Patent Application
20250003583
Apparatus for the combustion for synthetic gases deriving from the treatment of organic material.
The present invention also concerns a plant and a process for treatment of organic material.
The invention may find advantageous application in the management and use of civil and industrial sewage sludges from agricultural waste, from waste management systems, for example of civil origin, or from energy production systems.
There are known methods and related apparatuses for the treatment of organic material, for example sludges from waste water, by the application of heat. Known methods allow the production of synthetic gases usable as combustibles and of carbon residues, which may be further refined and used for making products or materials of various type.
Known apparatuses for the treatment of organic material has a treatment chamber or reactor where the organic material, heated at temperatures between 300° C. and 800° C., generates synthetic gases and dusty residues that may be sucked by the treatment chamber and used as combustibles for the production of energy.
Although the above-described apparatus allows the combustion of synthetic gases generated by the treatment of organic material, the Applicant has found that these solutions have limitations and drawbacks.
Firstly, in known apparatuses, the synthetic gases produced usually contain a relatively high amount of dust particles that certainly reduce the quality of the gas and may cause clogging and scaling.
Furthermore, in known apparatuses, due to a non-optimal temperature control of the synthetic gas, this gas may partially condense into oils and tars if its temperature drops below a predetermined threshold. The formation of oils and tars is practically certain if the initially higher temperature, decreases and falls below a critical point (usually around 400° C.), thus preventing an efficient operation of the apparatus.
A first object of one or more embodiments of the present invention is to provide an apparatus and a process for the treatment of organic material for the efficient production of synthetic gases and/or for the generation of carbonaceous materials usable in various technological fields.
It is also an auxiliary object of one or more embodiments is to provide a solution that limits the formation and the transport of mixtures of synthetic gases with excessive dusty residues.
Another auxiliary object of one or more embodiments is to provide an apparatus that limits the formation of scaling and the accumulation of dusty residues.
It is also an auxiliary object of one or more embodiments to design a solution that minimizes or excludes the formation of oils and tars deriving from the condensation of the synthetic gas.
Another auxiliary object of one or more embodiments is to provide a solution suitable for treating organic material with a reduced energy consumption.
A further auxiliary object of one or more embodiments is to provide a solution with an improved operational reliability that reduces the service costs of its components, such as for example the reactor and/or the combustion chamber, by reducing the number of maintenance operations required.
One or more of these objects and others, which will be more apparent from the following description, may be substantially achieved by one or more embodiments of an apparatus and a process for the combustion for synthetic gases deriving from the treatment of organic material according to one or more of the accompanying claims and/or the following aspects.
Aspects of one or more embodiments of the invention are described below.
In a 1st aspect is provided a reactor for the treatment, for example for the pyrolytic treatment, of organic material, said reactor comprising:
In a 2nd aspect according to the preceding aspect the inlet (3) and the outlet (4) of the main channel are arranged at opposing ends (31a, 31b) of the main channel itself.
In a 3rd aspect according to any one of the preceding aspects the gas outlet opening (8) is closer to the outlet (4) of the main channel (31) than the inlet (3) of the main channel itself (31).
In a 4th aspect according to any one of the preceding aspects the gas outlet opening (8) is positioned at a terminal section of the main channel (31) of extension equal to no more than ⅓ of an overall extension of the main channel itself (31).
In a 5th aspect according to any one of the preceding aspects the gas branch manifold (7) comprises an expansion section (7c) extending between the proximal portion (7a) and the distal one (7b).
In a 6th aspect according to the preceding aspect the expansion section (7c) of the gas branch manifold (7) extends in radial direction with respect to a lateral surface of the main channel (31).
In a 7th aspect according to any one of the preceding aspects the gas discharge orifice (10) has a gas passage area lower than a gas passage area of the gas outlet opening (8) of the main channel.
In an 8th aspect according to the preceding aspect a ratio between the gas passage area of the gas outlet opening (8) of the main channel and the gas passage area of the gas discharge orifice (10) is comprised between 0.01 and 0.06, optionally comprised between 0.02 and 0.05.
In a 9th aspect according to any one of the preceding aspects the gas outlet opening (8) and the proximal portion of the gas branch manifold (7) are located at an upper half of the main channel (31).
In a 10th aspect according to any one of the preceding aspects from 5th to 9th the expansion section (7c) of the gas branch manifold (7) extends radially, optionally in vertical direction, from the gas outlet opening (8) positioning the distal portion (7b) of the gas branch manifold (7) at a maximum height (H) from the gas outlet opening (8).
In a 11th aspect according to the preceding aspect the main channel (31) has a longitudinal development direction (A) and wherein said main channel also has, immediately upstream and/or immediately downstream of said gas outlet opening, a cross section with vertical dimension (D1), measured transversely to the longitudinal development direction (A), lower than the maximum height (H) of the gas branch manifold (7).
In a 12th aspect according to the preceding aspect the ratio between the maximum height (H) of the gas branch manifold (7) and the vertical dimension (D1) of the main channel (31) is comprised between 1.2 and 2.5.
In a 13th aspect according to any one of the preceding aspects the gas branch manifold (7) does not diverge moving away from the gas outlet opening (8).
In a 14th aspect according to any one of the preceding aspects the gas branch manifold (7) has a constant cross section for the whole extension of the manifold.
In a 15th aspect according to any one of the preceding aspects the gas branch manifold (7) has a tubular shape, even more optionally prismatic or cylindrical tubular shape.
In a 16th aspect according to any one of the preceding aspects from 11th to 15th the gas outlet opening (8) is at a minimum distance (Dm) from the outlet of the main channel (31) having size greater than said vertical dimension (D1) of the main channel (31).
In a 17th aspect according to the preceding aspect the ratio between said minimum distance (Dm) and a length (L) of the main channel (31), measured parallel to the longitudinal development direction (A) of the main conveyor (17), is comprised between 0.1 and 0.3.
In a 18th aspect according to any one of the preceding aspects the gas outlet opening (8) has an elongated conformation parallel to the/a longitudinal development direction (A) of the main channel (31).
In a 19th aspect according to any one of the preceding aspects the ratio between a length of the gas outlet opening (8) and the/a length (L) of the main channel (31) measured parallel to the/a longitudinal development direction (A) of the main conveyor (17) is comprised between 0.1 and 0.5.
In a 20th aspect according to any one of the preceding aspects the reactor comprises:
In a 22nd aspect according to any one of the two preceding aspects the loading channel (12a) extends between a first end, at or in immediate proximity of the inlet (3) of the main channel (31), and a second end, located inferiorly to the first end.
In a 23rd aspect according to any one of the three preceding aspects the loading channel (12a) is sloped with respect to a horizontal plane by an inner angle comprised between 5° and 60°, optionally comprised between 10° and 45°.
In a 24th aspect according to any one of the two preceding aspects the first end (15a) of the loading channel (12a) is laterally engaged to the main channel (31).
In a 25th aspect according to any one of the five preceding aspects the loading conveyor (15) is a screw or auger conveyor which operates in the loading channel (12a).
In a 26th aspect according to any one of the six preceding aspects the loading channel (12a) comprises a radial inlet mouth (32a) defined in proximity of the second end of the loading channel itself.
In a 27th aspect according to any one of the seven preceding aspects the reactor comprises a hopper (33) for the containment of the organic material to be treated, said hopper (33) comprising an unloading opening (34) for the movement by gravity of the organic material in the loading channel (12a), optionally through the inlet mouth (32a) of the loading channel (12a).
In a 28th aspect according to the preceding aspect the reactor comprises an unloading channel (35) which connects the unloading opening (34) of the hopper (33) with the loading channel (12a), optionally with the inlet mouth (32a) of the loading channel (12a).
