Pyrolysis System

Abstract

A process for the pyrolysis of at least one material includes: introducing the material into a pressurized rotary retort system, heating the material in the pressurized rotary retort system within a desired temperature range and within a desired pressure range for a desired period of time; and, advancing the heated and pressurized material from a first end to a second end of the pressurized rotary retort by rotating the pressurized retort about its longitudinal axis; where at least a quantity of the material is converted into one or more end products. Also the system generally includes: a pressurized rotary retort system configured for producing at least one gaseous product from pyrolysis of material, and having a pressurized furnace vessel and a retort positioned within the pressurized furnace vessel; and; a solids reactor system operatively connected to the rotary retort for receiving material from the pressurized rotary retort system.

1 . A process for the pyrolysis of at least one material, comprising:
 i) introducing the material into a pressurized rotary retort system;   ii) heating the material in the pressurized rotary retort system within a desired temperature range and within a desired pressure range for a desired period of time; and   iii) advancing the heated and pressurized material from a first end to a second end of the pressurized rotary retort by rotating the pressurized retort about its longitudinal axis;   wherein at least a quantity of the material is converted into one or more end products.   
     
     
         2 . The process of  claim 1 , wherein the pressurized rotary retort system is configured for producing at least one gaseous product from pyrolysis of the material; and further including a gas reactor for receiving the gaseous product from the pressurized rotary retort system. 
     
     
         3 . The process of  claim 1 , wherein the material is supplied under elevated pressures and at elevated temperatures. 
     
     
         4 . The process of  claim 1 , wherein the pressure within the rotary retort system provides forces for driving the gaseous products from the rotary retort system. 
     
     
         5 . The process of  claim 1 , further including subjecting by-products of the pyrolysis process to a further pyrolization process. 
     
     
         6 . The process of  claim 1 , further including a solids system reactor for receiving a supply of un-pyrolyzed material and/or by-products from the rotary retort system. 
     
     
         7 . The process of  claim 1 , further including a solids reactor system operatively connected to the rotary retort for receiving un-pyrolyzed by-product and for generating at least one additional gaseous product. 
     
     
         8 . The process of  claim 1 , wherein a supply of the gaseous product is used to supply heat to the rotary retort system. 
     
     
         9 . The process of  claim 1 , including advancing the material through the pressurized rotary retort system using a plurality of flights positioned within the rotary retort system. 
     
     
         10 . The process of  claim 1 , wherein the rotary retort is rotated about a longitudinally extending axis at more than one speed. 
     
     
         11 . A pyrolysis system comprising:
 i) a pressurized rotary retort system configured for producing at least one gaseous product from pyrolysis of material; and having a pressurized furnace vessel and a retort positioned within the pressurized furnace vessel; and   ii) a solids reactor system operatively connected to the rotary retort for receiving and pyrolyzing un-pyrolyzed material from the pressurized rotary retort system.   
     
     
         12 . The system of  claim 11 , further including a gas reactor for receiving the gaseous product from the pressurized rotary retort system. 
     
     
         13 . The system of  claim 12 , wherein the material is supplied under elevated pressures and at elevated temperatures. 
     
     
         14 . The system of  claim 12 , wherein the pressure within the rotary retort system provides forces for driving the gaseous products from the rotary retort system. 
     
     
         15 . The system of  claim 12 , further including a heat exchanger system configured for capturing heat generated by pyrolysis of material and/or heat generated by production of gaseous products. 
     
     
         16 . The system of  claim 12 , wherein a supply of the gaseous product is used to supply heat to the rotary retort system. 
     
     
         17 . The system of  claim 12 , including advancing the material through the pressurized rotary retort system using a plurality of separately spaced flights positioned within the pressurized rotary retort system. 
     
     
         18 . The system of  claim 12 , wherein the pressurized rotary retort is rotated about a longitudinally extending axis at more than one speed. 
     
     
         19 . A process for the pyrolysis of at least one material, comprising:
 i) introducing the material into a pressurized rotary retort system;   ii) heating the material in the pressurized rotary retort system within a desired temperature range and within a desired pressure range for a desired period of time; and   iii) advancing the heated and pressurized material from a first end to a second end of the pressurized rotary retort by rotating the pressurized retort about its longitudinal axis;   wherein the pressurized rotary retort system is configured for producing at least one gaseous product from pyrolysis of the material; and further including a gas reactor for receiving the gaseous product from the pressurized rotary retort system; and   wherein at least a quantity of the material is converted into one or more end products.   
     
     
         20 . The process of  claim 19 , wherein the material is supplied under elevated pressures and at elevated temperatures. 
     
     
         21 . The process of  claim 19 , wherein the pressure within the rotary retort system provides forces for driving the gaseous products from the rotary retort system. 
     
     
         22 . The process of  claim 19 , further including subjecting by-products of the pyrolysis process to a further pyrolization process. 
     
     
         23 . The process of  claim 19 , further including a solids system reactor for receiving a supply of un-pyrolyzed material and/or by-products from the rotary retort system. 
     
     
         24 . The process of  claim 19 , further including a solids reactor system operatively connected to the rotary retort for receiving un-pyrolyzed by-product and for generating at least one additional gaseous product. 
     
     
         25 . The process of  claim 19 , wherein a supply of the gaseous product is used to supply heat to the rotary retort system. 
     
     
         26 . The process of  claim 19 , including advancing the material through the pressurized rotary retort system using a plurality of flights positioned within the rotary retort system. 
     
     
         27 . The process of  claim 19 , wherein the rotary retort is rotated about a longitudinally extending axis at more than one speed.