[0001] The invention relates to chemical technology and equipment, in particular, to methods
and apparatuses for processing (pyrolysis and gasification) in volume in molten salts
and/or alkalis of household and industrial waste containing organic substances.
[0002] US Patent No. 6799595 IPC F16K 13/00, F16K 13/10 describes the method for waste processing, which comprises
waste supply into molten salts or alkalis and the apparatus for implementation thereof,
wherein the waste is fed into the melt in air stream. At that flameless oxidation
of waste occurs.
[0003] The closest technical solution for inventive method is the method for industrial
and household waste processing, comprising waste supply through loading channel into
the melt of salt or alkali mix, known from
RU Patent No. 228021, IPC F23G 5/00. The method for waste processing in melt is carried out at the absence
of oxygen. Depending on morphological structure of waste calculated quantity of mineral
additives are added to them in order to minimize the amount of gas which is obtained
during waste processing.
[0004] UA patent No. 75555 IPC C10B 49/00, F23G 7/00 describes the apparatus for waste processing, which comprises
the vessel with conical bottom, device for waste loading with vertical loading pipe,
shell coaxial with the vessel and loading pipe, screw surfaces inside of the shell
and displacing device connected with the conical bottom.
[0005] However, the disadvantage of said solutions is that the volume minimization is connected
with degradation of both thermal power of obtained gas and its chemical composition.
It impedes the use of obtained gas both in power generation cycle and for synthesis
of, e.g., petrol.
[0006] The object of the invention is to increase the cost-effectiveness by acceleration
of processing, to increase quality and quantity of gas obtained at processing for
its further use and to improve slag discharge conditions.
[0007] Set tasks are solved by inventive method for organic industrial and household waste
processing, comprising the supply of waste into the apparatus - reactor through the
vertical loading channel into molten salt and/or alkali mix to area of high-temperature
processing within the temperature range from 850 to 950°C. Wastes are supplied into
the reactor through the pipe of loading device and movable gas-tight plug is formed
by compression of waste using a piston. An area of low-temperature waste processing
is formed in operating volume of vertical loading pipe, for this purpose temperature
regime within the range from 20 to 550 °C is set along it, at that case temperature
regulation is carried out by dosed supply of water vapor and/or carbon dioxide into
the layer of products of low-temperature processing, formed in loading channel.
[0008] Additionally, metals, and oxides, salts or oxide hydrates thereof can be added to
melt as catalysts. Also water vapor and/or carbon dioxide can be supplied to the area
of high-temperature processing, and for melt regeneration silicon dioxide is added
to waste.
[0009] The proposed apparatus for implementation of the method for industrial and household
waste processing supports solving the set tasks. Said apparatus comprises the vessel
with conical bottom, device for waste loading with vertical loading channel, shell,
which is located concentrically relative to the vessel with screw surfaces inside,
heating tubes, cutter, located over the shell, displacing device, connected through
the mouth with conical bottom of the vessel, loading channel chamber, where the reactor
pipe is placed coaxially with the waste loading pipe, at that case lower opened end
of loading device pipe is located at the level of upper end of reactor pipe. The pipe
of loading device is equipped with the cooler in the area of gas-tight plug formation,
and reactor pipe has longitudinal slits, widening downwards, damper chamber is located
outside reactor pipe, and the pipe for supply of water vapor and/or carbon dioxide
is introduced into said pipe. Screw surfaces inside the shell can be made as blades,
and lower blades are made with elevation from the center to peripheral part in radial
direction, and blades located above are made horizontal in radial direction, and blades
of the upper layer are equipped with aprons used to direct liquid-gas flow to the
center, and each blade is installed with a gap relative to underlying blade and with
overlap in horizontal position. It is also provided that the diameter of the loading
device pipe can be less than the diameter of the reactor pipe, and the diameter of
the reactor pipe is less than the diameter of damper chamber.