In a 29th aspect according to any one of the preceding aspects the reactor comprises:
In a 30th aspect according to the preceding aspect the unloading channel (12b) is sloped.
In a 31st aspect according to any one of the two preceding aspects the unloading channel (12b) extends between a first end at or in immediate proximity of the outlet (4) of the main channel (31), and a second end located upperly to the first end.
In a 32nd aspect according to any one of the three preceding aspects the unloading channel (12b) is sloped with respect to a horizontal plane by an inner angle comprised between 5° and 60°, optionally comprised between 10° and 45°.
In a 33rd aspect according to any one of the two preceding aspects the first end of the unloading channel (12b) is laterally engaged to the main channel (31).
In a 34th aspect according to any one of the five preceding aspects the unloading conveyor (16) is a screw or auger conveyor which operates in the unloading channel (12b).
In a 35th aspect according to any one of the six preceding aspects the unloading channel (12b) comprises a radial outlet mouth (32b) defined in proximity of the second end of the unloading channel itself.
In a 36th aspect according to the 20th and 29th aspect the reactor comprises two motors (14a, 14b) respectively connected to the loading conveyor (15) and to the unloading conveyor (16) for allowing a respective movement thereof relative to the loading channel (12a) and to the unloading channel (12b).
In a 37th aspect according to the preceding aspect the reactor comprises a control unit connected to said motors (14a, 14b) and configured for commanding the movement of the loading and unloading conveyors (15, 16) thereof as a function of a predetermined speed profile.
In a 38th aspect according to any one of the preceding aspects the main conveyor (17) has:
In a 39th aspect according to the preceding aspect each hollow rotor (20) has one or more transversal spokes (23) engaging respective sections of the perimeter edge (21) to the shaft (18).
In a 40th aspect according to the preceding aspect the spokes (23) of a respective hollow rotor (20) are angularly offset to each other, optionally by an angle comprised between 70° and 110°, even more optionally comprised between 80° and 100°.
In a 41st aspect according to any one of the three preceding aspects at least one of said one or more helical rotors (19) is a solid rotor (24) devoid of cavities radially extending from the shaft to an inner surface of the main channel (31).
In a 42nd aspect according to the preceding aspect at least one of said one or more hollow rotors (20) are consecutively joined to a solid rotor (24).
In a 43rd aspect according to any one of the two preceding aspects at least a solid rotor (24) of the main conveyor (17), optionally having one or more coils, operates in proximity of the inlet (3) of the treatment chamber (2).
In a 44th aspect according to any one of the three preceding aspects at least a solid rotor (24) of the main conveyor (17), optionally having one or more coils, operates in proximity of the outlet (4) of the treatment chamber (2).
In a 45th aspect according to any one of the preceding aspects from the 38th to the 44th the main conveyor (17) comprises one or more wings (25) transversely emerging from the shaft (18) and spaced from the helical rotors (19), configured for terminally contacting an inner surface of the main channel (31).
In a 46th aspect according to the preceding aspect the wings (25) are spaced apart to each other along the shaft (18).
In a 47th aspect according to any one of the two preceding aspects each wing (25) is angularly offset from an adjacent wing, optionally by an angle comprised between 70° and 200°.
In a 48th aspect according to any one of the three preceding aspects each wing (25) has:
In a 49th aspect according to the preceding aspect the terminal body (25b) of the wing (25) has a platelike conformation.
In a 50th aspect according to any one of the two preceding aspects the terminal body (25b) has an elongated conformation transversely to the rod (25a) of the wing (25), defining, in cooperation with the rod (25a), a substantially “T” or “L” shape.
In a 51st aspect according to any one of the three preceding aspects the terminal body (25b) of the wing (25) has at least a contact surface sloped with respect to a horizontal plane passing by the shaft (18) of the main conveyor (17).
In a 52nd aspect according to any one of the preceding aspects the main conveyor (17) comprises:
In a 53rd aspect according to the preceding aspect the shaft (18) of the main conveyor (17) extends in length between the inlet (3) and the outlet (4) of the treatment chamber (2), wherein the main conveyor (17), for a preponderant part of the length of the shaft (18), has a plurality of first sectors interspersed by second sectors.
In a 54th aspect according to any one of the two preceding aspects the first and second sectors cover at least the 70% of the length of the shaft (18).
In a 55th aspect according to any one of the three preceding aspects the main conveyor (17) has respective first sectors in proximity of the inlet (3) and of the outlet (4) of the treatment chamber (2), said first sectors comprising solid rotors and/or hollow rotors (19).
In a 56th aspect according to any one of the four preceding aspects a central section of the main conveyor (17) has one or more first sectors comprising exclusively hollow rotors (19).
In a 57th aspect according to any one of the preceding aspects the reactor comprises a motor (26) connected to the main conveyor (17) for allowing a rotation thereof with respect to the treatment chamber (2).
In a 58th aspect according to the preceding aspect the reactor comprises a control unit (50) connected with the motor and configured for commanding the movement of the main conveyor (17) as a function of a predetermined speed profile, optionally at constant angular speed.
In a 59th aspect according to any one of the preceding aspects the heater comprises:
In a 60th aspect according to the preceding aspect the first and the second section (2a, 2b) cover substantially all the longitudinal extension of the main channel (31).
In a 61st aspect according to any one of the two preceding aspects the fluid heater (5) comprises a fluid supply line (5a) active on the first section (2a) of the main channel (31), configured for being placed in fluid communication with a hot fluid source, the supply line developing around the first section (2a) for transferring heat to the main channel (31).
In a 62nd aspect according to any one of the three preceding aspects the first section (2a) of the treatment chamber (2) extends in length for a preponderant part of the main channel (31) parallel to a/the longitudinal development direction (A) of the main channel (31).
In a 63rd aspect according to the preceding aspect said preponderant part covers more than the 50% of an overall extension of the main channel (31).
In a 64th aspect according to any one of the preceding aspects the reactor comprises a temperature sensor (28) active in the treatment chamber (2) and configured for generating one or more signals representative of a temperature inside the treatment chamber (2).
In a 65th aspect according to the preceding aspect the/a control unit (50) is connected to the temperature sensor (28) and configured for:
In a 66th aspect according to the preceding aspect the control unit (50) is connected to the electrical heater (6) active on the second section (2b) of the treatment chamber (2) and is configured for commanding the electrical heater (6) as a function of said one or more measured values of temperature, optionally if said measured values of temperature are lower than the threshold value of temperature.
In a 67th aspect according to any one of the preceding aspects the reactor comprises a pressure sensor (29) active in the treatment chamber (2) and configured for generating a signal representative of a relative pressure inside the treatment chamber (2).
In a 68th aspect is provided a process for the treatment of organic material through a reactor according to any one of the preceding aspects.
In a 69th aspect according to the preceding aspect the process comprises the steps of:
In a 70th aspect according to the preceding aspect the step of withdrawing gas from the treatment chamber (2) comprises a step of adjusting a pressure in the treatment chamber (2) sucking gas from the gas branch manifold (7) so that the pressure inside the treatment chamber is lower than the environmental pressure, reigning outside the plant, by a quantity comprised in a reference range between 10 Pa and 250 Pa, optionally between 20 Pa and 100 Pa.
In a 71st aspect according to the preceding aspect the step of adjusting the pressure in the treatment chamber (2) involves moving gas in the gas branch manifold (7), optionally in the expansion section (7c), at a speed comprised between 0.05 m/s and 0.8 m/s, optionally comprised between 0.1 m/s and 0.4 m/s.
In a 72nd aspect according to any one of the three preceding aspects the step of supplying organic material in the treatment chamber (2) comprises the steps of:
In a 73rd aspect according to the preceding aspect the step of moving organic material comprises a step of controlling a speed of movement of the loading conveyor (15) along the operative section.
