Catalyst for distributed batch microwave pyrolysis, system and process thereof

Abstract

The present document describes a catalyst to initiate microwave pyrolysis of waste, a process for the microwave pyrolysis of waste using the catalyst, as well as a microwave pyrolysis system.

1 . A pyrolysis system which comprises:
 a) a reactor vessel having
 a waste inlet; 
 a fluid inlet for injecting a fluid into said reactor vessel; and 
 an internal coating to prevent accumulation of microwave reactive residues in said reactor vessel; and 
   b) a microwave source emitting microwaves within said reactor vessel.   
     
     
         2 . The pyrolysis system according to  claim 1 , further comprising an anaerobic means for purging said reactor vessel of air. 
     
     
         3 . The pyrolysis system according to  claim 1 , further comprising a temperature probe for measuring a core temperature within said reactor vessel. 
     
     
         4 . The pyrolysis system according to  claim 1 , further comprising a microwave diffuser diffusing said microwave within said reactor vessel. 
     
     
         5 . The pyrolysis system according to any one of  claims 1 - 4 , wherein said internal coating is made from a refractory material. 
     
     
         6 . The pyrolysis system according to  claim 5 , wherein said refractory material is chosen from a ceramic and a porcelain. 
     
     
         7 . The pyrolysis system according to  claim 2 , wherein said anaerobic means is at least one of an inert gas or a liquid. 
     
     
         8 . The pyrolysis system according to  claim 7 , wherein said liquid is liquid water. 
     
     
         9 . The pyrolysis system according to  claim 7 , wherein said inert gas is at least one of argon, nitrogen, and steam. 
     
     
         10 . The pyrolysis system according to any one of  claims 7 - 9 , wherein said anaerobic means is provided to said pyrolysis system through said fluid inlet in fluid communication with said reactor vessel. 
     
     
         11 . The pyrolysis system according to any one of  claims 1 - 10 , wherein said fluid is chosen from an acidic solution, said anaerobic means or combinations thereof. 
     
     
         12 . The pyrolysis system according to  claim 1 , wherein said anaerobic means is a source of a vacuum. 
     
     
         13 . The pyrolysis system according to  claim 12 , wherein said source of vacuum is applied prior to operation of the source of microwave. 
     
     
         14 . The pyrolysis system according to any one of  claims 1  to  13 , wherein said temperature probe comprises a sealed channel with very low microwave interaction. 
     
     
         15 . The pyrolysis system according to any one of  claims 1  to  14 , wherein said microwave source is a magnetron tube. 
     
     
         16 . The pyrolysis system according to  claim 15 , wherein said magnetron tube is coupled to a microwave diffuser diffusing said microwave inside the reactor vessel. 
     
     
         17 . The pyrolysis system according to any one of  claims 1  to  16 , further comprising a pressure probe. 
     
     
         18 . The pyrolysis system according to any one of  claims 1 - 17 , further comprising a pressure safety valve. 
     
     
         19 . The pyrolysis system according to any one of  claims 1 - 18 , further comprising a shredder, to break and mix the waste material within the reactor vessel. 
     
     
         20 . The pyrolysis system according to any one of  claims 1 - 19 , further comprising a separation grid for separation of a recyclable residue from a carbonaceous residue after a pyrolysis reaction. 
     
     
         21 . The pyrolysis system according to  claim 20 , wherein said separation grid is a vibrating grid. 
     
     
         22 . The pyrolysis system according to any one of  claims 1 - 21 , further comprising a collection element for collecting the gas and oil produced therein. 
     
     
         23 . The pyrolysis system according to  claim 22 , wherein said collection element is at least one valve. 
     
     
         24 . The pyrolysis system according to any one of  claims 22 - 23 , wherein said collection element is coupled to a filter. 
     
     
         25 . The pyrolysis system according to  claim 24 , wherein said filter is at least one of removable, cleanable and disposable. 
     
     
         26 . The pyrolysis system according to  claim 24 , wherein said filter is chosen from a cyclone filter, a centrifuge, an electrostatic precipitator, or combinations thereof. 
     
     
         27 . The pyrolysis system according to any one of  claims 24  to  26 , further comprising a scrubber coupled to said filter. 
     
     
         28 . The pyrolysis system according to any one of  claims 22 - 27 , wherein said collection element comprises a condenser element. 
     
     
         29 . The pyrolysis system according to  claim 28 , wherein said condenser element further comprises at least one pressure reducing valve. 
     
     
         30 . The pyrolysis system according to  claim 28 , wherein said condenser element further comprises at least one pressure probe. 
     
     
         31 . The pyrolysis system according to  claim 28 , wherein said condenser element further comprises at least one cooling system. 
     
     
         32 . The pyrolysis system according to  claim 28 , wherein said condenser element comprises at least one condenser. 
     
     
         33 . The pyrolysis system according to any one of  claims 22 - 32 , wherein said collection element further comprises at least one receiving vessel. 
     
     
         34 . The pyrolysis system according to  claim 33 , wherein said receiving vessel is serially coupled to a gas receiving vessel. 
     
     
         35 . The pyrolysis system according to  claim 34 , further comprising a compressor connected to a serial coupling between said receiving vessel and said gas receiving vessel. 
     
     
         36 . The pyrolysis system according to  claim 33 , wherein said at least one receiving vessel is a combined oil and gas receiving vessel. 
     
     
         37 . The pyrolysis system according to any one of  claims 22  to  36 , further comprising a catalyst bed arrangement for locally upgrading of said oil. 
     