[0010] The method can be realized in the reactor, which is schematically depicted in the
following Figures:
Fig. 1 schematically shows the apparatus for industrial and household waste processing,
wherein
- 1 - cylindrical vessel; 2 - conical bottom; 3 - vertical loading channel; 4 - device
for waste loading; 5 - piston; 6 - drive of reciprocal; 7 - cooler; 8 - reactor pipe;
9 - bridge; 10 - damper chamber; 11 - pipe for supply of vapor and/or carbon dioxide;
12 - shell; 13 - guiding blades; 14 - heating tubes; 15 - impingement plate; 16 -
pipe branch for discharge of gaseous products of processing; 17 - displacing device;
18 - mouth of displacing device; 19 - shell of displacing device mouth; 20 - external
heater; 21 - bottom of displacing device; 22 - plate heater; 23 - driving mechanism;
24 - melt level sensor; 25 - plug of displacing device.
[0011] The Fig. 2 symbolically depicts the distribution of functional areas in reactor's
operating volume, where various stages of waste processing are occurred, wherein:
Area 1 - Sections of low-temperature processing;
Areas 3-5 - Areas of high-temperature processing.
[0012] The implementation of the invention and operation of the apparatus are described
below.
[0013] The reactor for industrial and household waste processing has cylindrical vessel
1 with conical bottom 2. Device for waste loading 4 is installed in direction of the
vessel 1, at that the lower end of the waste loading device 4 is located under reactor's
cover. Vertical loading channel 3 of the waste loading device 4 is equipped with the
piston 5 with the drive 6 of reciprocal motion and cooler 7. The lower open outlet
end of the loading device pipe 4 is located at level of the lower end of the cooler
7. The pipe of the loading device 4 has an opening for waste supply into the loading
device pipe 4 under the upper position of the piston 5. The loading device pipe 4
is turned into the reactor pipe 8 in such a way that the upper annular clearance between
the pipe of the loading device 4 and reactor pipe 8 is blocked with the bridge 9.
[0014] Damper chamber 10 is located coaxially with reactor pipe 8 outside of it. The diameter
of the loading device pipe 4 can be less than the diameter of the reactor pipe 8,
and the diameter of the reactor pipe 8 is less than the diameter of damper chamber
10. The reactor pipe 8 contains the slits, which are enlarged downwards. The pipe
11 for supply of vapor and/or carbon dioxide is introduced into the damper chamber
10.
[0015] The shell 12 is placed coaxially to the reactor pipe 8 and the pipe of loading device
4 in the vessel 1, the lower end of said shell is located under the end of reactor
pipe 8, and the upper one is located above the melt level. One or several screw surfaces
or guiding blades 13 are installed in annular space between the damper chamber 10
and the shell 12, at that lower blades are made as sloped from the center to the periphery
in radial direction and the blades are located above, in horizontal and vertical directions,
the blades of the upper layer are equipped with aprons for liquid-gas flow guiding
to the center. Also, the blades are installed with a gap relative to the underlying
blade in vertical direction with overlap in horizontal direction. The blades are located
spirally in vertical direction. Such way of blade making allows to have maximal dispensing
of gas bubbles and to enlarge gas path in the melt, thus, to intensify heat mass exchange.
[0016] The heating tubes 14 are located in the area between the shell 12 and the vessel
1. The impingement plate 15 is located over the shell 12 with a gap. The upper part
of the vessel 1 comprises the pipe branch 16 for gaseous processing products discharge.
[0017] The conical bottom 2 is connected with the displacing device 17, the mouth 18 of
which is equipped with the covering 19. The displacing device 17 is made in the form
of inverse cone and has the external heater 20, plug 25 with a drive and the bottom
21, which can be made as flap or as a gate valve. The bottom 21 is opened by the means
of driving mechanism 23 and comprises plate heater 22.
[0018] The vessel 1 contains melt's level sensor 24.
[0019] The method is realized in said apparatus as follows:
Prior to start of heating, a gas-tight plug from waste is formed in the shaft of loading
device 4.
[0020] The heating tubes 14 and the heater 20 are permanently switched on and they heat
up the melt within the reactor vessel and displacing device to the temperature of
900-950 °C. The flap bottom 21 is adjoined to the displacing device 17. The plug 25
is at the upper position. Dispensed waste portions are supplied to the loading device
pipe 4 under the piston 5 in the moments when the piston is at the uppermost position.
At motion of the piston 5 downward the waste is compressed due to pipe wall friction
and upon achievement of primarily installed plug they move it along the loading channel.
