Live Blueprint Simulation

Integrated Pyrolysis Waste Management Truck Blueprint

Continuous waste-to-fuel conversion while collecting municipal solid waste — #naturejab

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1. System overview

1.1 Vehicle platform

Rear-loader trash truck Diesel Pyrolysis module

Base vehicle: 25,000–33,000 lb GVWR rear-loader municipal trash truck with hydraulic compactor and diesel engine (200–350 hp).

Mission: Convert sorted plastics and waste oils into pyrolysis crude/fuel fractions while driving and collecting, using exhaust heat and alternator power.

Core subsystems:

  • Pyrolysis reactor skid: auger reactor + exhaust heat shroud.
  • Vapor handling: air + water-cooled condensers, cyclone, desiccant tower.
  • Fuel collection: crude tank with optional mini-distillation at depot.
  • Gas handling: non-condensable gas flare or exhaust injection.
  • Controls: cab HMI, sensors, interlocks, and PID temperature control.
Figure 1 — Side elevation (animated)
Cab Compactor / Hopper Pyrolysis Skid ACTIVE Auger Reactor 350–500 °C Air-Cool Condenser Crude / Fuel Tank Engine Exhaust Heat Vapor to Condensers Gas Flare Char Bin
■ Pyrolysis skid   ■ Exhaust heat   ■ Vapor / condensers   ■ Crude / fuel   ■ Gas flare

2. Mechanical integration

2.1 Skid and mounting

  • Skid frame: 80×80×6 mm square steel tubing, welded, with 4× M20 mounting pads.
  • Location: Passenger-side frame rail, between cab and rear axle, clear of suspension travel.
  • Isolation: 4× elastomeric vibration mounts (shore A 60–70) between skid and truck frame.
  • Envelope: 1500 mm (L) × 700 mm (W) × 1000 mm (H), max mass ~800–1000 kg.

2.2 Reactor assembly

  • Shell: SS304, Ø300 mm, 9.5 mm wall, 1200 mm cylindrical length.
  • Auger: SS304, 50 mm shaft, 19 mm flight, 150 mm pitch, 1–5 rpm via hydraulic motor.
  • Feed end: removable head with high-temp gasket and clamp ring; rotary airlock from hopper.
  • Discharge end: char outlet to sealed bin for later disposal or use as carbon product.

2.3 Hopper and feed

  • Hopper: 50–80 L, abrasion-resistant steel, mounted above reactor feed end.
  • Interface: double-gate or rotary airlock to maintain low-oxygen environment.
  • Waste oil port: 1" NPT with metering valve, feeding directly into reactor mid-section.
Figure 2 — Reactor + skid top view (animated)
Pyrolysis Skid — Top View Auger Reactor Exhaust Heat Shroud Feed Hopper Vapor Air-Cooled Condenser Water-Cooled HX Condensate Crude / Fuel Tank FILL Frame Mount Pads
Top view — auger flights animated in cross-section; vapor flows right into condensers; condensate routes to fuel tank.

3. Process flow and operation

3.1 Process description (PFD-level)

  1. Feed preparation: Operator or automated sorter diverts plastics and waste oils into a dedicated hopper at depot or during route.
  2. Reactor loading: Hopper feeds reactor via rotary airlock; auger slowly advances material through heated zone.
  3. Heating: Engine exhaust routed through heat shroud; reactor wall temperature controlled via exhaust bypass valve (and optional electric heaters).
  4. Pyrolysis: At 350–500 °C (design range), plastics and oils thermally decompose into vapors + char.
  5. Vapor handling: Hot vapors exit reactor top, pass through air-cooled and then water-cooled condensers.
  6. Condensation: Heavy and light fractions condense into liquid; remaining gas passes through cyclone and desiccant tower.
  7. Collection: Condensed liquid flows into crude/fuel tank; non-condensable gas is sent to flare or exhaust injection.
  8. Char discharge: Solid char exits reactor discharge end into sealed bin for later disposal or use.

