Patent ID: 7947248
Filing Date: 2011-05-24
Classification: B29B,B65B,C01P,C09C,C10B,C10G,C22B,Y02P,Y10T

Abstract:
1. A pyrolysis process, comprising the steps of; depositing a quantity of waste into a porous container, the porous container adapted to allow at least one convective stream of substantially anaerobic gas to flow therethrough; inserting the porous container into a pyrolysis thermal processor; sealing the thermal processor; circulating the at least one convective stream of gas in the pyrolysis thermal processor; heating the waste with the convective stream of gas according to a predetermined time-temperature profile to pyrolyze the waste and form a carbonaceous char, wherein the time-temperature profile includes ramping, a temperature of the thermal processor from an initial temperature to a first temperature over a period of about 40 to 60 minutes, wherein the initial temperature is one of ambient temperature and a temperature to which the thermal processor was cooled following a previous pyrolysis cycle, wherein the first temperature is from about 550° F. to about 650° F., holding the temperature of the thermal processor at the first temperature for a first soak period of about 5 to about 15 minutes to evolve quantities of product oils and product gases from the waste, ramping the temperature of the thermal processor to a second temperature over a period of about 90 to 120 minutes, wherein the second temperature is from about 770° F. to about 870° F., holding the temperature of the thermal processor at the second temperature for a second soak period of about 30 to about 60 minutes to pyrolyze the waste and form the carbonaceous char, the second temperature adapted to minimize a graphitization of the carbonaceous char, and cooling the thermal processor to a third temperature by circulating the at least one convective stream through the thermal processor and the cooler, wherein the third temperature is between about 120° F. and about 160° F., wherein the pyrolysis process is performed under substantially atmospheric pressure; cooling the carbonaceous char by circulating the at least one convective stream of gas through a cooler; and collecting at least one of a carbon black product, an oil product, a gaseous hydrocarbon product, and a recyclable metal product.