And this is repeated sequentially portion by portion.
[0021] Due to cooling of waste in cooler area and heating up from the melt, temperature
area is formed in the vertical loading channel, this area consists of several sections,
where the following processes take place:
Area 1. Area of vertical loading channel is the area of low-temperature processing.
It is intended for drying of waste (raw materials) fed into the reactor, their destruction
and low-temperature processing. This area is symbolically divided by temperature ranges
for 5 sections:
section 1 (temperature variation range is 20÷100 °C) - area the cooler of loading
channel, within which the following processes take place:
- compressing of loaded raw materials and formation of gas-tight plug;
- initial warming up of raw materials, evaporation of free moisture;
- starting of vapor formation at boiling of free moisture (drying of plug material).
section 2 (temperature variation range is 100÷200 °C) - a part of loading channel,
within which the following processes take place:
- vapor formation and partial overheating of water vapor (depending on temperature and
pressure by section of plug material);
- starting of raw materials destruction processes.
section 3 (temperature variation range is 200÷350 °C) - a part of loading channel,
within which the following processes take place:
- intensification of processes of organic polymers decomposition and destruction;
- formation of saturated and non-saturated carbons;
- change of aggregate state of low-melting materials of organic and inorganic origin.
section 4 (temperature variation range is 350÷450 °C) - a part of loading channel,
within which the following processes occur:
- decomposition and destruction of organic compounds with covalent bonds cleavage in
polymers and crystal lattices of organic compounds;
- change of aggregate state of low-melting materials, transition of plug materials to
plastic state.
section 5 (temperature variation range is 450÷550 °C) - a part of loading channel,
within which the following processes take place:
- evolution of light tarry compounds, hardening of plastic material and carbonization
of external material layers;
- predominance of reactions of synthesis of, mainly, simple saturated and non-saturated
hydrocarbons.
[0022] At that case the top limit of this temperature range within this area becomes less
than the temperature of aromatic hydrocarbons formation.
[0024] The dynamics of melt in this area is performed due to bearing capacity of gas formed
at raw materials processing, both in the area of loading channel and in operating
area as such.
[0025] Constructive realization of this area represents a liquid-gas system, which is equipped
with special blades, located between the damper chamber and the shell of operating
area, intended for:
- delay of gas and non-reacted residue of raw materials in melt;
- maximal agitation of melt and formed gas;
- dispersion of gas component;
- gas purification.
[0026] All of this is, in turn, is required for intensification of chemical reactions. Moving
along the surfaces of operating area gas captures lower layers of warmed melt, providing
to it complex traveling locus by blades and surfaces, turbulizing melt flow, which,
in turn, is used for gas purification from liquid and solid components of raw materials
processing.
[0027] The difference between gas and melt rates results in the dispersion of gas in the
melt.
[0028] The dispersion of gas and turbulization of liquid-gas flow promotes the maximal agitation
in this area, additionally, they preset the dynamics to the whole molten volume in
the reactor, which, in turn, is necessary for:
- improving of heat withdrawal from heating surfaces;
- washing out of inorganic residue from internal walls of the vessel and operating surfaces
of the reactor;
- distribution and intensification of carbon movement dynamics in the whole molten volume;
- arrangement of dynamics in the area of dynamic purification of melt from inorganic
components.
[0029] Along with mentioned above, reactions with reagents (CaO, K
2O, Na
2O, NaOH, KOH etc.), fed into the reactor with raw materials or formed with it, are
intensified within the operating area due to melt dynamics. One of the functions of
these reagents is to accept CO
2, for example:
[0030] Gases, formed within the area of low-temperature processing, form gas bubbles in
the melt, which on the way to the surface in closed volume of the operating area capture
the melt, forming gas lift flow in such a way. While lifting the gas is warmed up
by the melt both by convection and heat radiation. But at the first stage of the process
warming up is weak due to poor transparence of gas, contaminated with liquid and solid
processing products, small surface of the bubble relative to its volume, as well as
due to endothermic nature of chemical reactions taking place.
