Factor 3000

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Primary Retort (Upper Chamber)

• Temperature: 300–320°C
• Process: Drying and initial pyrolysis      stage
• Output: Volatile hydrocarbons begin      to release
• Gas      handling:      Evolving gases are extracted by an exhaust blower and routed to the      cooling and separation system.

Secondary Retort (Middle Chamber)

• Temperature: 430–440°C
• Process: Primary pyrolysis stage —      deep thermal cracking of carbon chains
• Output: Peak production of pyrolysis      gas and pyrolysis oil

Tertiary Retort (Lower Chamber)

• Final      Stage: Completes decomposition of residues; burns off non-cracked      compounds.
• Output:      Stable solid residue with minimal unstable components (≤3% volatiles).

Inter-Retort Transition

• Gravity-fed      material transfer through sealed junctions prevents clogging and      leaks.

Optional Feature: Superheated Steam Injection

• The      system can be equipped with a steam generator (400°C) that      delivers steam directly into the retorts via auger shafts.

 Steam Injection System Features

• Uniform      Distribution:      Steam is evenly dispersed throughout the entire retort length —      across all three temperature zones.
• Controlled      Consumption:      Steam usage is limited to ≤3% of feedstock mass for optimal      efficiency.
• Precision      Delivery:      Steam is injected via integrated nozzles within the auger      shafts.

Advantages of Steam Injection

• Increased      Pyrolysis Gas Yield: Promotes mild hydrocracking, enhancing      hydrocarbon recovery.
• Self-Cleaning      Augers: Prevents coke buildup, reducing maintenance downtime.
• Improved      Heat Distribution: Ensures uniform temperature across the      retort.
• Reduced      Toxic Byproducts: Minimizes formation of unstable or hazardous      compounds.
• Optimized      Polymer Processing: Enhances efficiency when handling complex or      mixed plastics.

Gas Treatment and Recirculation System

The produced pyrolysis gases pass through a three-phase separator:

• Liquid      phase (water) is      drained downward.
• Gases are dehydrated and      purified.
• Clean      gas is      recirculated to the burners, serving as the primary fuel      source and ensuring the system's energy self-sufficiency.

  Unique Retort Design

• Three-tier      rotary retort system made of heat-resistant AISI 310 steel
• Temperature-equalizing      strips (3 cm thick) along the entire length of each retort ensure absolute      thermal stability
• Counter-rotating      augers and retorts enhance mixing, guarantee uniform heating, and      eliminate dead zones

Unmatched Feedstock Flexibility

• Processes all      carbon-based waste - municipal, industrial, medical, chemical,      and organic
• No pre-sorting or cleaning      required -      handles heavily contaminated inputs

Advanced Thermal Destruction

• Precision-controlled pyrolysis at up to 460°C
• Superheated steam injection (400°C) enables:
      ✓ Accelerated reaction rates
      ✓ Mild hydrocracking for premium outputs
      ✓ Continuous self-cleaning of components

 Extreme Energy Efficiency

• Fully energy-autonomous through pyrolysis gas      recirculation
• Industry-leading <2 kWh energy      consumption per ton processed
• Closed-loop operation with 93% thermal      efficiency

Safety & Environmental Compliance

• Oxygen-free vacuum environment (-500 Pa) eliminates fire      risks
• Three-stage gas treatment + scrubber:
      ✓ Emissions 50% below EU standards
      ✓ Particulate matter <10 mg/Nm³
• Fully sealed system - zero leaks, odors or      contamination

Industrial-Grade Control System

• Siemens/Honeywell/Yokogawa automation
• Real-time digital monitoring via:
      ✓ Modbus TCP protocol
      ✓ Remote diagnostics
      ✓ Predictive maintenance alerts

• Combustion Chamber  1100–1200°C
• Gas Supply Channels  1050–1150°C
• Working Chamber (Retort Surroundings) 900–960°C
• Inside Retorts  Up to 460°C
• Gas Collection Box  ~380°C
• Inside Feedstock Augers  >100°C (Dehydration)
• After Heat Exchanger  180–220°C

• System      capacity: 3 tons/hour
• Material: Mixed polymers  (polyethylene, plastics), pre-shredded
• Bulk density of material: 80–140 kg/m³
• Total      input volume: ~30–40 m³/h
• Preheating: 80–90°C      (using gases)
• Oxygen-free environment: Fully sealed system
• Final goal: Converting material into      a paste-like/liquid state and feeding it into the first retort

   Augers:

• Quantity: 4
• Rotation speed: 12 - 70 RPM
• Throughput per auger: ~7.5–10 m³/h
• Phase 1 (first 7 meters):
  
  • Preheating with flue gases up to ~90°C
  • Material remains loose and flowable
• Phase 2 (second auger, steam section):
  
  • Injection of superheated steam (400°C) at the beginning (3–4 turns)
  • Auger temperature: ~400°C
  • Pressure: 12–18 bar
  • Goal: Converting the polymer into a viscous mass without decomposition

Key Advantages of This Design:

• High processing speed without sticking or coking risks
• Efficient heat transfer via steam at controlled pressure
• Zero oxygen contact throughout all stages
• Minimized mechanical clogging and slag formation
• Optimal preparation for controlled pyrolysis in the retort

  Thermodynamic Behavior of the Material:

After the First Phase:

• Material is uniformly preheated to softening temperature
• Safe from coking due to absence of localized overheating

Second Auger (Steam Treatment):

• Rapid softening/melting under superheated steam exposure
• Steam is injected along the flow direction, preventing direct contact with the overheated auger
• High-pressure ensures uniform melting without foaming
• Forms a dense, viscous mass at ~150–180°C
• Material flows smoothly—no sticking or decomposition

At Auger Outlet:

• Material is in a plastic-liquid state
• Internal pressure retains gases and moisture, but they are quickly removed in the next stage

Transition to Pyrolysis Retort:

• Material enters nearly in liquid form, oxygen-free
• A gas screw pump at the retort end:
  • Extracts steam, residual gases, and volatile hydrocarbons
  • Maintains negative pressure in the retort
  • Enables preliminary fractional separation of gas and steam