Catalyst For Decomposing A Plastic

Abstract

A catalyst for decomposing a plastic includes a porous support having an exterior surface and defines at least one pore therein. The catalyst also includes a depolymerization catalyst component disposed on the exterior surface of the porous support for depolymerizing the plastic. The depolymerization catalyst component includes a Ziegler-Natta catalyst, a Group IIA oxide catalyst, or a combination thereof. The catalyst further includes a reducing catalyst component disposed in the at least one pore. The catalyst is formed by a method that includes the step of disposing the depolymerization catalyst component on the exterior surface. The method further includes the step of disposing the reducing catalyst component in the at least one pore.

Description

RELATED APPLICATIONS[0001]This application claims priority to and all the advantages of U.S. Provisional Patent Application Ser. No. 61 / 630,894, filed Dec. 21, 2011, which is expressly incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE[0002]The present disclosure generally relates to a catalyst for decomposing a plastic and a method of forming the catalyst. More specifically, the present disclosure relates to a catalyst including a depolymerization catalyst component and a reducing catalyst component.BACKGROUND[0003]Plastics are typically made from non-renewable petroleum resources and are often non-biodegradable. In the United States, plastics are produced in amounts exceeding 115,000 million pounds annually. Plastics are used in many industries to form products for sale in both industrial and residential markets. In industrial markets, plastics are used to form packaging, insulation, construction products, etc. In residential markets, plastics are used to for...

AI Technical Summary

Benefits of technology

[0010]The catalyst of the instant disclosure tends to allow for controlled and efficient formation of specific hydrocarbons e.g. having from 4 to 40 carbons, which can be used as fuel. The catalyst also tends to allow for increased decomposition of plastic thereby reducing reliance on, and slowing depletion of, non-renewable energy sources. The catalyst further tends to reduce a need for new mining and drilling operations on unused land and also reduces energy expenditure associated with refining petroleum to form fuels. Still further, the catalyst tends to reduce potential environmental pollution by allowing for the decomposition of the plastics that are discarded in landfills and by reducing runoff and soil erosion from the mining and drilling operations. The catalyst tends to contribute to decomposition of the plastic and direct formation of these hydrocarbons, typically without a need for additional processing or purification. Also, the catalyst tends to be inexpensive to dispose of or recycle. The method the instant disclosure allows for controlled disposition of catalyst components on the catalyst. This controlled disposition permits formation of the catalyst such that the catalyst can be used to decompose the plastic for efficiently producing the hydrocarbons.

Problems solved by technology

Plastics are typically made from non-renewable petroleum resources and are often non-biodegradable.

Yet, recycling efforts for polyethylenes, polypropylene, and polystyrene have not been maximized.

Plastics that are not recycled and re-used present potential environmental pollution risks when discarded, are not utilized for energy or raw materials, and contribute to an increased reliance on non-renewable petroleum resources.

However, neither of these methods are particularly efficient because of the complexities involved in processing plastics of different colors, textures, and consistencies and producing other products.

Traditionally, this decomposition through heating forms monomers having an inconsistent and / or unpredictable number of carbon atoms, while leaving much of the plastic unusable.

However, many of these catalysts are ineffective in selectively cracking the plastics to form specific monomers.

Although traditional catalytic cracking is more efficient in forming monomers than simple decomposition of plastics through heating alone, many of these traditional catalysts still form monomers having an inconsistent and / or unpredictable number of carbon atoms and still leave much of the plastic unusable and un-cracked.

However, the various types of open-loop recycling described above traditionally result in diesel fuel having an insufficient amount of hydrocarbons having 11 to 25 carbons for the diesel fuel to be commercially used.

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