[0031] Carbon dioxide (CO
2), which is contained in gas of loading channel, passes into the melt and reacts with
inorganic components of the latter and raw materials both in areas of low-temperature
and high-temperature processing, forming at that corresponding carbonates. Similar
interaction occurs at the initial stage, when gas and inorganic compounds are not
sufficiently heated. This reaction occurs with heat evolution, which facilitates warming
up of the reagents. Formed carbonates move within the melt with gradual heating. In
the upper part of operating area or warming area, thermal decomposition of carbonates
occurs with isolation of CO
2 in a form of the smallest bubbles. In such a way carbon dioxide is dispersed and
distributed in the whole volume of melt within the reactor, where it reacts with carbon.
[0032] The use of reagents - acceptors of carbon dioxide allows:
- to remove a part of carbon dioxide from gas being obtained at the outlet of the reactor;
- to decrease the effect of endothermic reactions of pyrolysis and gasification on temperature
of gas and melt inside loading channel and operating area;
- to increase the reactivity of CO2 due to dispersing thereof.
[0033] Molten salts of alkali and alkaline-earth metals is powerful redox environment where
reduction of elementary chemical elements from oxides takes place, carbon is oxidized
by reactions with H
2O and CO
2 with formation of gases containing H
2, CO, CO
2, CH
4 and other components under the influence of gas dynamic processes and high temperature.
Organic and inorganic structures are destroyed with simultaneous formation of new
chemical compounds.
[0035] Then formed metals can interact with compounds, which are present in the melt, for
example:
[0036] Thermodynamic properties of the melt play important role in activation of these processes,
namely, high heat capacity and thermal conductivity, which, correspondingly, are three
and more orders higher than gas has, which is, in turn, facilitates the increasing
of efficiency of energy transfer in the process of thermal decomposition of raw materials
and carbon gasification.
[0037] Increased activity of ionic state of alkali and alkali-earth metal salts at high
temperatures has catalytic influence with intensification of organic mass destruction.
Owing to the introduction of metal ions into carbon structure of raw materials the
weakening of the structure occurs followed by the cleavage of carbon bonds, opening
of aromatic rings etc.
[0038] One of the mechanisms of interaction of carbon with an oxidizing agent in melt is
connected with the formation of intermediate compounds of metals - oxides and hydroxides,
playing a role of catalysts.
[0039] For example:
[0040] Other metals, such as iron, nickel and chromium, have similar catalytic influence
on chemical processes in melt. These metals are reduced in molten environment, and
after that they start to effect formation of, predominantly, saturated hydrocarbons,
mainly methane CH
4, and, to a lesser extent, ethane C
2H
6 and propane C
3H
8, from the mixture of hydrogen and carbon dioxide:
[0041] Aromatic hydrocarbons are not formed due to the following factors:
- low partial pressure of non-saturated hydrocarbons;
- high temperature (more than 800 °C);
- presence of H2O, H2, metals oxides and hydroxides, which have catalytic action on aromatic hydrocarbons
destruction due to dehydration.
[0042] At sufficient amount of H
2O and corresponding introduced catalysts at this temperature the process for vapor
conversion of hydrocarbons with formation of gas mix takes place, where said mix maximally
contains H
2 and CO, the most suitable for further synthesis of hydrocarbon fuel.
[0043] Area 3. Area of melt cutting off.
[0044] The area of melt cutting off is used for change of direction of upward gas flow at
the outlet from reactor operating area following by its distribution in the whole
volume of heating area.
[0045] The cutter is made as a plate and is also used for:
- opening of gas bubbles and maximal dynamic distribution of gas and molten elements;
- final gas purification from liquid and solid elements;
- dynamic hammering of solid carbon residue under melt mirror within the heating area;
- breaking of solid foam formations on the surface of the heating area under the influence
of melt flow reflected from the cutter.
[0046] Area 4. Gas area of the reactor.
[0047] Gas area is located over the melt mirror and has a volume, which is approximately
equal to one third of the cylindrical shell of the reactor. It is intended for maximal
separation of obtained gas from the melt. This area is the continuation of reaction
areas, and its temperature varies within the limits of 900 - 700 °C. The reactions
of interaction of warmed gases, water vapors and pyrocarbon are continued in the whole
volume of gas area.
[0048] Area 5. Area of reactor heating.
