Technology and technological solutions for deep processing of plastic waste of household origin to obtain commercial products
The developed technology of deep processing of household waste, in the form of plastic selected for further processing, is based on modern, patented efficient processes of autothermal vortex gasification and fast pyrolysis, which are implemented in two reactors: gasification and pyrolysis.
The essence of the proposed technology lies in the use of an innovative solution for waste processing without the incineration, and using thermochemical duplex destruction with the destruction of molecular bonds of plastic waste and the further formation of new material bodies (substances) in the form of solid (pyrochar), liquid (heating oil, synthetic oil) and gaseous (combustible gas) energy carriers, as well as inert material in the form of metal oxides and mineral salts (contained in the feedstock).
Thermal decomposition of waste is carried out in a continuous and fully automated process. This process is carried out in two reactors functionally and structurally combined into a single module, which received the name – duplex destruction module, which is supplemented with auxiliary equipment and is a multi-functional, block-modular complex for the complete decomposition of organic waste into energy products in the form of gas, pyrolytic coal, synthetic oil (heating oil) and ash.
The main functional element of the complex is a duplex destruction module, which consists of an auto-thermal vortex gas generator, where plastic waste supplied to the gas generator is destroyed to produce hot generator gas and ash and a pyrolysis reactor, where this waste and the resulting hot generator gas are also fed and where, under the influence of its thermal and chemical energy, the destruction of waste occurs in a reducing gas environment with the formation of carbon and vapor gases, which are further separated in a separating apparatus into a liquid fraction (heating oil, synthetic oil) and combustible gas.
The technology effectively implements the process of deep waste processing in the sequence of the following processing operations.
Prepared (dried and crushed) plastic waste from the storage hopper is continuously conveyed to both reactors via a conveyor, in the proportion: 1 unit of volume to the reactor of the vortex gas generator and 4 units of volume to the reactor of fast pyrolysis. At the same time, hot air is dosed into the gas generator to ensure a controlled vortex gasification process, which ensures the separation of raw materials into generator gas and ash residue. The ash produced in the gas generator is mechanically withdrawn into the storage, and the generator gas with a temperature of 1202-1652 ° F enters the fast pyrolysis reactor, where at a temperature of 842-1112 ° F the pyrolysis reaction takes place to obtain energy products in a liquid solid and vapor-gas state. Separation of vapor gases is carried out into liquid fraction and non-condensable gas in a separator-cooler. Thermal and electrical energy from non-condensable gas can be obtained through a steam power unit, including: a high-temperature furnace, a boiler, a steam turbine, or, after cleaning and cooling, through gas-piston power plants.
Liquid (heating oil) synthesis oil can be used in furnaces, can be processed as a petrochemical product in a wide range of commercial applications.
Solid fuel (carbon) can be used as fuel in furnaces, boilers, or after activation, as a sorbent, as a reducing agent, or in briquetted form, as a household smokeless fuel.
In the case of targeted production of petrochemical products from plastic, carbon can be returned for reuse in a mixture with the initial portion of the feedstock to increase the volume of condensable and non-condensable output product of the processing complex.
The basic set of a technological complex for the processing of mixed plastic waste includes: a waste preparation section (drying, grinding and homogenization, removal of metal objects and other non-combustible materials), a duplex destruction module (production of carbon, pyrolysis liquid, pyrolysis gas), a purification and separation unit steam gases for a condensable fraction (synthetic oil) and a non-condensable fraction (power gas), a section for generating electricity and heat (gas piston power plant with a heat exchanger), automatic process control system.