In a 74th aspect according to any one of the five preceding aspects the step of heating the organic material comprises a sub-step of adjusting a temperature inside the treatment chamber (2) in a range comprised between 250° C. and 800° C., even more optionally comprised between 280° C. and 600° C.
In a 75th aspect according to any one of the six preceding aspects the step of heating the organic material is performed simultaneously to the step of moving organic material through the main conveyor (17).
In a 76th aspect according to any one of the seven preceding aspects the step of heating the organic material is performed through the fluid heater (5) and the electrical heater (6).
In a 77th aspect according to any one of the eight preceding aspects the process comprises the steps of:
In a 78th aspect according to the preceding aspect the step of withdrawing treated organic material from the treatment chamber (2) comprises a step of moving, through the unloading conveyor (16), the treated organic material outside the treatment chamber (2).
In a 79th aspect according to the preceding aspect said step of moving treated organic material comprises a step of controlling a movement speed of the unloading conveyor (16) along the operative section.
In an 80th aspect it is provided an apparatus for the combustion of synthetic gases deriving from the treatment of organic material, for example through pyrolysis, said apparatus comprising:
In an 81st aspect according to the preceding aspect the burner (75) has:
In an 82nd aspect according to any one of the two preceding aspects the fluid supply circuit (65) has a gas access (67) for receiving the comburent gas, optionally room air, from an environment outside the combustion chamber (62) and a gas outlet (68) in communication with the combustion chamber (62) or with the comburent access (76) of the burner (75).
In an aspect 82b is according to any one of the preceding aspects of apparatus the burner (75) is placed upstream or internally to the combustion chamber.
In an 83rd aspect according to any one of the three preceding aspects said one or more channels (66) of the fluid supply circuit (65) are formed from subsequent sections of a single continuous channel or from distinct channels in communication to each other.
In an 84th aspect according to any one of the four preceding aspects said channels (66) are overlapped to a preponderant part, optionally at least the 70%, of the outer surface (62a) of the combustion chamber (62).
In an 85th aspect according to any one of the five preceding aspects the combustion chamber (62) extends along a development direction (X), and wherein said one or more channels (66) of the fluid supply circuit (65) are arranged transversely to the development direction (X) of the combustion chamber (62).
In an 86th aspect according to any one of the six preceding aspects said one or more channels (66) form at least a single continuous channel extending around the outer surface (62a) of the combustion chamber (62) along a helical trajectory.
In an 87th aspect according to any one of the seven preceding aspects said one or more channels (66) form annular-shaped segments (66a), optionally with circular shape, extending around to the outer surface (62a) of the combustion chamber (62), wherein each of said segments (66a) is in communication with an adjacent channel (66).
In an 88th aspect according to any one of the eight preceding aspects the combustion chamber (62) has a hollow tubular conformation, optionally tubular cylindrical or prismatic.
In an 89th aspect according to any one of the preceding aspects from the 80th to the 88th the outer surface (62a) has a cylindrical shape with circular profile or polygonal profile.
In a 90th aspect according to any one of the preceding aspects from the 80th to the 89th the combustion chamber (62) has a first and a second terminal wall (62′, 62″) which delimit longitudinally the combustion chamber itself.
In a 91st aspect according to the preceding aspect the burner (75) is carried by the first terminal wall (62′).
In a 92nd aspect according to any one of the two preceding aspects the fluid supply circuit (65) contacts the outer surface (62a) from an area next to the second terminal wall (62″) until an area next to the first terminal wall (62′).
In a 93rd aspect according to any one of the preceding aspects from the 80th to the 92nd the inlet (63) and the outlet (64) of the combustion chamber (62) are respectively defined on the first and the second terminal walls (62′, 62″).
In a 94th aspect according to any one of the preceding aspects from the 80th to the 93rd the fluid supply circuit (65) comprises a sleeve (68) which wraps the combustion chamber (62) and is radially outside the outer surface (62a) of the combustion chamber (62) itself to form a gap for receiving said comburent gas.
In a 95th aspect according to any one of the preceding aspects from the 80th to the 94th the fluid supply circuit (65) comprises one or more walls (69) arranged transversely to a/to the development direction (X) of the combustion chamber (62), wherein subsequent sections of the one or more separating walls (69) parallel to each other.
In a 96th aspect according to the two preceding aspects said walls (69) extend radially, outside of the outer surface (62a) of the combustion chamber (62) and internally to the sleeve (68).
In a 97th aspect according to any one of the three preceding aspects said one or more channels (66) are laterally delimited from subsequent sections of the one or more separating walls (69) and radially delimited by the sleeve (68).
In a 98th aspect according to any one of the three preceding aspects said one or more walls (69) are interconnected to each other to define a single helical element extending around the outer surface (62a) of the combustion chamber (62) for a preponderant part, optionally for all of a length of the combustion chamber (62) measured parallel to the development direction (X).
In a 99th aspect according to any one of the preceding aspects from the 94th to the 98th the apparatus comprises a case (70) radially outside the sleeve (68) that defines a gap between the sleeve (68) and an inner surface (70a) of the case (70).
In a 100th aspect according to any one of the preceding aspects from the 80th to the 99th at least one of: the combustion chamber (62), the sleeve (68), said one or more walls (69) and the case (70), are made in metallic material, optionally steel, for example stainless steel.
In a 101st aspect according to any one of the preceding aspects from the 80th to the 100th the combustion chamber (62), the sleeve (68) and/or the case (70) are devoid of coatings made in refractory or thermally insulating materials.
In a 102nd aspect according to any one of the preceding aspects from the 80th to the 101st the burner (75) comprises an auxiliary access (88) in communication with the combustion chamber (62), optionally the mixing chamber (78), for receiving combustible gas and allowing an initial ignition of the apparatus.
In a 103rd aspect according to any one of the preceding aspects from the 80th to the 102nd the fluid supply circuit (65) comprises a connection duct (74) which connects with the burner (75) a terminal part, adjacent to the burner itself, of the gap formed by said sleeve (68).
In a 104th aspect it is provided a process for the combustion of synthetic gases deriving from the treatment of organic material, through an apparatus according to any one of the preceding aspects.
In a 105th aspect according to the preceding aspect the process comprises the steps of:
In a 106th aspect according to the preceding aspect the process comprises a step of activating the activation device (72) of the burner (75) for triggering the combustion between combustible gas and comburent gas.
In a 107th aspect according to any one of the two preceding aspects the step of heating the comburent gas involves a gradual heating of the comburent gas after a progressive movement of the comburent gas itself in the fluid supply circuit (65) and toward the burner (75).
In a 108th aspect according to any one of the three preceding aspects the step of heating said comburent gas in the fluid supply circuit (65) involves heating the comburent gas from a room temperature, optionally comprised between 5° C. and 45° C., to a threshold temperature, optionally greater than 250° C., even more optionally comprised between 450° C. and 650° C.
In a 109th aspect according to the preceding aspect the step of supplying the comburent gas to the burner (75) comprises the sub-steps of:
In a 110th aspect it is provided a plant for the treatment of organic material comprising an apparatus (60) according to any one of the preceding aspects from the 80th to the 103rd.
In a 111th aspect according to the preceding aspect the plant comprises:
In a 112th aspect according to the preceding aspect the gas branch manifold (7) has a gas discharge orifice (10), opposite to the gas outlet opening (8) and configured for supplying gas deriving from the main channel (31).
In a 113th aspect according to the preceding aspect the gas discharge orifice (10) of the reactor (1) is in communication with the burner (75) of the apparatus (60).
In a 114th aspect according to any one of the two preceding aspects the plant comprises a connection channel (81) which connects the gas discharge orifice (10) of the gas branch manifold (7) of the reactor (1) with the burner (75) of the apparatus (60), wherein said connection channel (81) is configured for supplying to the burner (75), gas coming from the treatment chamber (2) of the reactor (1).