[0049] The heating area is located between the internal wall of reactor vessel and the shell
of operating area. It contains heating tubes, performing indirect internal heating
of molten salts to the temperature of 950 °C by electrical or other method.
[0050] This area is, per se, a circulation circuit with the heating of melt.
[0051] In this area the following take place under influence of thermodynamic and physical-chemical
processes:
- warming up of both the melt and solid carbon residue, which is obtained at solid carbon
residue processing, to the temperature of 950 °C
- penetration of the melt into carbon pores;
- activation of carbon;
- weakening of bonds in carbon lattice under influence of alkali and alkali-earth metals.
[0052] All of this is the continuation of processes in reactor operating area and, finally,
results in catalytic carbon gasification, partially, in heating area as such, but
to a higher extent, in reactor operating area, where the melt containing activated
carbon is further supplied. In the same heating area, the process for catalytic carbon
gasification occurs with the participation of, mainly, carbon dioxide, formed at decomposition
of carbonates of alkali and alkali-earth metals, supplied together with the melt from
reactor operating area.
[0053] These interactions can be described by the example of calcium carbonate (CaCO
3), which is formed in the loading channel and the beginning of reactor operating area
from components of loaded raw materials. With passing of carbonates along the loading
channel and melt of operating area, they are warmed up. At the temperature above 800
°C calcium carbonate is thermally not stable and interacts with carbon according to
reactions:
[0055] HCl is formed at decomposition of chlorinated organic molecules present in raw materials.
[0056] The decomposition of carbonates, depending on their warming rate, can occur both
in the heating area and the upper part of the operation area.
[0057] Area 6. Area of dynamic purification of the melt.
[0058] The area is located in the lower part of internal volume of the reactor between the
operation area and the cone of displacing system.
[0059] It is characterized by annular centrifugal movement of the whole molten volume in
this area. Just in the area inorganic components, supplied together with raw materials
into the melt, as well as the components formed and not reacted during the process
of operation of the reactor, are separated by densities. For example, such as CaSiO
3, CaCO
3, CaS, CaO, SiO
2 etc.
[0060] Area 7. Area of the displacing system.
[0061] The area of the displacing system is located at the bottom of reactor volume, between
its cone part and the lower gate. The displacing area is made as truncated cone with
slight angle of opening. It has separate external heating element, which warms up
and maintains the temperature of 900 °C inside the displacing volume.
[0062] In this volume finally separation of inorganic elements by density, separation from
the melt, concentration and formation of infusible residue occur.
[0063] The lower part of the cone is equipped with the gate, intended for short-term opening
at removal of formed residue and for draining of the whole molten volume of the reactor.
[0064] The presence of carbonates CaCO
3, Na
2CO
3 and carbon in displacing system, which did not react at the temperature of ∼ 900
°C provides for the continuation of carbon gasification reactions with formation of
CO:
[0065] Under these conditions reactions of silicate formation and crystallization simultaneously
take place:
[0066] Na
2O + SiO
2 = Na
2SiO
3 followed by maximal displacing of the melt with infusible inorganic residue.
[0067] During operation permanent monitoring of composition of obtained gas is carried out.
In case of increase of carbon dioxide concentration on more than 3%, the salts, oxides
or oxide hydrates of alkali-earth metals, for example, calcium oxide, are added to
waste before the loading.
[0068] The principle of reactor operation is the implementation of constant melt circulation
under the influence of gases formed as the result of organic waste processing. It
is performed as follows: the melt, set in motion and discharged under the influence
of gas lift from the space between damper chamber and operation area shell, as well
as twisted on screw surfaces or special blades, and hampered from the impingement
plate, is supplied with twisting into the area between operation area shell and reactor
vessel. At that the melt passes downwards along the surfaces of heating tubes, carrying
carbonaceous solid components of processing. The increasing of raw materials supply
volume results in more intensive gas formation, and hence leads to more intensive
melt circulation, which, in turn, allows to compensate increased heat consumption
for raw materials processing at the expense of more intensive heat exchange of heating
tubes with the melt.
[0069] Solid non-fused slugs formed as the result of the processing and fed into the reactor
together with the raw material, are separated from main melt volume in the cone part
of the reactor and deposited in the displacing device, with displacement of lighter
melt from said device. This results in increase of the melt level in the reactor.
