Low-value waste plastic resource utilization process and system

Abstract

The invention provides a low-value waste plastic resource utilization process and system.The system comprises an intelligent sorting and preprocessing module, a nano-catalysis and conversion module, a refining and high-value module, a pollution control module and an intelligent management and control module.The AI multispectral sorting is combined with plasma activation, so that the sorting precision and the processing speed are remarkably improved, and the cost is reduced; according to the method, the identification bottleneck of the mixed plastic is broken, meanwhile, the alpha-olefin selectivity is larger than or equal to 90% at the low temperature of 280 DEG C through the selected Pt-Z IF-8 nano confinement catalyst, and huge transformation of the low-value waste plastic from environmental burden to strategic resources is achieved through three-in-one innovation of molecular-level precise deconstruction, digital intelligent regulation and negative carbon cycle value addition.

Description

Technical Field

[0001] The present invention relates to the technical field of low-value waste plastics processing, and in particular to a process and system for resource utilization of low-value waste plastics. Background Art

[0002] Low-value waste plastics refer to discarded plastic products with high recycling costs and low economic value, including plastic bags, food packaging films, composite plastics (such as aluminum-plastic films), heavily contaminated PET bottles, etc. Their materials are mixed (such as PE / PP / PET mixed), contain impurities (oil stains, labels, etc.) or have complex structures (multi-layer composites), resulting in low efficiency of traditional mechanical recycling, poor quality of recycled products and meager profits. This type of plastic is often landfilled or incinerated due to the difficulty in sorting and high cleaning costs. However, landfilling takes hundreds of years to degrade and pollutes soil and groundwater. Incineration releases dioxins and carbon dioxide (accounting for 3.3% of global carbon emissions), exacerbating the climate crisis. Resource utilization can resolve the contradiction between environment and resources: on the one hand, plastic comes from non-renewable petroleum resources. Recycling 1 ton of waste plastic is equivalent to saving 5 tons of crude oil and reducing 3 tons of carbon emissions; on the other hand, low-value plastics account for more than 12% of urban solid waste. Their high carbon chain structure can be converted into α-olefins (high-end chemical raw materials), synthesis gas hydrogen production or biodegradable plastics (such as PHB) through catalytic cracking, replacing the petroleum route to reduce production costs by more than 40%, while reducing microplastic pollution (there are more than 5 trillion pieces of microplastics in the ocean); in addition, resource utilization can activate the circular economy. It is estimated that the resource utilization of every 10,000 tons of low-value plastics can create 50 jobs and an annual output value of more than 50 million yuan, promoting the green closed loop of "pollution control-resource recycling-industrial value-added".

[0003] The core defects of the existing low-value waste plastic resource recovery process are concentrated in the sorting and catalysis links: traditional sorting relies on manual or single spectral technology, and has insufficient recognition ability for dark, multi-layer composite and surface-contaminated plastics, resulting in mixed impurities interfering with subsequent processing and low sorting efficiency; the catalytic cracking link uses conventional catalysts such as silicate, which requires high temperature conditions and poor selectivity. The products are mainly mixed hydrocarbons, which require additional hydrogenation to improve purity. At the same time, the catalyst is easily deactivated due to carbon deposition and has poor operating stability. These two major bottlenecks lead to insufficient sorting accuracy, high cracking energy consumption, and low product added value. It is difficult to achieve targeted conversion of high-purity chemicals, and it is even more impossible to solve the problems of dioxin generation and carbon emissions, ultimately resulting in a lose-lose situation in terms of economic efficiency and environmental protection efficiency. Summary of the Invention

[0004] (1) Technical problems solved

[0005] In response to the shortcomings of the existing technology, the present invention provides a process and system for the resource utilization of low-value waste plastics, which solves the problems of insufficient sorting accuracy, high cracking energy consumption, and low product added value in the catalysis and sorting during the processing and utilization of low-value waste plastics.

[0006] (2) Technical solution

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: a low-value waste plastic resource utilization system, including an intelligent sorting and pretreatment module, a nanocatalysis and conversion module, a refining and high-value module, a pollution control module and an intelligent management and control module.