In a 115th aspect according to any one of the preceding aspects from the 110th to the 114th the plant comprises a comburent gas supply line (85) in communication with the fluid supply circuit (65) of the apparatus (60) for supplying gas in said one or more channels (66).
In a 116th aspect according to the preceding aspect the plant comprises a gas movement device (84), for example a fan, active on the comburent gas supply line (85) for moving the comburent gas, for example air, coming from an environment outside the plant.
In a 117th aspect according to any one of the preceding aspects from the 110th to the 116th the plant comprises an exhaust gas evacuation line (73) in communication with the outlet (64) of the combustion chamber (62) of the apparatus (60) and configured for ejecting an exhaust gas from the combustion chamber itself.
In a 118th aspect according to the preceding aspect the plant comprises a suction device (120) connected to a terminal end of the exhaust gas evacuation line (73) opposite to the outlet (64) of the combustion chamber (62), configured for evacuating the exhaust gas in an environment outside the plant.
In a 119th aspect according to any one of the preceding aspects from the 110th to the 118th the reactor comprises:
In a 120th aspect according to any one of the preceding aspects from the 110th to the 119th the suction device (120) is active on the gas branch manifold (7) of the reactor.
In a 121st aspect according to the two preceding aspects the/a control unit (50) is connected to the suction device (120) and is configured for commanding the suction device itself as a function of said measured values of pressure received from the pressure sensor (29), so as to keep a status of depression in the treatment chamber with respect to the outer environment, optionally wherein the control unit is configured for controlling the suction of the suction device such that the pressure inside the treatment chamber is lower than the environmental pressure by a quantity comprised in a reference range between 10 Pa and 250 Pa, optionally between 20 Pa and 100 Pa.
In a 122nd aspect according to any one of the preceding aspects from the 110th to the 121st the reactor (1) comprises:
In a 123rd aspect according to the preceding aspect the fluid heater (5) comprises a fluid supply line active on the first section (2a) of the main channel (31) and extending around the first section (2a) for transferring heat to the main channel.
In a 124th aspect according to any one of the two preceding aspects the plant comprises:
In a 125th aspect according to the preceding aspect the plant comprises at least a heat exchange unit (98) which has:
In a 126th aspect according to the preceding aspect the hot fluid chamber (98′) comprises:
In a 127th aspect according to any one of the two preceding aspects the plant comprises:
In a 128th aspect according to the preceding aspect a/the control unit (50) is connected to the loading cell (103) and configured for:
In a 129th aspect according to any one of the two preceding aspects a/the control unit (50) is connected to the pressure sensor (104) and configured for:
In a 130th aspect according to any one of the two preceding aspects a/said control unit (50) is connected to the loading cell of the collection container (102) and to the pressure sensor (104), said control unit (50) being configured for:
In a 131st aspect according to any one of the preceding aspects from the 124th to the 130th the plant comprises a recirculation valve (110) active on the recirculation line (108) and having:
In a 132nd aspect according to the preceding aspect the plant comprises a connection branch (112) which connects the second outlet door (110c) of the recirculation valve (110) and the first branch (108a) of the recirculation line (108).
In a 133rd aspect according to any one of the preceding aspects from the 124th to the 132nd the plant comprises a check valve (111) active on the first branch (108a) of the recirculation line (108) for preventing the movement of the heating fluid along the first branch (108a) and toward the reactor (1).
In a 134th aspect according to the preceding aspect the check valve (111) is located on a section of the first branch (108a) of the recirculation line in interposition between a joining point (J) between the connection branch (112) and the first branch itself and the reactor (1).
In a 135th aspect according to any one of the four preceding aspects the recirculation valve (110) is configurable between:
In a 136th aspect according to the preceding aspect a/the control unit (50) is connected to the recirculation valve (110) and wherein the cleaning procedure of the control unit (50) comprising the steps of:
In a 137th aspect according to any one of the preceding aspects from the 110th to the 136th the plant comprises:
In a 138th aspect according to any one of the preceding aspects from the 110th to the 137th the plant comprises a filter (91), optionally a cyclonic filter, which operates downstream of the combustion chamber (62) for separating dusts or debris from exhaust gases leaving the combustion chamber (62).
In a 139th aspect according to the preceding aspect the filter (91) comprises:
In a 140th aspect according to any one of the two preceding aspects the filter (91) comprises:
In a 141st aspect according to the preceding aspect a/the control unit (50) is connected to the loading sensor (96) and configured for:
In a 142nd aspect according to the preceding aspect the plant comprises a/said control unit (50) connected to the loading sensor of the collection tank (95) and configured for performing at least one of the following steps:
In a 143rd aspect according to any one of the preceding aspects from the 110th to the 142nd the plant comprises a bypass line (99) connected to a section of the exhaust gas evacuation line (73) downstream of the outlet (64) of the combustion chamber (62) of the apparatus (60) and optionally upstream of the heat exchange unit (98).
In a 144th aspect according to the preceding aspect the plant comprises an auxiliary gas movement device (123), for example a fan, active on the bypass line (99) for ejecting exhaust gases, for example air, in an environment outside the plant.
In a 145th aspect according to any one of the two preceding aspects the plant comprises a bypass valve (101) active on the bypass line (99) for selectively allowing the passage of gas in said bypass line (99).
In a 146th aspect according to any one of the preceding aspects from the 110th to the 145th the plant comprises a temperature sensor (90) active on the outlet (64) of the combustion chamber (62) and configured for generating a signal representative of a gas temperature leaving the combustion chamber (62).
In a 147th aspect according to the preceding aspect a/the control unit (50) connected to the temperature sensor (90) and configured for:
In a 148th aspect according to the three preceding aspects the control unit (50) is connected to the bypass valve (101) and configured for commanding an opening condition thereof as a function of said measured values of temperature from the temperature sensor (90), optionally if one or more of said measured values of temperature are greater than the threshold value of temperature.
In a 149th aspect according to any one of the preceding aspects from the 110th to the 148th the plant comprises a reactor according to any one of the preceding aspects from the 1st to the 67th aspect.
In a 150th aspect it is provided a process for the treatment of organic material through a plant according to any one of the preceding aspects from the 110th to the 150th.
In a 151st aspect according to the preceding aspect the process comprises the steps of:
In a 152nd aspect according to the preceding aspect the step of expelling the combustible gas in the combustion chamber (62) of the apparatus (60) comprises the sub-step of conveying, through the connection channel (81), said combustible gas in the burner (75) of the apparatus (60).
In a 153rd aspect according to any one of the three preceding aspects the process comprises a step of injecting, through the comburent gas supply line (85), a comburent gas, for example air, in the fluid supply circuit (65) of the apparatus (60).
In a 154th aspect according to any one of the four preceding aspects the process comprises a step of withdrawing an exhaust gas from the combustion chamber (62) of the apparatus (60) and subsequently:
In a 155th aspect according to the preceding aspect the process provides for the step of channeling, through the bypass line (99), said exhaust gas in an environment outside the plant.
In a 156th aspect according to any one of the preceding aspects from the 150th to the 155th the process comprises a step of heating which involves the following sub-steps:
In a 157th aspect according to the preceding aspect the step of conveying the exhaust gas in the hot fluid chamber (98′) comprises a step of withdrawing said exhaust gas from the exhaust gas evacuation line (73).
In a 158th aspect according to any one of the two preceding aspects the steps of supplying the fluid to be heated in said one or more cold fluid channels (98″) and moving the heated fluid in the fluid supply line of the reactor (1) comprises the sub-step of moving, through the recirculation pump (109), said fluids in the first and second branch (108a, 108b) of the recirculation line (108).
