubes can be used .

Abstract

The present invention relates to the field of waste treatment technology. More particularly, the present invention relates to a thermal decomposition reactor (100) comprising (a) a first chamber (102) for decomposing the waste material, wherein the first chamber (102) comprises a feed inlet (104) for feeding the first chamber (102) with the waste material, means for supplying magnetized air (106) into the first chamber (102), and means for receiving an ignition source (108) such that the ignition source ignites the magnetized air during a start-up phase of the thermal decomposition to heat the first chamber (102) to a first predetermined temperature for decomposing the waste material; and (b) a second chamber (110) in fluid communication with the first chamber (102) for burning exhaust gas produced therein thereby reducing or eliminating hazardous particles in the exhaust gas, wherein the second chamber (110) comprises a burner (112) for heating the second chamber (110), a temperature sensor (not shown) for detecting temperature in the second chamber (110), the arrangement being such that the burner (112) is activated when the temperature in the second chamber (110) drops below a second predetermined temperature, and a gas exhaust outlet (114) for discharging the exhaust gas therefrom. Such arrangement allows the thermal decomposition reactor (100) to be operated at a reduced operating cost. Further, the present invention further relates to a thermal decomposition system (300) comprising the thermal decomposition reactor (100) and at least one purification unit for removing hazardous particles from the exhaust gas.

Description

A THERMAL DECOMPOSITION REACTOR FOR DECOMPOSING WASTE MATERIAL AND A THERMAL DECOMPOSITION SYSTEM
FIELD OF INVENTION
The present invention relates to the field of waste treatment technology. More particularly, the present invention relates to a thermal decomposition reactor for decomposing waste material and a thermal decomposition system.
BACKGROUND OF THE INVENTION
Solid waste treatment via thermal decomposition has been subjected to stringent regulation due to public health and environmental concerns. Exhaust gas produced from thermal decomposition contains harmful particles such as carbon dioxide, carbon monoxide, heavy metals such as lead and mercury, acid gases, volatile chlorinated organic compounds, dioxins, and furans. In addition, the exhaust gas may contain hazardous particles especially when the solid waste treatment involves scheduled wastes or medical wastes. The hazardous particles may not be completely decomposed before being discharged to the environment.
In Europe, Austria, and Canada, a medical incinerator requires two chambers in which a first chamber is provided for decomposing solid wastes, whereas a second chamber operating at 850 °C is provided to destroy hazardous particles. On the other hand, in China, the first chamber is required to be operated at more than 850 °C, whereas the second chamber is required to be operated at more than 1100 °C when hazardous wastes are involved.
China Patent Number CN106949480A discloses a pyrolysis incinerator comprising a first combustion chamber, a second combustion chamber, and an exhaust gas purification device. The second combustion chamber is configured to operate at a higher temperature as compared to the first combustion chamber. In addition, the second combustion chamber is configured to operate continuously by adjusting air intake to maintain the temperature therein. On the other hand, China Patent Number CN105333440A discloses an incinerator comprising a first combustion chamber equipped with at least one first burner and a second combustion chamber equipped with a second burner. The generated combustible gas in the first chamber is sent to the second chamber for further combustion at a higher temperature that meets the regulatory requirement.
The aforementioned incinerators comprise a burner in the second chamber that is configured to operate continuously to provide heat thereto. This imposes a relatively high operating cost due to the continuous fuel consumption by the burner such that the temperature therein is maintained at a temperature that is higher than that of the first chamber. Therefore, it is desirable to provide a thermal decomposition reactor and system for decomposing waste material in a more efficient and effective way thereby reducing the operating cost. The present invention provides a solution to the problem.