When the sensor of melt level signalizes that the melt level is increased on value,
which corresponds to the volume of displacing device, waste supply is stopped. The
locking plug of the displacing device is lowered by means of the drive into the mouth
of the displacing cone, at that the cooling agent - air or water, are supplied into
the covering around the mouth. The melt in a gap between the plug and the mouth is
crystallized, separating the melt in the reactor vessel from slugs in the displacing
device.
[0070] Simultaneously the plate heater is switched on. The salt in the area of contact of
cone end of the displacing device and flap bottom is melt, the bottom is thrown off
by the means of the drive, and the content of displacing device is removed. During
all this process the heater and heating tubes are still switched on. The bottom is
closed by the drive, and the plate heater is switched off. The supply of cooling agent
to the mouth covering of the displacing device is stopped. The salt is melted under
the influence of high temperature in a gap between the plug and the mouth of displacing
device, and the plug is raised by means of the drive, releasing the mouth.
[0071] The introduction of the waste is renewed and all process is continued.
[0073] At development of molten salt regeneration method the properties of electrolytes
were used, namely the capacity of strong bases to displace weak bases from melts (solutions)
of salts thereof. The exchange reaction with the salts of alkali-earth metals results
in formation, for example, of calcium silicate CaSiO
3, which is more heat-resistant than Na
2SiO
3:
[0074] Calcium silicate is precipitated as crystals, at that melt's dynamic viscosity and
residue melting temperature decrease due to formation of sodium chloride.
[0075] As the above description discloses the principles of the invention, with examples
provided for illustration, one should realize that the use of the invention comprises
all usual variations, adaptations and/or modifications, forming a part of the scope
of the following claims, and equivalents thereof.
1. A method for processing of organic industrial and household waste, comprising the
supply of waste into the apparatus through the vertical loading channel of the device
of waste supply into molten mix of salts and/or alkalis into the area of high-temperature
waste processing, which characterized in that movable gas-tight plug is formed in the loading channel from waste by compressing
of waste with a piston, and form the area of low-temperature waste processing in the
volume of loading channel, at that in area of low-temperature waste processing the
temperature regime is set within the range from 20 to 550 °C along the loading channel,
temperature regulation is performed by dosed supply of water vapor and/or carbon dioxide
into the loading channel, into the volume of products formed during low-temperature
waste processing.
2. The method for processing according the claim 1, which characterized in that metals, oxides, salts or oxide hydrates thereof are added into melt as catalysts.
3. The method for processing according the claim 1, which characterized in that water vapor is supplied into high-temperature processing area.
4. The method for processing according the claim 1, which characterized in that carbon dioxide, is supplied into high-temperature processing area.
5. The method for processing according the claim 1, which characterized in that the melt is regenerated by addition of silicon dioxide to waste.
6. An apparatus for realization of the method for waste processing according the claims
1-5, comprising of the vessel with conical bottom, device for waste loading with vertical
loading channel, shell, which is located concentrically to the vessel, screw surfaces
in the shell, heating tubes, cutter, which is located over the shell, displacing device,
which is connected through the mouth with conical bottom of the vessel, which characterized in that the vertical loading channel of the loading device comprises the loading device pipe
with the reactor pipe placed coaxially with it, and the lower open end of the loading
device pipe is located at the level of the upper end of the reactor pipe, loading
device pipe is equipped with the cooler in the area of gas-tight plug formation, and
the reactor pipe comprises the longitudinal slits, which are enlarged downwards, at
that the damper chamber is located outside of the reactor pipe is located, wherein
water vapor and/or carbon dioxide is supplied.
7. The apparatus according the claim 6, which characterized in that the screw surfaces inside the shell are made as the blades, at that the lower blades
are made elevated from the center to the tips in radial direction, the blades, which
are located over them, are made horizontal in radial direction, the blades of the
upper layer have aprons for guiding of liquid-gas flow to the center, and any of blades
is installed with a gap relative to underlying blade.
8. A device according the claim 6, which characterized in that the diameter of the loading device pipe is less than the diameter of the reactor
pipe, and the diameter of reactor pipe is less than the diameter of damper chamber.