In a 159th aspect according to any one of the preceding aspects from the 150th to the 158th the process comprises a step of discharging dusts from the collection container (102) associated to the heat exchange unit (98), as a function of weight values of the collection container itself, optionally if said weight values of the collection container (102) are greater than a threshold value of weight.
In a 160th aspect according to any one of the preceding aspects from the 150th to the 159th the process comprises a cleaning procedure of said heat exchange unit (98) as a function of weight values of the collection container (102) and/or as a function of measured values of a pressure detected in the hot fluid chamber (98′) of the heat exchange unit (98), said cleaning procedure comprises the step of commanding in activation one or more cleaning nozzles (106) which operate in the hot fluid chamber (98′) of the heat exchange unit (98).
In a 161st aspect according to any one of the preceding aspects from the 150th to the 160th the process comprises a step of filtering, through the filter (91), the exhaust gas leaving the combustion chamber (62) of the apparatus (60).
In a 162nd aspect according to any one of the preceding aspects from the 150th to the 161st the process comprises a maintenance procedure of the filter (91) of the apparatus (60) comprising a step of discharging dusts from the collection tank (95) as a function of weight values of the collection tank (95), optionally if said weight values of the collection tank (95) are greater than a threshold value of weight.
In a 163rd aspect according to any one of the preceding aspects from the 150th to the 162nd the process comprises a step of conveying gas in the bypass line (99) as a function of one or more temperature values detected by the temperature sensor (90), optionally wherein said temperature values are greater than the threshold value of temperature, even more optionally comprised between 900° C. and 1200° C.
In a 164th aspect it is provided a main conveyor (17) comprising:
In a 165th aspect according to the preceding aspect each hollow rotor (20) has one or more transversal spokes (23) which engage respective sections of the perimeter edge (21) to the shaft (18).
In a 166th aspect according to the preceding aspect the spokes (23) of a respective hollow rotor (20) are angularly offset to each other, optionally by an angle comprised between 70° and 110°, even more optionally comprised between 80° and 100°.
In a 167th aspect according to any one of the three preceding aspects at least one of said one or more helical rotors (19) is a solid rotor (24) free from cavities which extends radially from the shaft to an inner surface of the main channel (31).
In a 168th aspect according to the preceding aspect at least one of said one or more hollow rotors (20) are consecutively joined to a solid rotor (24).
In a 169th aspect according to any one of the two preceding aspects at least a solid rotor (24) of the conveyor (17), optionally having a or more coils, operates at one or each terminal section of the shaft (18).
In a 170th aspect according to any one of the preceding aspects from the 164th to the 169th the conveyor (17) comprises one or more wings (25) transversely emerging from the shaft (18) and spaced from the helical rotors (19), configured for terminally contacting an inner surface of the main channel (31).
In a 171st aspect according to the preceding aspect the wings (25) are spaced apart to each other along the shaft (18).
In a 172nd aspect according to any one of the two preceding aspects each wing (25) is angularly offset from an adjacent wing, optionally by an angle comprised between 70° and 200°.
In a 173rd aspect according to any one of the three preceding aspects each wing (25) has:
In a 174th aspect according to the preceding aspect the terminal body (25b) of the wing (25) has a platelike conformation.
In a 175th aspect according to any one of the two preceding aspects the terminal body (25b) has an elongated conformation transversely to the rod (25a) of the wing (25), defining, in cooperation with the rod (25a), a substantially “T” or “L” shape.
In a 176th aspect according to any one of the three preceding aspects the terminal body (25b) of the wing (25) has at least a contact surface sloped with respect to a horizontal plane passing by the shaft (18) of the conveyor (17).
In a 177th aspect according to any one of the preceding aspects from the 164th to the 176th the conveyor (17) comprises:
In a 178th aspect according to the preceding aspect the conveyor (17), for a preponderant part of the length of the shaft (18), has a plurality of first sectors interspersed by second sectors.
In a 179th aspect according to any one of the two preceding aspects the first and second sectors cover at least the 70% of the length of the shaft (18).
In a 180th aspect according to any one of the three preceding aspects the conveyor (17) has respective first sectors in proximity of each terminal section of the shaft (18), said first sectors comprising solid rotors and/or hollow rotors (19).
In a 181st aspect according to any one of the four preceding aspects a central section of the conveyor (17) has one or more first sectors comprising exclusively hollow rotors (19).
If used herein, the term “substantially” has the same meaning as “significantly,” and can be understood to modify the term that follows by at least about 75%, at least about 90%, at least about 95%, or at least about 98%. The term “not substantially” as used herein has the same meaning as “not significantly,” and can be understood to have the inverse meaning of “substantially,” i.e., modifying the term that follows by not more than 25%, not more than 10%, not more than 5%, or not more than 2%.
Numeric values used herein include normal variations in measurements as expected by persons skilled in the art and should be understood to have the same meaning as “approximately” and to cover a typical margin of error, such as +5% of the stated value.
Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration.
The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of” and “comprises at least one of” followed by a list refers to any one of the items in the list and any combination of two or more items in the list.
As used here, the term “or” is generally employed in its usual sense including “and/or” unless the content clearly dictates otherwise. The term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.
The recitations of numerical ranges by endpoints include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc. or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). Where a range of values is “up to” or “at least” a particular value, that value is included within the range.
The words “preferred” and “preferably” refer to embodiments that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.
The above summary of the invention is not intended to describe each embodiment or every implementation of the apparatus and methods described herein. Rather, a more complete understanding of the invention will become apparent and appreciated by reference to the following description of illustrative embodiments and claims in view of the accompanying figures of the drawing.
Some embodiments and aspects of the invention will be described herein with reference to the accompanying figures, provided for illustrative purposes only and therefore not limiting wherein:
It is noted that in the present detailed description corresponding parts shown in the various figures are indicated with the same numerical references. Figures may illustrate the object of the invention through unscaled representations; therefore, parts and components shown in the figures relating to the object of the invention may relate exclusively to schematic representations.
Further, in the following description, reference is made to the accompanying figures of the drawing which form a part hereof, and in which are shown, by way of illustration, specific embodiments. It is to be understood that other embodiments may be utilized, and changes may be made without departing from the scope of the present invention.
At least one between the reactor and the plant herein described and claimed may comprise/use at least a control unit designed to control the operating conditions set up by the reactor itself and/or plant and/or to control the steps of the processes herein described and/or claimed.
The control unit may be a single unit or be formed by a plurality of distinct control units depending on design choices and operational requirements.
As a control unit it is intended a component of electronic type which may comprise at least one of: a digital processor (CPU), an analogue type circuit, or a combination of one or more digital processors with one or more analogue type circuits. The control unit may be “configured” or “programmed” to perform some steps: this may be practically made by any means that allows to configure or program the control unit. For example, in case of a control unit comprising one or more CPUs and one or more memories, one or more programs may be stored in appropriate memory banks connected to the CPU or CPUs; the program or programs contain instructions which, when executed by the CPU or by the CPU(s), program or configure the control unit to perform the operations described in relation to the control unit. Alternatively, if the control unit is/or comprises circuitry of an analogue type, then the circuit of the control unit may be designed to include circuitry configured, in use, to process electrical signals in such a way as to perform the steps related to the control unit. Parts of the process herein described may be made by means of a data processing unit or control unit, technically replaceable with one or more computers designed to carry out a portion of a software program or firmware uploaded onto a memory support. This software program may be written in any programming language of known type. The computers, if two or more in number, may be connected to each other by means of a data connection such that their computing powers are in any way shared; the same computers may thus be installed in geographically different locations as well, thereby realizing by means of the aforesaid data connection a distributed computing environment. The data processing unit, or control unit, may be a general-purpose processor configured to perform one or more parts of the process identified in the present invention via the software or firmware program, or being an ASIC or dedicated processor or an FPGA, specifically programmed to carry out at least part of the operations of the process herein described. The memory support may be non-transitory and may be inside or outside the processor, or control unit, or data processing unit, and can, specifically, be a memory geographically located remotely with respect to the computer. The memory support may also be physically divided into several portions, or in the form of cloud, and the software or firmware program may be stored on memory portions geographically divided to each other.
