Cyclonic plasma pyrolysis/vitrification system

The present invention relates to a cyclonic plasma pyrolysis/vitrification system pyrolyzing and vitrifying waste materials into exhaust gas and slag using a plasma torch. The plasma torch circulates the exhaust gas in a main reactor with a maximum circulating power by strong plasma jet, and makes flyashes contained in the circulating exhaust gas to be melted after being adsorbed at the inner walls or in the melted materials of waste at the bottom of the main reactor by a centrifugal force. Accordingly, discharge of flyashes containing toxic materials to the outside is prevented, and pyrolysis and gasification of the waste materials are induced by circulating the exhaust gas rapidly.

TECHNICAL FIELD

The present invention relates generally to a pyrolysis/vitrification system for treating waste materials and, more particularly, to a plasma pyrolysis/vitrification system utilizing plasma with low mass, ultra high temperature and high enthalpy to transform organic waste materials into fuel gas by pyrolysis and gasification, and inorganic waste materials into harmless recyclable slag by melting simultaneously.

BACKGROUND ART

Recently the amount of industrial/household waste materials is increasing rapidly due to fast industrialization and population growth. Landfill is generally used for treating the waste materials. However, the landfill may not be a perfect solution due to shortage of landfill sites, and contamination of underground water and soil. Based on incineration, various new technologies having advantages such as volume reduction and energy recycling have been developed, and are being used currently. However, they have a disadvantage of generating harmful exhaust gases such as dioxin, and residual ashes containing heavy metals.

To solve the above-mentioned problems, technologies for pyrolysis/melting using a plasma torch have been developed and applied to treat the waste materials more efficiently. The plasma torch generates extremely high temperature plasma jet by applying highly pressurized arc to ionized plasma gas. High temperature environment ranging from 4,000 to 7,000 degrees Centigrade is generally created by the plasma torch.

Plasma torches are generally classified into non-transferred torch and transferred torch depending on their structures. The plasma generator includes electrodes, nozzles, gas inflow system and cooling system as main components. Copper is generally used for an anode material and tungsten treated for easy electron emission is used for a cathode material.

Various transferred or non-transferred plasma torches with the capacity ranging from hundreds Kilowatts to Megawatts are being developed, depending on materials to be treated. Plasma torch technologies for pyrolysis/melting are used for treating waste materials utilizing high temperature plasma of various gases. Organic compounds are decomposed into combustion gases and chemically stable compounds such as C, CnHm, CO, and H2, by high temperature and heat capacity of the plasma torch. Inorganic compounds are melted and decomposed into very minute materials, or vitrified into solids.

Accordingly, if harmful wastes or coal are treated using the plasma torch, purified combustion gases free from harmful materials are produced by pyrolysis and may thereby be reused. Volume of the waste materials may be substantially reduced by vitrification in a non-dissolvable form due to melting.

DISCLOSURE

Technical Problem

However, plasma pyrolysis/vitrification systems reported till now have a disadvantage that a large quantity of flyashes is floated by strong plasma jet and considerable portions of floated flyashes are discharged to the outside. To reduce them, plasma jet injected from the plasma torch may be configured to contact waste materials directly. However, in this case, pyrolysis/melting reaction of the waste materials is decreased rapidly, and it is inevitable that some portion of flyashes is discharged to the outside with the flow of exhaust gas in a main reactor, in which the waste materials are pyrolyzed and melted by the plasma torch.

The advantage of plasma treatment that volume of landfill is decreased may be offset when the volume of the flyashes is large, because the flyashes discharged to the outside should be either re-treated after collecting in a gas purification equipment or landfilled.

Accordingly, development of new plasma pyrolysis/vitrification system is urgently required so that the advantage of the plasma pyrolysis/vitrification system is maximized and the flyashes are prevented from being discharged to the outside when waste materials are treated.

TECHNICAL SOLUTION

The present invention is provided to solve the above-described problems of conventional technologies. It is an object of the present invention to provide a cyclonic plasma pyrolysis/vitrification system that can significantly reduce flyashes containing a large quantity of toxic materials such as heavy metals to be discharged to the outside.

To achieve the above-mentioned technical objects, a plasma torch is provided to circulate exhaust gases which are generated by pyrolysis and melting of waste materials in a main reactor, by a strong plasma jet with a maximum circulating power. Flyashes contained in the circulating exhaust gas are melted after being adsorbed at the inner walls or in the melted materials of wastes at the bottom of the main reactor by a centrifugal force. Discharge of flyashes containing toxic materials to the outside is thereby prevented, and effective pyrolysis and gasification reaction of waste materials is induced by rapid circulation of the exhaust gas.