SUMMARY OF INVENTION
One aspect of the present invention is to provide a thermal decomposition reactor for decomposing a waste material and then further reducing or eliminating hazardous particles in exhaust gas produced from the decomposed waste material at a reduced operating cost. This can be achieved by providing a thermal decomposition reactor having a first chamber for decomposing the waste material and a second chamber in fluid communication with the first chamber for burning exhaust gas produced therein using a burner, wherein the burner activates only when the temperature in the second chamber drops below a certain temperature. Another aspect of the present invention is to provide a thermal decomposition system comprising the thermal decomposition reactor and at least one purification unit for removing hazardous particles from the exhaust gas.
At least one of the preceding aspects is met, in whole or in part, in which the embodiment of the present invention describes a thermal decomposition reactor (100) comprising (a) a first chamber (102) for decomposing the waste material, wherein the first chamber (102) comprises a feed inlet (104) for feeding the first chamber (102) with the waste material, means for supplying magnetized air (106) into the first chamber (102), and means for receiving an ignition source (108) such that the ignition source ignites the magnetized air during a start-up phase of the thermal decomposition to heat the first chamber (102) to a first predetermined temperature for decomposing the waste material; and (b) a second chamber (110) in fluid communication with the first chamber (102) for burning exhaust gas produced therein thereby reducing or eliminating hazardous particles in the exhaust gas, wherein the second chamber (110) comprises a burner (112) for heating the second chamber (110), a temperature sensor (not shown) for detecting temperature in the second chamber (110), the arrangement being such that the burner (112) is activated when the temperature in the second chamber (110) drops below a second predetermined temperature, and a gas exhaust outlet (114) for discharging the exhaust gas therefrom.
Preferably, the first chamber (102) further comprises plasma generation means (116) for accelerating the heating process during the start-up phase.
Preferably, the first chamber (102) further comprises a residue collector (118) for collecting residues produced from the thermal decomposition, and means for removing the residues (120) from the first chamber (102).
In another embodiment of the present invention, the thermal decomposition reactor (100) further comprises a feed processing unit (200) connected to the feed inlet (104), wherein the feed processing unit (200) comprises shredding means (202) for reducing size of the waste material.
Preferably, the feed processing unit (200) comprises a storage facility (204) for storing the shredded waste material and feeding means (206) for supplying the shredded waste material from the storage facility (204) to the first chamber (102) via the feed inlet (104).
Preferably, the feeding means (206) is a hydraulic feed cylinder or a pneumatic feed cylinder.
Further embodiment of the present invention describes a thermal decomposition system (300) comprising a thermal decomposition reactor (100) as hereinbefore described and further comprising a first purification unit (302) in fluid communication with the second chamber (110), wherein the first purification unit (302) is configured with means for mixing the exhaust gas with a scrubbing medium (304) so as to reduce temperature of the exhaust gas and remove hazardous particles therefrom.
Preferably, the thermal decomposition system (300) further comprises a second purification unit (306) in fluid communication with the first purification unit (302), wherein the second purification unit (306) comprises a plurality of spray nozzles (308) for spraying mist to wash down hazardous particles from the exhaust gas.
Preferably, the thermal decomposition system (300) further comprises a first filtration unit (310) disposed between the first purification unit (302) and the second purification unit (306) for separating hazardous particles from the exhaust gas.
Preferably, the thermal decomposition system (300) further comprises a second filtration unit (312) in fluid communication with the second purification unit (306) for filtering the exhaust gas prior to discharge thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the present invention, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the present invention, its construction and operation and many of its advantages would be readily understood and appreciated.
Figure 1 shows a thermal decomposition reactor (100).
Figure 2 shows a thermal decomposition reactor (100) comprising a feed processing unit (200).
Figure 3 shows a thermal decomposition system (300).
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention shall be described according to the preferred embodiments of the present invention and by referring to the accompanying description and drawings. However, it is to be understood that limiting the description to the preferred embodiments of the present invention is merely to facilitate discussion of the present invention and it is envisioned that those skilled in the art may devise various modifications without departing from the scope of the appended claim.