3.2 Operating modes

  • HEAT-UP: Reactor brought to setpoint using exhaust + electric assist; auger stopped or very slow.
  • RUN: Reactor at setpoint; auger advances feed; vapors condensed and collected continuously.
  • COOL-DOWN: Heat removed; exhaust bypassed; auger clears remaining material.
Figure 3 — Process flow (animated PFD)
Feed Hopper Plastics + Waste Oil Pyrolysis Reactor Auger · 350–500 °C Air-Cooled HX Primary Condenser Water-Cooled HX Secondary Condenser Cyclone Separator Desiccant Tower Crude/Fuel Tank Pyrolysis Oil Output Gas Flare / Exhaust Injection Char Bin Carbon Output Feed 25°C Reactor ~450°C Condensed ~40°C ⚡ Throughput ~2.4 kg/hr 🛢 Fuel yield ~0.9 L/hr 🌡 Reactor temp 452 °C ♻ Char out ~0.3 kg/hr
Green = feed · Orange = heat reaction · Blue = vapor/condensation · Purple = fuel output · Yellow = gas flare

4. Controls and interlocks

4.1 Instrumentation

  • Reactor temperature: 3× thermocouples along reactor length (TIR-101/102/103).
  • Vapor temperature: 1× thermocouple at reactor outlet (TIR-201).
  • Exhaust in/out temperature: 2× thermocouples on shroud (TIR-301/302).
  • Reactor pressure: 1× pressure transmitter (PIR-101) + mechanical relief valve (PRV-101).
  • Crude tank level: level switch or transmitter (LIR-401).
  • Gas line pressure: pressure switch (PSH-501) for flare safety.

4.2 Control logic (high-level)

MODE: OFF / HEAT-UP / RUN / COOL-DOWN IF MODE = HEAT-UP: - Enable exhaust bypass valve control. - PID: Reactor_Temp_SP → Exhaust_Valve_Position. - Electric heaters ON if Reactor_Temp < SP - ΔT. - Auger STOP or 0.5 rpm. IF MODE = RUN: - Maintain Reactor_Temp_SP via exhaust + heaters. - Auger at 1–3 rpm (tunable). - Monitor Tank_Level; if HIGH → alarm, optional auto-stop. - Monitor Gas_Pressure; if HIGH → close gas valve, stop heating. IF MODE = COOL-DOWN: - Exhaust bypassed around shroud. - Heaters OFF. - Auger runs to clear reactor. - When Reactor_Temp < Safe_Temp → allow char bin access. INTERLOCKS: - No HEAT if Reactor_Hatch_Open. - No HEAT if Cooling_Flow_Fault. - Emergency STOP → Heaters OFF, Exhaust Bypass, Auger STOP.
Figure 4 — Control loop (animated)
Reactor TIR-101 TIR-102 TIR-103 PIR-101 Pyrolysis Controller PID + Interlocks ■ RUN Exhaust Bypass Valve — 63% open Electric Heaters Standby / BOOST Auger Drive Hydraulic Motor Speed: 2.1 rpm Cab HMI Mode · Status · Alarms
Signal pulses show real-time PID feedback: reactor thermocouples → controller → valve + heaters + auger. HMI feeds mode commands.

5. Safety, constraints, and implementation notes

5.1 Safety features

  • Pressure relief: PRV-101 on reactor, vented to flare; PSH-501 on gas line to shut down heating on overpressure.
  • Thermal protection: automatic shutdown on over-temperature; heat shields between skid and truck body.
  • Gas management: non-condensable gas always routed to flare or controlled exhaust injection, never vented raw.
  • Access control: interlocks prevent heating when reactor hatch or char bin access doors are open.

5.2 Design constraints

  • Weight: skid mass must stay within axle load limits; structural analysis required for frame mounting.
  • Emissions: integration with exhaust and flare requires emissions modeling and regulatory review.
  • Feedstock variability: plastics and oils must be pre-screened (no metals, glass, high chlorine content) to protect reactor and downstream systems.

5.3 Implementation path

  1. Translate these schematics into 3D CAD (truck frame, skid, reactor, piping, and wiring harness).
  2. Run FEA on skid mounts and thermal simulations on reactor + shroud.
  3. Prototype on a single truck, instrument heavily, and characterize throughput vs. route profile.
  4. Iterate on condenser sizing and control tuning to maximize stable fuel production during normal collection duty cycles.