Pyrolysis system with optimized reaction sequencing

Abstract

Systems and methods for processing pyrolyzable materials in order to recover one or more usable end products are provided. Pyrolysis methods and systems according to various aspects of the present invention are able to thermally decompose carbon-containing materials, including, for example, tires and other rubber-containing materials, in order recover hydrocarbon-containing products including synthesis gas, pyrolysis oil, and carbon black. Systems and methods according to aspects of the present invention may be successful on a commercial scale, and may be suitable for processing a variety of feedstock including, but not limited to, used tires and other types of industrial, agricultural, and consumer waste materials.

What is claimed is: 
     
         1 . A pyrolysis facility for pyrolyzing a rubber-containing material, said facility comprising:
 a filling zone configured to at least partially fill at least one crucible with a first quantity of said rubber-containing material;   a pyrolysis zone comprising at least one pyrolysis furnace defining at least one individual heating zone for receiving and heating said crucible under conditions sufficient to pyrolyze at least a portion of said first quantity of rubber-containing material to thereby provide pyrolysis vapors and pyrolysis solids, wherein said pyrolysis solids comprise carbon black and carbon black fines;   a solids processing zone configured for recovering at least one product from said pyrolysis solids, wherein said solids processing zone comprises a solids transfer zone;   a solids cooling zone configured to cool pyrolysis solids;   at least one solids separation zone configured to separate pyrolysis solids, which the separation includes separating carbon black from the pyrolysis solids;   at least one loading zone configured to load at least a portion of the separated carbon black into one or more storage containers; and   a fines capturing system for capturing at least a portion of said carbon black fines emitted into the surrounding environment within at least one of said solids transfer zone, said solids cooling zone, said solids separation zone, said loading zone, wherein said loading zone is configured to receive carbon black fines captured in at least a portion of said fines capturing system.   
     
     
         2 . The system of  claim 1 , wherein said fines capturing system comprises at least a first dust collection zone and at least a second dust collection zone, wherein said first dust collection zone is configured to capture at least a portion of said carbon black fines emitted within said solids transfer zone and said second dust collection zone is configured to capture at least a portion of said carbon black fines emitted within said loading zone. 
     
     
         3 . The system of  claim 1 , wherein said fines capturing system further comprises a third dust collection zone and a fourth dust collection zone, wherein said third dust collection zone is configured to capture at least a portion of said carbon black fines emitted within said solids cooling zone and wherein said fourth dust collection zone is configured to capture at least a portion of said carbon black fines emitted within said solids separation zone. 
     
     
         4 . The system of  claim 1 , wherein at least one of said first, said second, said third, and said fourth dust collection zones are operated independently from the other or others of said first, said second, said third, and said fourth dust collection zones. 
     
     
         5 . The system of  claim 1 , wherein said fines capturing system includes at least one filter device configured to separate the captured fines collected from said at least one of said solids transfer zone, said solids cooling zone, said solids separation zone, and said loading zone, and wherein said filter device is in communication with said loading zone. 
     
     
         6 . The system of  claim 1 , wherein said solids processing zone further comprises a grinding zone for reducing the average particle size of the carbon black from said solids separation zone, wherein said fines capturing system further comprises a dust collection zone for capturing at least a portion of the carbon black fines emitted within said grinding zone. 
     
     
         7 . The system of  claim 1 , wherein said filling zone is configured to fill at least a first crucible and a second crucible with respective first and second quantities of said rubber-containing material, wherein said pyrolysis zone comprises at least two pyrolysis furnaces each defining at least one individual heating zone, wherein each individual heating zone is configured to receive and heat said first and said second crucibles under conditions sufficient to pyrolyze at least a portion of said first and second quantities of said rubber-containing material, wherein said individual heating zones are configured such that at least a portion of said heating of said first and said second crucibles are carried out simultaneously. 
     
     
         8 . The system of  claim 1 , the fines capturing system configured to pass a stream of gas through at least a portion of the surrounding environment to entrain at least a portion of the carbon black fines emitted into the surrounding environment. 
     
     
         9 . The system of  claim 9 , the fines capturing system further configured to pass the stream of gas including entrained carbon black fines through at least one filter device to provide a filtered gas stream and remove the back carbon fines from the stream of gas. 
     
     
         10 . The system of  claim 1 , wherein the pyrolysis solids further comprise metallic elements, wherein the separation zone is further configured to remove the metallic elements from the pyrolysis solids. 
     
     
         11 . The system of  claim 10 , the separation zone further comprising a magnetic element configured to remove the metallic elements from the pyrolysis solids. 
     
     
         12 . The system of  claim 1 , wherein the solids transfer zone and the loading zone are at least partially enclosed. 
     
     
         13 . The system of  claim 1 , wherein the rubber-containing material comprises shredded and/or whole tires.