Figure 1 illustrates an embodiment of the present invention. Accordingly, the present invention provides a thermal decomposition reactor (100) for decomposing a waste material and then further reducing or eliminating hazardous particles in exhaust gas produced from the decomposed waste material. The waste material may be a scheduled waste or a medical waste. Alternatively, the waste material may be a municipal waste. The waste material may be a solid waste or liquid waste, preferably solid waste.
According to a preferred embodiment of the present invention, the thermal decomposition reactor (100) comprises a first chamber (102) for decomposing the waste material. Preferably, the first chamber (102) comprises a feed inlet (104) for feeding the first chamber (102) with waste material, means for supplying magnetized air (106) into the first chamber (102), and means for receiving an ignition source (108) such that the ignition source ignites the magnetized air during a start-up phase of the thermal decomposition to heat the first chamber (102) to a first predetermined temperature for decomposing the waste material.
Preferably, the feed inlet (104) is disposed at upper section of the first chamber (102) to facilitate feeding process of the waste material thereto. Such configuration prevents accumulation of waste material between the first chamber (102) and the feed inlet (104) thereby preventing clogging of the waste material during the feeding process.
The means for supplying magnetized air (106) may comprise an air suction unit and a permanent magnet or an electromagnet located in the air suction unit. The magnet magnetizes the air provided through the air suction unit. Preferably, the means for supplying magnetized air (106) is disposed at exterior of the first chamber (102) at a suitable distance therefrom to avoid heat from the first chamber (102) to adversely affect the magnetism of the magnet housed in the means for supplying magnetized air (106). In addition, the means for supplying magnetized air (106) can be housed in a heat-insulated housing or covered by a layer of heat insulating material.
Preferably, the means for receiving an ignition source (108) is disposed at lower section of the first chamber (102) for the ease of access by a user. Preferably, the means for receiving an ignition source (108) is an opening disposed at a side wall of the first chamber (102), in which the opening is configured with a hinged cover. The ignition source may be an ignition tool such as a lighter or a burner.
The first predetermined temperature can be selected based on the type of waste material. For example, the first predetermined temperature is preferably at about 1100 °C to about 1300 °C when the waste material comprises a scheduled waste, a medical waste, or a combination thereof. Alternatively, the first predetermined temperature can be at a lower temperature of about 800 °C to about 1100 °C when the waste material is municipal solid waste.
According to the preferred embodiment of the present invention, the thermal decomposition reactor (100) comprises a second chamber (110) in fluid communication with the first chamber (102) for burning exhaust gas produced therein. By way of example, the first chamber (102) and the second chamber (110) are connected via a pipe such that the exhaust gas produced in the first chamber (102) travels to the second chamber (110) therethrough. The movement of exhaust gas from the first chamber (102) to the second chamber (110) is the due to difference in pressure within these chambers (102, 110). Preferably, the second chamber (102) comprises a burner (112) for heating the second chamber (110), a temperature sensor (not shown) for detecting temperature in the second chamber (110), the arrangement being such that the burner (112) is activated when the temperature in the second chamber (110) drops below a second predetermined temperature, and a gas exhaust outlet (114) for discharging the exhaust gas therefrom.
As set forth in the preferred embodiment of the present invention, the burner (112) does not operate continuously to burn the exhaust gas produced in the first chamber (102). This reduces operating cost of the thermal decomposition reactor (100). The burner (112) only activates when the temperature in the second chamber (102) drops below a second predetermined temperature. The second predetermined temperature can be selected based on the local regulatory requirement where the thermal decomposition reactor (100) is being deployed. Preferably, the second predetermined temperature is about 800 °C to about 1300 °C, more preferably at about 1100 °C. The regulatory requirement in Malaysia for this particular chamber is 1100 °C with a retention time of 2 seconds.