With reference to the accompanying figures, one illustrative embodiment of a plant for the thermochemical treatment of organic material, for example sludges from civil or industrial sewage, for producing a combustible gas subsequently referred to as synthetic gas, has been overall indicated with 100. Further carbonaceous residues, obtained by heating the organic material, may be refined to obtain further products such as, for example, active carbons.
As shown in
Before going into the details of the structure and operation of the individual elements that compose the plant 100, the general operation and structure of the plant will be described below, focusing on the interactions between the various components.
As mentioned, the reactor 1 comprises at least one heater active on a main channel 31 of the reactor 1 to heat, partially or integrally, a treatment chamber 2 inside the main channel 31, in which the organic material to be treated is located. The heater comprises a fluid heater 5 formed by a supply line 5a, for example helically shaped, whose coils are wound around the reactor, where circulates a heating fluid, optionally oil, for heating the organic material and transferring heat to the main channel 31. During the normal operation at steady state of the plant, the heating of the organic material results in the production of synthetic gas which is transferred, via a connection channel 81, to the apparatus 60 for being combusted when mixed with a comburent gas, optionally air. The supply of the comburent gas to the apparatus 60 may be made by means of a comburent gas supply line 85 for channeling the comburent gas itself, from an environment outside the plant, towards the apparatus 60. The plant 100 may also comprise a movement device 84, for example a fan, active on the comburent gas supply line 85 for supplying the comburent gas towards the apparatus 60. After the combustion of the synthetic gas with the comburent gas, an exhaust gas having a temperature comprised between 800° C. and 1000° C. is obtained, which is expelled from the apparatus 60 through an exhaust gases evacuation line 73 which channels it to a heat exchange unit 98 later described. The plant 100 may also comprise a suction device 120, for example a fan, operating on the exhaust gas evacuation line 73, to suck the exhaust gas from the apparatus 60, move it in the heat exchange unit 98 and expel it in the environment.
Unlike what has been described above which, as it has been said, refers to a condition of normal operation at steady state of the plant 100, in a condition of first start-up of the plant itself, and therefore in the absence of synthetic gas produced by the reactor, it is provided, by means of an auxiliary access 88, the forced supply of an exhaust gas, for example methane gas, for producing the exhaust gas useful for heating the heating fluid circulating in the reactor 1.
As mentioned above, the exhaust gas in the apparatus 60, is used by the heat exchange unit 98 for transferring heat to the heating fluid circulating in the fluid heater 5 of the reactor 1. The plant 100 may therefore have a recirculation line 108 that transfers the heating fluid of the fluid heater 5 from the reactor 1 until the heat exchange unit 98 is reached for being heated. In an example, the recirculation line 108 comprises a first branch 108a connected to a terminal end of the fluid heater 5 for channeling the heating fluid to the heat exchange unit 98, as well as a second branch 108b, connected to an initial end of the fluid heater 5, for receiving the heating fluid, opportunely heated, deriving from the heat exchange unit 98. The plant 100 may also comprise a recirculation pump 109, for example active on the first branch 108a of the recirculation line 108 as shown in
The plant may further comprise a check valve 111 which operates in the first branch 108a of the recirculation line 108, in interposition between a joining point J between the connection branch 112 with the first branch 108a of the recirculation line and the reactor 1. This check valve 111 prevents, in the second operating condition of the recirculation valve 110, the passage of the heating fluid into the first branch 108a of the recirculation line, in the direction of the reactor 1.
As shown in detail in
The plant 100 may also comprise one or more collection containers 102, each of which located inferiorly and in communication with a respective heat exchange unit 98 for withdrawing dusts or solid debris which separate themselves from the exhaust gas in circulation in the hot fluid chamber 98′. A loading cell 103 may be associated to each collection container 102 for generating a signal representative of a weight of the collection container itself: as a function of this signal it is possible to determine an alarm condition indicative of a maximum filling of the collection container 102. The control unit 50 connected to the loading cell/s 103 is configured for:
The control unit 50 is then configured for determining an alarm condition, as a function of the measured values of weight of each collection container 102, which commands an emitter 97 for reproducing an alarm signal (for example optical and/or acoustic) addressed to a user, in charge of performing a manual cleaning procedure of the collection container 102 and of one or more heat exchange units 98. Alternatively, the control unit 50 may be configured for commanding an automatic cleaning procedure of the heat exchange unit 98 which involves commanding the activation of one or more cleaning nozzles 106 inside the hot fluid chamber 98′ of a respective heat exchange unit 98, for dispensing a cleaning fluid acting both in the hot fluid chamber 98′ itself and in the collection tank 102. It is noted that the cleaning procedure additionally involves commanding the movement of the recirculation valve 110 from the first to the second operating condition.
The plant may also comprise one or more pressure sensors 104 which operate inside a hot fluid chamber 98′ of a respective heat exchange unit 98, each of which configured for generating a pressure signal related to the pressure inside a respective hot fluid chamber 98′. It is noted that the presence of pressure sensors 104 facilitates the determination of possible clogging in the hot fluid chambers 98′ by means of the detection of the trend over time of the pressure in a predefined point of the heat exchange unit or pressure variation over the heat exchange unit itself.
The control unit 50 may be connected to each pressure sensor 104 and configured for:
Subsequently, the control unit 50 may be configured for determining an alarm condition if one or more measured values of pressure indicate the occurrence of clogging and subsequently, commanding the emitter 97 for the emission of an alarm signal or commanding the execution of the automatic cleaning procedure described above.
As for example shown in
The control unit 50 is then configured for determining an alarm condition as a function of the measured values of weight of the collection tank 95, for example if these measured values of weight are greater than a threshold value of weight. This alarm condition involves commanding the emitter 97 for the reproduction of an alarm signal, for example optical or acoustic, or for commanding an automatic maintenance procedure of the filter.
The plant may also comprise a bypass line 99 connected to a section of the exhaust gases evacuation line 73 downstream of the outlet 64 of the apparatus 60, for deviating a flow of the exhaust gas directly in the environment without passing through the heat exchange unit 98 and/or the filter 91. It is noted that if the exhaust gas leaving the apparatus 60 has a temperature greater than a threshold value of temperature, optionally comprised between 800° C. and 1200° C., it is preferable to disperse directly into the environment the exhaust gas and avoid unwanted overheating and malfunctions of the heat exchange unit 98. For this purpose, the plant 100 may also comprise a bypass valve 101 which operates on the bypass line 99 for selectively allowing the passage of the exhaust gas through the bypass line itself. The plant 100 may also comprise an auxiliary gas movement device 123, for example a fan, active on the bypass line 99 for ejecting the exhaust gas into the atmosphere. The detection of the temperature of the exhaust gas is made by means of a temperature sensor 90, active on the outlet 64 of the apparatus 60 (
If the control unit 50 detects that one or more of the measured values of temperature, obtained by means of the temperature sensor 90, are greater than the threshold value of temperature, then the control unit 50 is configured for commanding an opening condition of the bypass valve for allowing the channeling of the exhaust gas in the bypass line 99 and, consequently, preventing the passage thereof towards the heat exchange unit 98.
To complete the description of the plant 100, the structure and the functionality of the single reactor 1 and the single apparatus 60 will be described in detail below.