Additionally, the present invention provides a plasma pyrolysis/vitrification system that enables smooth discharge of slag by forming a slag outlet just under the plasma torch to maintain the slag at a high temperature.

The present invention relates to a cyclonic plasma pyrolysis/vitrification system which generates exhaust gas and slag by pyrolysis and melting of waste materials using a plasma torch. The cyclonic plasma pyrolysis/vitrification system comprises: a main reactor having a waste inlet through which waste materials are supplied, an exhaust gas outlet through which exhaust gas is discharged, and a slag outlet through which slag is discharged; a plasma torch inclined at a predetermined angle with respect to the internal bottom surface of the main reactor to give a maximum circulating power to the exhaust gas, pyrolyzing and vitrifying the waste materials; an auxiliary reactor connected to the exhaust gas outlet of the main reactor, discharging the exhaust gas to the outside; a slag discharger connected to the slag outlet of the main reactor, discharging the slag to the outside; wherein the plasma torch circulates the exhaust gas in the main reactor by strong plasma jet with a maximum circulating power, and makes flyashes contained in the circulating exhaust gas to be melted after being adsorbed at the inner walls or in the melted materials of wastes at the bottom of the main reactor by a centrifugal force.

Preferably, the cyclonic plasma pyrolysis/vitrification system in accordance with the present invention has the slag discharger formed just under the plasma torch.

Preferably, the cyclonic plasma pyrolysis/vitrification system in accordance with the present invention includes the waste inlet and the ex wherein the cyclonic gas flow rotates throughout substantially the entire main reactor; haust gas outlet having a designated distance therebetween in the main reactor, and further includes a separator wall of a designated length formed therebetween.

Preferably, in the cyclonic plasma pyrolysis/vitrification system in accordance with the present invention, the exhaust gas outlet is disposed in the center of the circulating exhaust gas, namely, in the center of an inner sidewall of a main reactor.

Preferably, in the cyclonic plasma pyrolysis/vitrification system in accordance with the present invention, the plasma torch is inclined at the angle ranging from 20 to 40 degrees with respect to the bottom surface of the main reactor.

BEST MODE

Hereinafter, example embodiments of the present invention will be described in more detail with reference to the accompanying drawings.

Although the invention has been described in detail herein, it should be understood that the invention is not limited to the embodiments herein disclosed. Various changes, substitutions and modifications may be made thereto by those skilled in the art without departing from the spirit or scope of the invention as described and defined by the appended claims.

FIG. 1is a partial sectional view showing a cyclonic plasma pyrolysis/vitrification system in accordance with Example 1 of the present invention andFIG. 2is a partial side view showing the cyclonic plasma pyrolysis/vitrification system in accordance with Example 1 of the present invention.

Referring toFIGS. 1 and 2, a cyclonic plasma pyrolysis/vitrification system1is an equipment used for pyrolyzing and vitrifying waste materials. The cyclonic plasma pyrolysis/vitrification system1comprises a plasma torch2pyrolyzing and vitrifying the waste materials, a main reactor3generating exhaust gas and slag by pyrolyzing and vitrifying the waste materials using the plasma torch2, an auxiliary reactor4to which the exhaust gas generated in the main reactor3is supplied and which discharges the exhaust gas to the outside, and a slag discharger5to which the slag generated in the main reactor3is supplied and which discharges the slag to the outside. The main reactor3has a waste inlet7formed on a side of its inner wall through which waste materials are fed by a hydraulic feeding device7′ and a plasma torch injection hole2aformed on a wall12perpendicular to the waste inlet7. The plasma torch2is installed in the plasma torch injection hole2aat the angle ranging from 20 to 40 degrees with respect to the bottom surface of the main reactor3so that exhaust gas circulates with maximum circulating power inside the main reactor3. A slag outlet9is formed just under the plasma torch2so that high temperature is maintained by the heat of the plasma torch2. A first gas burner injection hole6ais formed in a side of the plasma torch2. A first gas burner6is installed in the first gas burner injection hole6atowards the center of bottom of the main reactor3to preheat the main reactor3together with the plasma torch2. A first exhaust gas outlet10is formed in the center of an inner wall of the main reactor3, the axis of circulating exhaust gas, which is located opposite to the waste inlet7. Exhaust gas is circulated at maximum circulating power in a space between the wall12having the plasma torch2and the other wall13opposite to the wall12, and flyashes contained in the exhaust gas are thereby melted after being adsorbed into melted materials of wastes (not shown) at the bottom surface, at the wall12or at the other wall13by a centrifugal force. Accordingly, exhaust gas containing relatively low concentration of flyashes, existing in the center of circulating exhaust gas, is discharged through the first exhaust gas outlet10.