In some embodiments of the present invention, the first predetermined temperature in the first chamber (102) is higher than the second predetermined temperature in the second chamber (110) to further reduce the need of operating the burner (112). The heat in the first chamber (102) can be provided by the incineration of magnetized air provided by the means for supplying magnetized air (106). This approach is more effective for heating the first chamber (102) as compared to a conventional burner or a conventional pyrolysis as described in prior art. However, the temperature in the first chamber (102) may change during thermal decomposition due to various factors such as inconsistent waste material feed rate and presence of different ingredients in the waste material. These will affect the thermal decomposition thereby resulting in a change in the temperature in the first chamber (102). In some situations, the temperature in the first chamber (102) may drop below the first predetermined temperature thereby resulting in an incomplete elimination of hazardous particles in the exhaust gas or failure to meet the regulatory requirement. Therefore, the second chamber (110) equipped with the burner (112) and the temperature sensor (not shown) is provided as a safety measure to ensure that the exhaust gas produced in the first chamber (102) is burned at the second predetermined temperature prior to discharge.
According to another preferred embodiment of the present invention, the first chamber (102) further comprises plasma generation means (116) for accelerating the heating process during the start-up phase. In addition, the use of plasma generation means (116) together with the means for supplying magnetized air (106) can produce a high temperature of about 1300 °C to about 1600 °C in the first chamber (102).
Still, according to another preferred embodiment of the present invention, the first chamber (102) further comprises a residue collector (118) for collecting residues such as ash produced from the thermal decomposition, and means for removing the residues (120) from the first chamber. The means for removing the residues (12) may be another opening disposed at the side wall of the first chamber (102), wherein the opening can be configured with another hinged cover.
According to another embodiment of the present invention as illustrated in Figure 2, the thermal decomposition reactor (100) further comprises a feed processing unit (200) connected to the feed inlet (104). Preferably, the feed processing unit (200) comprises shredding means (202) for reducing size of the waste material thereby improving the thermal decomposition thereof. For example, the shredding means (202) is a shredder. The shredder may be driven by electric or hydraulic motor. In addition, the feed processing unit (200) comprises a storage facility (204) connected to the shredding means (202) for storing the shredded waste material. Further, the feed processing unit (200) comprises feeding means (206) connected to the storage facility for supplying the shredded waste material from the storage facility (204) to the first chamber (102) via the feed inlet (104). For example, the feeding means (206) is a hydraulic feed cylinder or a pneumatic feed cylinder.
The present invention further provides a thermal decomposition system (300) as illustrated in Figure 3. Accordingly, the thermal decomposition system (300) comprises athermal decomposition reactor (100) as hereinbefore described and further comprising a first purification unit (302) in fluid communication with the second chamber (110). The first purification unit (302) can be configured with means for mixing the exhaust gas with a scrubbing medium (304) so as to reduce temperature of the exhaust gas and remove hazardous particles therefrom. The means for mixing the exhaust gas with a scrubbing medium (304) can be a stirrer, whereas the scrubbing medium Is preferably water. By way of example, the temperature of the exhaust gas can be reduced by adjusting stirring speed of the stirrer or retention time of the exhaust gas in the first purification unit (302).
Preferably, the thermal decomposition system (300) further comprises a second purification unit (306) in fluid communication with the first purification unit (302). By way of example, the first purification unit (302) and the second purification unit (306) are connected via another pipe such that purified exhaust gas in the first purification unit (302) travels to the second purification unit (306) therethrough. The movement of purified exhaust gas from the first purification unit (302) to the second purification unit (306) is due to the difference in pressure within these purification units (302, 206). The second purification unit (306) can be configured with a plurality of spray nozzles (308) for spraying mist to wash down hazardous particles from the exhaust gas. The combined use of the first purification unit (302) and the second purification unit (306) improves removal of the hazardous particles from the exhaust gas. This is because hazardous particles with higher temperature are more difficult to be removed via water mist spraying.