With reference to the accompanying figures which depict one illustrative embodiment of a reactor 1 for the treatment of organic material, suitable for preventing the formation and the transport of dusty particles mixed with synthetic gases produced by the reactor itself. As for example shown in
The reactor 1 may also have a connection channel 30, cylindrical tubular-shaped, which puts in communication the outlet 4 of the main channel 31 with an unloading conveyor 16 subsequently detailed, for the unload of material treated in the main channel 31. As for example shown in
The reactor 1 may also comprise a heater active on the main channel for heating the organic material present in the treatment chamber 2. In the following, reference is made in a non-limiting way, to a heater comprising a fluid heater 5 and an electric heater 6. However, it is possible to provide a single heater comprising exclusively a fluid heater or an electric heater or other types of heaters. As for example shown in
As previously mentioned (see
As previously mentioned, the heater may also comprise an electric heater 6 active on a second section 2b of the main channel 31 interposed between the first section 2a and the outlet 4 of the main channel 31. The second section 2b extends for a terminal section of the main channel 31 next to the outlet 4, having a length lower than the first section 2a. The organic material may be almost totally heated by the fluid heater 5, whereas it may be only marginally heated by the electric heater 6. The electric heater 6 may comprise one or more electrical resistances in contact with the outer surface of the main channel 31 for heating the organic material when connected to the power grid.
The reactor 1 may also comprise a temperature sensor 28, active in the treatment chamber 2 in proximity of a gas outlet opening 8 and connected to the control unit 50 which is responsible for controlling the temperature of the fluid heater 5 and the electric heater 6. The temperature sensor 28 is configured for generating one or more signals representative of a temperature inside the treatment chamber 2, used by the control unit 50 for determining one or more measured values of temperature to be compared with a threshold value of temperature comprised between 280° C. and 800° C., optionally comprised between 320° C. and 680° C. The control unit 50 may also be connected to both the fluid heater 5 and to the electric heater 6 for commanding the functioning thereof as a function of measured values of temperature. Optionally the control unit 50 may command the heaters 5 and 6 in a completely independent manner, implementing dedicated control strategies for each heater. A temperature control strategy may for example involve heating the treatment chamber 2 by means of the fluid heater 5, until a first threshold is reached, for example comprised between 250° C. and 450° C., followed by heating by means of the electric heater 6 until a second temperature threshold is reached, optionally comprised between 400° C. and 800° C. It is noted however that both control logics implementable by the control unit 50, use as temperature feedback signal the signals provided by the temperature sensor 28.
The reactor may also comprise a pressure sensor 29 active in the treatment chamber 2 and configured for allowing the control unit 50 to maintain a substantially constant level of pressure in the treatment chamber 2: the pressure in the treatment chamber is for example constantly maintained lower than the environmental pressure present in the environment outside the reactor. The control unit 50 is connected to the pressure sensor 29 and is configured for:
According to an aspect the control unit 50 verifies if one or more of the measured values of pressure indicate that the pressure inside the treatment chamber is lower than the environmental pressure by a quantity comprised in a reference range between 10 Pa and 250 Pa, optionally between 20 Pa and 100 Pa.
If one or more measured values of the relative pressure in the reactor 1 are external to the above specified reference range, the control unit 50 is configured for commanding the suction device 120 for adjusting consequently the ejection of the synthetic gas from the main channel 31.
As for example shown in
As previously mentioned, the reactor 1 may also comprise or be associated to a hopper 33 connected to the loading conveyor 15 and configured for storing the organic material to be treated in the treatment chamber 2. The hopper 33 may have a container having a truncated pyramid shape or an inverted cone shape, equipped with an unloading opening 34 on a lower end of the container, for discharging the organic material downstream in the direction of the loading conveyor 15. The hopper 33 may also comprise an unloading channel 35 which connects the unloading opening 34 of the hopper with the inlet mouth 32a of the loading channel 12a, defining a single fluid tight connection which prevents the dispersion of dusts in the environment. The reactor 1 may also comprise a conveyor or an auger, activated by an electric motor, active on the unloading channel 35 for controlling the movement of organic material towards the loading channel 12a.
As for example shown in
In an example, one or more helical rotors 19 are hollow rotors 20, i.e. have a cavity 22 defining a passage radially interposed between the shaft 18 of the main conveyor 17 and a perimeter edge 21 of the hollow rotor 20 which surrounds the shaft 18. It is noted that the cavity 22 of each hollow rotor 20 allows not only the passage of organic material under treatment, but also the passage of synthetic gases generated by heating of the organic material itself, thereby increasing the efficiency of the treatment. The presence of hollow rotors 20 prevents also a movement of synthetic gases through the material under treatment, thus avoiding the lifting of dusty particles which, when mixed with the synthetic gas, contribute to reduce the overall quality of the synthetic gas.
The hollow rotors 20 may be engaged to the shaft 18 by means of an adjacent solid rotor 24 or by means of one or more transversal spokes 23 which connect respective sections of the perimeter edge 21 to the shaft 18. In an example, each hollow rotor may have one or more spokes 23 angularly offset to each other by an angle comprised between 70° and 110°, even more optionally comprised between 80° and 100°, for conferring structural rigidity to the hollow rotors 20. The main conveyor 17 may also comprise one or more wings 25 radially emerging from the shaft 18 until at the inner surface of the main channel, configured for moving the material under treatment in contact with the inner surface itself of the main channel 31. The wings 25 allow to mix the organic material under treatment and, bringing it into contact with the inner surface of the channel, make the heat transmission with the main channel 31 more efficient. Referring again to
The ejection of the treated organic material in the treatment chamber 2 is made by an unloading conveyor 16 which operates in proximity of the outlet 4 of the main channel 31 (
As shown in
The reactor 1 comprises a gas branch manifold 7 suitable for supplying the synthetic gases generated in the main channel towards the burner 60. The specific structure of the gas branch manifold 7 and, subordinately, the positioning thereof with respect to the main channel 31, allow to convey the synthetic gases mixed with reduced quantities or total absence of dust particles. With reference to
Moving on now to describe one illustrative embodiment of the apparatus 60 for the combustion of synthetic gases, it comprises, as previously mentioned, a combustion chamber 62 for the combustion of synthetic gases, for example generated in the reactor 1. The combustion chamber 62 receives, by means of the connection channel 81, synthetic gases passing through the gas discharge orifice 10 of the reactor 1, as well as it has an outlet 64 destined to eject exhaust gases in the exhaust gases evacuation line 73.
As for example shown in
The apparatus also comprises a burner 75 for example carried by the first terminal wall 62′ or working inside the combustion chamber and responsible for realizing the combustion of the synthetic gases in the combustion chamber 62. In an example, the burner 75 may comprise a combustible access 77 in communication with the connection channel 81 for receiving the synthetic gas from the reactor 1, as well as a comburent access 76 suitable for receiving the comburent gas from the fluid supply circuit 65. The burner 75 may also comprise a mixing chamber 78 where the synthetic gases and the comburent gas are mixed and an activation device 72, for example an electric or spark plug ignition, triggers the combustion of the synthetic gas and with the comburent gas (alternatively the mixing of the two gases may take place directly in the combustion chamber without a different mixing chamber).
The burner 75 may also comprise an auxiliary access 88 in communication with the mixing chamber 78 for receiving a combustible gas and allowing an initial ignition of the apparatus as previously detailed.