     
         38 . The pyrolysis system of  claim 37 , wherein said catalyst bed is chosen from Nickel-Phosphate (Ni 2 P), Titanium oxides (TiO 2 , rutile, anatase), Aluminium oxides (Al 2 O 3 ), Iron oxides (Hematite, Fe 2 O 3 , Goethite FeO(OH), Silicium oxides (SiO 2 ), Ru—TiO 2 , calcium aluminum silicate (Ca a Al b Si c O d ), red mud and combinations thereof. 
     
     
         39 . The pyrolysis system of  claim 37 , wherein said catalyst bed comprises an oxide mixture comprising from about 30 to 40% Fe 2 O 3 , from about 15 to 25% Al 2 O 3 , from about 10 to 20% SiO 2 , and from about 3-8% TiO 2 . 
     
     
         40 . The pyrolysis system of any one of  claims 37  to  39 , wherein said catalyst bed further comprises a support of particles of alumina, silica, zirconium oxide (ZrO 2 ), and/or titanium oxide (TiO 2 ) having a pore size of about 20 to 60 microns. 
     
     
         41 . The pyrolysis system of any one of  claims 37  to  40 , wherein said catalyst bed is monolithic 
     
     
         42 . The pyrolysis system of any one of  claims 22  to  41 , further comprising a molecular sieve located after said catalyst for purification of said gas. 
     
     
         43 . The pyrolysis system of  claim 42 , wherein said molecular sieve is from about 3 Å to about 4 Å. 
     
     
         44 . A catalyst to initiate microwave pyrolysis of waste, which comprises a carbon-based compound to absorb microwaves, transfer heat to microwave-transparent waste and initiate a pyrolysis reaction. 
     
     
         45 . The catalyst according to  claim 44 , wherein said carbon based compound comprises from about 80% to about 90% carbon by weight. 
     
     
         46 . The catalyst according to any one of  claims 44 - 45 , wherein said carbon based compound comprises graphite. 
     
     
         47 . The catalyst according to any one of  claims 44 - 46 , wherein said carbon based compound is graphite. 
     
     
         48 . A pyrolysis process which comprises the step of:
 a) initiating pyrolysis of a waste in a media using the catalyst of  claim 44  and a microwave for a time sufficient to allow generation of heat through absorption of microwaves by the catalyst and the media.   
     
     
         49 . A pyrolysis process which comprises the step of:
 a) initiating pyrolysis of a waste in a media using a carbonated catalyst and a pyrolysis system according to any one of  claims 1 - 43  for a time sufficient to allow generation of heat through absorption of microwaves by the catalyst and the media.   
     
     
         50 . The pyrolysis process according to any one of  claims 48 - 49 , wherein said waste undergoes thermal depolymerization to form a microwave absorbent. 
     
     
         51 . The pyrolysis process according to  claim 50 , wherein said microwave absorbent allows a further generation of heat through absorption of microwaves and a thermal depolymerization of an unreacted waste. 
     
     
         52 . The pyrolysis process according to any one of  claims 48 - 49 , wherein said pyrolysis process is for distributed pyrolysis of waste. 
     
     
         53 . The pyrolysis process according to any one of  claims 48 - 49 , wherein said pyrolysis process is an at source process. 
     
     
         54 . The pyrolysis process according to any one of  claims 48 - 49 , wherein said pyrolysis process is a small scale to a medium scale process. 
     
     
         55 . The pyrolysis process according to  claim 54 , wherein said small scale to a medium scale process is from about 1 kg to about 40 kg of waste. 
     
     
         56 . The process of any one of  claims 48 - 55 , wherein said process is batch operated. 
     
     
         57 . The process of any one of  claims 48 - 56 , wherein no oxygen is added to said process. 
     
     
         58 . The process according to any one of  claims 48 - 57 , wherein said process is a steam-purged process. 
     
     
         59 . The process according to  claim 58 , wherein said steam purge is performed at a temperature of about 20° C. to about 100° C. 
     
     
         60 . The process according to  claim 58 , wherein said steam purge is performed for about 5 to about 120 min. 
     
     
         61 . The process according to  claim 58 , wherein during said steam purge is performed, a temperature of said waste is about 150° C. or less. 
     
     
         62 . The process according to  claim 58 , further comprising the addition of water to said waste prior to said steam purge. 
     
     
         63 . The process according to  claim 58 , further comprising the addition of an acid to said waste prior to said steam purge. 
     
     
         64 . The process according to  claim 58 , wherein said waste is shredded prior to said steam purge. 
     
     
         65 . The process according to any one of  claims 48 - 63 , wherein said process comprises air in a stoichiometric balance with said waste. 
     
     
         66 . The process of any one of  claims 48 - 65 , wherein said microwave has frequency from about 915 MHz to about 2450 MHz. 
     
     
         67 . The process of any one of  claims 48 - 66 , wherein said process has a reaction temperature from about 300° C. to about 400° C. 
     
     
         68 . A gas produced by the pyrolysis process according to any one of  claims 48  to  67 , having an energy content of about 8 megajoules/m 3  to about 15 megajoules/m 3 . 
     
     
         69 . A condensable hydrocarbon oil produced by the pyrolysis process according to any one of  claims 48  to  67 , having an energy content of about 15 megajoules/kg to about 22 megajoules/kg. 
     
     
         70 . A carbonaceous by-product produced by the pyrolysis process according to any one of  claims 48  to  67 , having a carbon content of at least about 80% by weight. 
     
     
         71 . The carbonaceous by-product according to  claim 70 , wherein said by-product may be used as a catalyst in a pyrolysis reaction.