In some embodiments of the present invention, the thermal decomposition system (300) further comprises a first filtration unit (310) disposed between the first purification unit (302) and the second purification unit (306) for separating hazardous particles from the exhaust gas. Preferably, the thermal decomposition system (300) further comprises a second filtration unit (312) in fluid communication with the second purification unit (306) for filtering the exhaust gas prior to discharge thereof. The filtration units (310, 312) may be a plurality of filtration trays stacked on top of one another or arranged in a series. Preferably, each filtration tray contains carbon material such activated carbon to remove heavy metal particles from the exhaust gas and to decolorize the exhaust gas. The activated carbon can be mixed with powder derived from coconut shell or further impregnated with minerals for improved filtration performance. Alternatively, carbon nanotubes can be used . One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiment described herein is not intended as limitations on the scope of the present invention.

Claims

1. A thermal decomposition reactor (100) comprising:
(a) a first chamber (102) for decomposing the waste material, wherein the first chamber (102) comprises a feed inlet (104) for feeding the first chamber (102) with waste material, means for supplying magnetized air (106) into the first chamber (102), and means for receiving an ignition source (108) such that the ignition source ignites the magnetized air during a start-up phase of the thermal decomposition to heat the first chamber (102) to a first predetermined temperature for decomposing the waste material; and
(b) a second chamber (110) in fluid communication with the first chamber (102) for burning exhaust gas produced therein thereby reducing or eliminating hazardous particles in the exhaust gas, wherein the second chamber (110) comprises a burner (112) for heating the second chamber (110), a temperature sensor (not shown) for detecting temperature in the second chamber (110), the arrangement being such that the burner (112) is activated when the temperature in the second chamber (110) drops below a second predetermined temperature, and a gas exhaust outlet (114) for discharging the exhaust gas therefrom.
2. The thermal decomposition reactor (100) according to claim 1, wherein the first chamber (102) further comprises plasma generation means (116) for accelerating the heating process during the start-up phase.
3. The thermal decomposition reactor (100) according to claim 1 or 2, wherein the first chamber (102) further comprises a residue collector (118) for collecting residues produced from the thermal decomposition, and means for removing the residues (120) from the first chamber (102).
4. The thermal decomposition reactor (100) according to any one of claims 1 to 3 further comprising a feed processing unit (200) connected to the feed inlet (104), wherein the feed processing unit (200) comprises shredding means (202) for reducing size of the waste material.
5. The thermal decomposition reactor (100) according to claim 4, wherein the feed processing unit (200) comprises a storage facility (204) for storing the shredded waste material and feeding means (206) for supplying the shredded waste material from the storage facility (204) to the first chamber (102) via the feed inlet (104).
6. The thermal decomposition reactor (100) according to claim 5, wherein the feeding means (206) is a hydraulic feed cylinder or a pneumatic feed cylinder.
7. A thermal decomposition system (300) comprising a thermal decomposition reactor (100) according to any one of claims 1 to 6 and further comprising a first purification unit (302) in fluid communication with the second chamber (110), wherein the first purification unit (302) is configured with means for mixing the exhaust gas with a scrubbing medium (304) so as to reduce temperature of the exhaust gas and remove hazardous particles therefrom.
8. The thermal decomposition system (300) according to claim 7 further comprising a second purification unit (306) in fluid communication with the first purification unit (302), wherein the second purification unit (306) comprises a plurality of spray nozzles (308) for spraying mist to wash down hazardous particles from the exhaust gas. The thermal decomposition system (300) according to claim 8 further comprising a first filtration unit (310) disposed between the first purification unit (302) and the second purification unit (306) for separating hazardous particles from the exhaust gas. The thermal decomposition system (300) according to claim 9 further comprising a second filtration unit (312) in fluid communication with the second purification unit (306) for filtering the exhaust gas prior to discharge thereof.
PCT/MY2023/050013 2022-03-01 2023-02-24 A thermal decomposition reactor for decomposing waste material and a thermal decomposition system WO2023167581A1 (en)

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