As mentioned, the apparatus comprises a fluid supply circuit 65 destined to supply a comburent gas, optionally ambient air, to the burner and/or to the combustion chamber 62. The fluid supply circuit 65 (for example a preponderant part thereof) contacts the outer surface 62a of the combustion chamber 62, from an area close to the second terminal wall 62″ where it has a gas access 67 for receiving the comburent gas from an outer environment, until an area next to the first terminal wall 62′ where it has a gas outlet 68 in communication with the comburent access 76 of the burner 75. The fluid supply circuit 65 may comprise one or more channels 66 placed outside and in contact with the outer surface 62a of the combustion chamber 62 for channeling the comburent gas, optionally air, towards the combustion chamber 62 itself. It is noted that the temperature of the comburent gas entered in the combustion chamber 62, contributes to increase the efficiency of the combustion process of the synthetic gases and furthermore, avoids the generation of undesired condensation and/or the formation of solid particles or dusts in the combustion chamber 62 which may compromise the normal operativity thereof. The positioning of the channels 66 in contact with the outer surface 62a of the combustion chamber 62 allows the heat exchange with the channels 66 of the fluid supply circuit 65, causing the heating of the comburent gas. Additionally, the channels 66 in contact with the outer surface 62a of the combustion chamber 62, define a thermally insulating layer which avoids the need of realizing the combustion chamber 62 itself in ceramic materials or covering the chamber with insulating or refractory materials for allowing the combustion of the synthetic gas at temperatures comprised between 800° C. and 1000° C. As further consequence there is the possibility of making the combustion chamber 62 having a more essential structure, for example realizable exclusively in metallic materials, optionally stainless steel, thus leading to a reduction of the costs of realization of the entire apparatus.
It is also noted that the channels 66 of the fluid supply circuit 65 may contact a preponderant part, optionally at least the 70%, of the outer surface 62a of the combustion chamber 62 for increasing the heat exchange surface with the combustion chamber itself. For this purpose, the channels 66 may be arranged transversely to the development direction X of the combustion chamber 62 and formed by successive sections of a single continuous channel extending along a helical trajectory (see
The fluid supply circuit 65 may also comprise a connection duct 74 which connects a terminal section of the supply circuit 65 next to the first terminal wall 62′, with the burner 75 or with the combustion chamber, for supplying the comburent gas in inlet to the combustion chamber 62.
The apparatus may also comprise a case 70 radially outside the sleeve 68 which defines a further gap between the sleeve 68 and an inner surface 70a of the case itself 70. This gap defined by the case 70 may optionally delimit an air bag having insulating or dissipating functions for the heat emitted by the combustion chamber 62.
Concerning materials, the sleeve 68, the walls 69 and the case 70 are made in metallic material, optionally stainless steel, devoid of coatings made of refractory or thermally insulating materials.
One or more embodiments of the present invention include a process for the treatment of organic material by means of the plant 100 according to the above description and according to the accompanying aspects and/or the accompanying claims.
In one or more embodiments, the process involves a thermochemical treatment of the organic material, optionally in granular or dust form, made by means of the reactor 1, for obtaining a combustible gas, subsequently indicated as synthetic gas, exploited by the apparatus 60 for generating heat and self-heating the reactor itself. The process initially involves supplying organic material in the treatment chamber 2 of the reactor 1, for example performing a step of unloading the organic material on the loading conveyor 15, followed by a step of moving the organic material itself towards the inlet of the treatment chamber 2 of the reactor 1. The process may comprise a step of controlling the speed of movement of the loading conveyor 15 for avoiding the lifting of dusts which could lead to malfunction to the reactor 1.
It is then expected a following step of moving, by means of the main conveyor 17, the organic material from the inlet 3 to the outlet 4 of the main channel 31. Simultaneously to moving the material, the process may also comprise a step of heating, performed by means of the fluid heater 5 and the electric heater 6, at a temperature comprised between 250° C. and 800° C., optionally comprised between 280° C. and 600° C.
The process also comprises a step of withdrawing the treated organic material from the treatment chamber 2 for being stored. For example, the step of withdrawing involves moving, by means of the unloading conveyor 16, the organic material outside the treatment chamber 2 of the reactor 1, controlling the movement speed of the unloading conveyor 16 itself, for preventing or limiting the lifting of dusts which could mix with the synthetic gas. The process may then comprise a step of withdrawing, by means of the gas branch manifold 7, the synthetic gas obtained by heating the treatment chamber 2. The step of withdrawing may in turn involve sucking the synthetic gas at a speed comprised between 0.05 m/s and 0.8 m/s, optionally comprised between 0.1 m/s and 0.4 m/s and/or a step of adjusting a pressure in the treatment chamber 2 such that this pressure is lower than the pressure of the environment outside the plant, for example such that the absolute inner pressure (assuming to use the plant described herein and claimed on the sea level) is comprised between 101320 Pa and 101000 Pa, optionally comprised between 101305 Pa and 101200 Pa. More generally, the pressure inside the treatment chamber 2 is maintained from 5 to 325 Pa, optionally 20 to 125 Pa, below the environmental pressure.
A step of transporting, by means of the connection channel 81, synthetic gas, from the reactor 1 towards the burner 75 of the apparatus 60 may follow the withdrawal of the synthetic gas from the reactor 1. The process may then comprise a step of channeling, by means of the comburent gas supply line 85, a comburent gas, optionally air, in the fluid supply circuit 65 of the apparatus 60, which, once heated, will be supplied to the combustion chamber 62 and therefore to the burner 75. The progressive advancement of the comburent gas in the fluid supply circuit 65 towards the burner/combustion chamber, involves a gradual heating of the comburent gas itself until a temperature greater than 250° C., optionally comprised between 450° C. and 650° C., is reached before being entered in the combustion chamber or supplied to the burner 75. In an example, the process involves channeling the comburent gas according to a helical or annular trajectory along the fluid supply circuit 65, so as to maximize the heat exchange between the combustion chamber 62 and the comburent gas. After supplying of the synthetic gas and of the comburent gas in the mixing chamber 78 of the burner 75 or directly in the combustion chamber, the process may involves triggering the combustion between these gases by means of the activation device 72.
The process may then comprise a step of withdrawing an exhaust gas in the combustion chamber 62 of the apparatus 60 and channeling it in the exhaust gases evacuation line 73 in direction of the heat exchange unit 98 or channeling it in the bypass line 99 if having at a temperature greater than the threshold value of temperature, optionally comprised between 900° C. and 1200° C. In order to perform heating of the fluid destined to the fluid heater 5 of the reactor 1, the process may involve conveying, in the hot fluid chamber 98′ of the heat exchange unit 98, the exhaust gas leaving the apparatus 60. The process may simultaneously involve supplying the fluid to be heated destined to the fluid heater 5, in one or more cold fluid channels 98″ of the heat exchange unit 98. The heat exchange between hot fluid chamber 98′ and each cold fluid channel 98″, involves heating the heating fluid which, by means of the second branch 108b of the recirculation line 108, is again entered in the fluid supply line of the fluid heater 5 of the reactor 1. The exhaust gas, after having exchanged heat with the heating fluid of the fluid heater 5 of the reactor 1, is ejected into an environment outside of the plant.
The process may also comprise for a step of discharging dusts present in a collection container 102 associated to a respective heat exchange unit 98, performed on the basis of the detection of the weight of the collection container itself by means of the loading cell 103. The process may then comprise a cleaning procedure of each heat exchange unit 98 for removing any clogging of dusts or debris such as to compromise the normal functioning of the heat exchange unit itself. In an example, the cleaning procedure may involve the activation of cleaning nozzles 106 for the emission of water jets in the hot fluid chamber 98′ of the heat exchange unit 98 and in the collection container 102.
The process may also comprise a step of filtering the exhaust gas leaving the apparatus 60 and upstream of the heat exchange unit 98, for withdrawing dusts or solid debris mixed in the exhaust gas, which will be then deposited in the collection tank 95. If clogging of the filter 91 is detected, the process may comprise a maintenance procedure which involves discharging dusts from the collection tank 95 if one or more weight values of the collection tank 95 itself are greater than a threshold value of weight.
Any references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific illustrative embodiments have been described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims.
The present application claims the benefit under 35 U.S.C. § 119 (e) of U.S. Provisional Patent Application 63/524,063 filed Jun. 29, 2023, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63524063 | Jun 2023 | US |