An auxiliary reactor4coupled with the first exhaust gas outlet10is installed at a side of the main reactor3, and exhaust gas from the main reactor3is delivered to the auxiliary reactor4. A second gas burner injection hole11ais formed on an inner wall of the auxiliary reactor4, opposite to the first exhaust gas outlet10.A second gas burner11is installed in the second gas burner injection hole11a, circulates and heats the exhaust gas. A second exhaust gas outlet8is formed on the ceiling of the auxiliary reactor4and the exhaust gas is discharged through the second exhaust gas outlet8to a gas purification equipment (not shown) connected thereto.

A slag discharger5is formed under the main reactor3and connected to a slag outlet9formed just under the plasma torch2. Slag generated in the main reactor3is delivered smoothly to the slag discharger5by maintaining high temperature using the heat of the plasma torch2. A slag treatment system (not shown) may be installed inside the slag discharger5to treat the slag.

FIG. 3is a partial sectional view showing a cyclonic plasma pyrolysis/vitrification system in accordance with Example 2 of the present invention andFIG. 4is a partial side view showing the cyclonic plasma pyrolysis/vitrification system in accordance with Example 2 of the present invention.

Referring toFIGS. 3 and 4, a cyclonic plasma pyrolysis/vitrification system201is an equipment for pyrolyzing and vitrifying waste materials, in the same manner as Example 1 shown inFIG. 1. The cyclonic plasma pyrolysis/vitrification system201comprises a plasma torch202pyrolyzing and vitrifying waste materials, a main reactor203generating exhaust gas and slag by pyrolyzing and vitrifying the waste materials using the plasma torch202, an auxiliary reactor204to which the exhaust gas generated in the main reactor203is fed and which discharges the exhaust gas to the outside, and a slag discharger205to which the slag generated in the main reactor203is fed and which discharges the slag to the outside.

In the same manner as Example 1 shown inFIG. 1, the main reactor203has a waste inlet207formed on a side of its inner wall through which waste materials are fed by a hydraulic feeding device207′ and a plasma torch injection hole202aformed on an inner wall perpendicular to the waste inlet207. The plasma torch202is installed in the plasma torch injection hole202aat the angle ranging from 20 to 40 degrees with respect to the bottom surface of the main reactor203so that exhaust gas circulates with maximum circulating power inside the main reactor203. A slag outlet209is formed just under the plasma torch202so that high temperature is maintained by the heat of the plasma torch202. A first gas burner injection hole206ais formed in a side of the plasma torch202. A first gas burner206is installed in the first gas burner injection hole206atowards the center of the main reactor203to preheat the main reactor203together with the plasma torch202.

In a different manner from Example 1 shown inFIGS. 1 and 2, a first exhaust gas outlet210is formed in the ceiling of the main reactor203opposite to the slag outlet209, and exhaust gas is discharged through the first exhaust gas outlet210. An auxiliary reactor204coupled with the first exhaust gas outlet210is installed on the top of the main reactor203, and exhaust gas from the main reactor203is delivered to the auxiliary reactor204. A second exhaust gas outlet208is formed on a side of an inner wall of the auxiliary reactor204, and discharges the exhaust gas to a gas purification equipment (not shown) connected thereto. A separator wall212is installed between the waste inlet207and the first exhaust gas outlet210to vitrify all flyashes generated during pyrolysis of waste materials by effectively circulating exhaust gas including flyashes. The separator wall212is protruded at a designated length from the inner ceiling of the main reactor203towards its bottom so that the plasma torch203can heat the bottom of the main reactor203. The separator wall212is located between a space in the main reactor203to which waste materials are introduced and the plasma torch202. So that the separator wall212may be provided to make flyashes to circulate more than one times in the main reactor203before discharge from the main reactor203. Exhaust gas passes near the highest temperature region of the plasma jet in the main reactor203before discharge from the main reactor203so that un-melted flyashes are melted and undestroyed organic components are destroyed. Other structures of the pyrolysis/vitrification system201according to Example 2 of the present invention will not be explained because they have the same structures as Example 1 shown inFIG. 1.

Referring toFIGS. 1 and 2, waste treatment process of the cyclonic plasma pyrolysis/vitrification system1according to Example 1 of the present invention will be described. The plasma pyrolysis/vitrification system1has a preheating process for preheating its inside. In the case that waste materials are treated by a plasma torch2without preheating, a large quantity of environmentally toxic materials and un-burned soots are discharged. Exhaust gases containing toxic materials and soots are discharged through an auxiliary reactor4, delivered to a gas purification equipment (not shown), and result in the reduction of the lifetime of the gas purification equipment.

