Methods and apparatus for pyrolyzing material

Abstract

Methods and systems for substantially continuously treating comminuted material containing carbon and hydrogen, for example, used tires, are provided. The methods include the steps of introducing the tire material to an elongated chamber, transferring the tire material through the elongated chamber, heating the tire material to a temperature sufficient to pyrolyze the material to produce a gaseous stream; discharging the gaseous stream from the chamber, and cooling at least some of the gaseous stream to liquefy components of the stream. The transfer may be effected by a flexible, center-less screw conveyor to minimize material buildup in the vessel. The cooling of the gaseous stream may be practiced by reverse condensation. The apparatus may further comprise an agitator positioned in a conduit operatively connected to an outlet from the chamber, the agitator adapted to displace any condensate formed in the conduit.

1 . An apparatus for pyrolyzing comminuted tire materials, the apparatus comprising:
 an elongated pyrolysis chamber having an inner surface and one or more inlets for introducing the comminuted tire materials;   a conveyor for continuously conveying the comminuted tire materials and pyrolysis products thereof through the pyrolysis chamber while substantially simultaneously removing build-up of the tire material and the pyrolysis products from the inner surface of the pyrolysis chamber;   means for maintaining a temperature within the pyrolysis chamber at a level sufficiently high to pryolyze at least some of the feed material to gaseous hydrocarbons; and   an outlet from the pyrolysis chamber for discharging the gaseous hydrocarbons;   wherein the apparatus further comprises an agitator positioned in a conduit operatively connected to the outlet for discharging gaseous hydrocarbons, the agitator adapted to displace any condensate formed in the conduit.   
     
     
         2 . The apparatus as recited in  claim 1 , wherein the agitator is one of a screw, an auger, a plunger, and a scraper. 
     
     
         3 . The apparatus as recited in  claim 2 , wherein the conduit operatively connected to the outlet comprises a radially directed conduit substantially perpendicular to a direction of elongation of the chamber. 
     
     
         4 . The apparatus as recited in  claim 2 , wherein the conduit operatively connected to the outlet comprises an obliquely directed conduit substantially non-perpendicular to a direction of elongation of the chamber 
     
     
         5 . The apparatus as recited in  claim 1 , wherein the conveyor comprises a helical, center-less screw mounted for rotation at a first end within the pyrolysis chamber and having an unsupported second end, the helical center-less screw comprising a helical bar having a rectangular cross section providing a surface adapted to displace build-up of tire material and pyrolysis products from the inner surface of the pyrolysis chamber. 
     
     
         6 . The apparatus as recited in  claim 5 , wherein the helical, center-less screw conveyor further comprises an initial portion comprising means for reducing a size of the feed material. 
     
     
         7 . The apparatus as recited in  claim 1 , wherein the apparatus further comprises a heat exchanger for cooling the gaseous hydrocarbons. 
     
     
         8 . The apparatus as recited in  claim 1 , wherein the apparatus further comprises means for using at least some of the gaseous hydrocarbons produced for the means for maintaining the temperature. 
     
     
         9 . The apparatus as recited in  claim 1 , wherein the apparatus further comprises a plurality of valves associated with the one or more inlets for introducing the comminuted tire materials for minimizing the introduction of air to the chamber. 
     
     
         10 . The apparatus as recited in  claim 1 , wherein the apparatus further comprises a first heat exchanger adapted to cool the gaseous hydrocarbons and condense a first liquid hydrocarbon from the gaseous hydrocarbons and a first cooler stream of gaseous hydrocarbons; and
 a second heat exchanger adapted to cool the first cooler stream of gaseous hydrocarbons to condense a second liquid hydrocarbon, different from the first liquid hydrocarbon, from the first cooler stream of gaseous hydrocarbons and a second cooler stream of gaseous hydrocarbons.