Gas is supplied to the inside of the pyrolysis/vitrification system1through a first gas burner6installed in the main reactor3. The gas supplied to the main reactor3is ignited by plasma jet injected from plasma torch2and preheats the main reactor3. In the case that the inside of the main reactor3is preheated only by the plasma torch2, a large quantity of NOx may be generated because oxidation atmosphere is formed by high temperature of the plasma jet. Accordingly, Excessive quantity of gas is injected by the first gas burner206to reduce the occurrence of NOx, and reduction atmosphere is formed in the main reactor3when the quantity of gas remaining after burning is larger than oxygen injected into the pyrolysis/vitrification system through the plasma torch2. Internal temperature of main reactor3is above 1,400 degrees Centigrade at which slag produced during waste treatment is melting. Subsequently, if the temperature of the auxiliary reactor4is below 1,300 degrees Centigrade which is a normal operating temperature, temperature of the gas supplied from the main reactor3to the auxiliary reactor4is further raised using a second gas burner11installed in the auxiliary reactor4. Waste materials are pressed by hydraulic feeding device and supplied into the preheated main reactor3through a waste inlet7formed on a side of the main reactor3. Supplied waste materials are pyrolyzed and melted by the plasma torch2and high temperature atmosphere, and slag and exhaust gas containing toxic flyashes are generated. The plasma torch2is inclined at a predetermined angle with respect to the bottom surface of the main reactor, and maximum circulating power is given to exhaust gas by plasma jet injected from the plasma torch2. The exhaust gas is circulated at a maximum circulating power in a space between a wall12on which the plasma torch2is installed and another wall13opposite to the wall12. Flyashes contained in the exhaust gas are melted after being absorbed by a centrifugal force into the wall12, the other wall13and melted materials at which temperature above 1,400 degrees Centigrade is maintained by the plasma torch202. Therefore, slag free from toxic materials, such as dioxin or furan contained in the flyashes, is generated.

Concentration of flyashes is relatively low in the center of the circulating gas and thereby a first exhaust gas outlet10discharges exhaust gas purified maximumly in the center of circulating exhaust gas. A slag outlet9is formed just under the plasma torch2, and generated slag is discharged smoothly to a slag discharger9by maintaining high temperature.

In the cyclonic plasma pyrolysis/vitrification system according to Example 2 of the present invention shown inFIGS. 3 and 4, exhaust gas is circulated rapidly by plasma jet ejected from the inclined plasma torch in an internal space between an inner wall having a waste inlet207, and a separator wall212formed between the waste inlet207and a plasma torch injection hole202a. Slag free from toxic materials is obtained by vitrifying and making flyashes contained in the exhaust gas to be absorbed into an inner wall and melted materials that maintain a temperature above 1,400 degrees Centigrade. Accordingly, By the action of the separator wall212formed in the main reactor203, even some portion of the exhaust gas containing flyashes is circulated without discharge to a first exhaust gas outlet210, and thereby possibility of vitrifying flyashes is increased more. Exhaust gas purified maximumly by efficient circulation is delivered to an auxiliary reactor204through the first exhaust gas outlet210, discharged to outside through a second exhaust gas outlet208formed on an inner sidewall of the auxiliary reactor204, and discharge of flyashes to the outside is prevented. In the case that a large capacity of waste treatment is required, a plurality of plasma torch202is installed in a parallel arrangement for efficient circulation.

INDUSTRIAL APPLICABILITY

A cyclonic plasma pyrolysis/vitrification system according to the present invention has a plasma torch inclined at a predetermined angle with respect to the bottom surface of a main reactor so that exhaust gas is circulated by plasma jet at maximum circulating power in the main reactor, slag is maintained in a melted state, flyashes contained in circulating exhaust gas is melted after being adsorbed at the inner walls or in the melted materials of wastes at the bottom of the main reactor by a centrifugal force, discharge of flyashes to the outside is prevented, and pyrolysis and gasification of waste materials are activated by circulating exhaust gas.

The cyclonic plasma pyrolysis/vitrification system according to the present invention has a separator wall formed between a waste inlet and an exhaust gas outlet so that all exhaust gas is circulated effectively, discharged to an outlet and melted ratio of the flyashes becomes higher.

A slag outlet is formed just under a plasma torch, and slag is discharged smoothly to the slag outlet by maintaining the slag in a high temperature.

The cyclonic plasma pyrolysis/vitrification system according to the present invention is applicable to urban and industrial wastes, and especially useful for vitrifying powder type wastes such as flyashes.