[0008] A low-value waste plastic resource utilization process, based on the above-mentioned low-value waste plastic resource utilization system, includes the following steps:

[0009] S1, intelligent sorting and pre-processing module:

[0010] (1) AI multi-spectral sorting + plasma activation: waste plastics enter the AI ​​multi-spectral sorting line via a conveyor belt, with a sorting accuracy of ≥99%. At the same time, a cold plasma gun bombards the surface to destroy the binding force of pollutants;

[0011] (2) Enzymatic cleaning: Using an engineered PET hydrolase solution to clean mixed plastics, selectively decompose PET into TPA monomers, and the remaining PE / PP is crushed at low temperature;

[0012] S2, Nanocatalysis and Conversion Module:

[0013] (3) Microwave-assisted cracking: The crushed material enters a microwave reactor and is added with a Pt@ZIF-8 catalyst to directionally crack PE / PP into α-olefins;

[0014] (4) Photothermal synergy enhancement: A Ti3C2Tx MXene photothermal film is integrated on the top of the reactor, and solar energy is focused to increase the local temperature to 500°C;

[0015] S3, Refining and High Value Module:

[0016] (1) Quantum chemical simulation distillation: cracked gas is separated into α-olefins and diesel fractions through a quantum computing optimized distillation tower;

[0017] (2) Microbial synthesis of high-value products: light component gas is introduced into the genetically engineered bacteria reactor to synthesize PHB bioplastics;

[0018] S4, pollution control module:

[0019] (1) Plasma tail gas purification: uncondensed gas is oxidized by atmospheric pressure plasma;

[0020] (2) Blockchain carbon asset management: full-process data is uploaded to the blockchain, and carbon credits are automatically generated for transactions or tax deductions;

[0021] S5. Intelligent management and control module: AI collects data such as reaction temperature, pressure, and product composition in real time, dynamically adjusts parameters through machine learning, and puts the entire process from waste plastic recycling to product sales on the chain to generate a carbon footprint label.

[0022] Preferably, in S1, a Langmuir probe can be used to monitor the plasma electron density and dynamically adjust the power.

[0023] Preferably, the particle size of the PE / PP in S1 after low-temperature crushing is ≤5 mm.

[0024] Preferably, the photothermal film in S2 is Ti3C2Tx MXene photothermal film.

[0025] Preferably, the quantum computing-optimized distillation column in S3 is based on IBM Quantum simulation data.

[0026] Preferably, the uncondensed gas in S4 generates OH radicals after being oxidized by atmospheric pressure plasma.

[0027] (3) Beneficial effects

[0028] The present invention provides a process and system for resource utilization of low-value waste plastics.

[0029] Beneficial effects:

[0030] 1. The present invention significantly improves sorting accuracy and processing speed through AI multi-spectral sorting combined with plasma activation, breaking the bottleneck of mixed plastic identification. At the same time, the selected Pt@ZIF-8 nano-confined catalyst achieves α-olefin selectivity ≥ 90% at a low temperature of 280°C. Through the three-in-one innovation of molecular-level precise deconstruction, digital intelligent regulation and negative carbon cycle value-added, it realizes a huge transformation of low-value waste plastics from an environmental burden to a strategic resource.

[0031] 2. The present invention utilizes a fractionation pathway optimized through quantum chemical simulation. The α-olefin purity in the cracking gas is ≥99% and the sulfur content is <5ppm. This allows direct use in the synthesis of high-end chemicals, eliminating the need for traditional multi-stage refining processes. Through syngas microbial conversion technology, the light component gas is efficiently converted into PHB bioplastics, achieving high-value utilization of all components of waste plastics and significantly improving resource recovery compared to traditional processes. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 The present invention provides a flowchart of a process and system for resource utilization of low-value waste plastics. DETAILED DESCRIPTION

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] Example:

[0035] like Figure 1 As shown, an embodiment of the present invention provides a low-value waste plastic resource utilization system, including an intelligent sorting and pretreatment module, a nanocatalysis and conversion module, a refining and high-value module, a pollution control module and an intelligent management and control module.

[0036] A low-value waste plastic resource utilization process, based on the above-mentioned low-value waste plastic resource utilization system, includes the following steps:

[0037] S1, intelligent sorting and pre-processing module:

[0038] (1) AI multi-spectral sorting + plasma activation: waste plastics enter the AI ​​multi-spectral sorting line via a conveyor belt, with a sorting accuracy of ≥99%. At the same time, a cold plasma gun bombards the surface to destroy the binding force of pollutants;

[0039] (2) Enzymatic cleaning: Use engineered PET hydrolase solution to clean mixed plastics, selectively decompose PET into TPA monomers, and crush the remaining PE / PP at low temperature. The waste plastics are conveyed to the sorting line through a conveyor belt. The plastic type (PE, PP, PET, etc.) is identified by near-infrared (NIR), and surface contaminants (such as ink and metal residues) are detected by laser-induced breakdown spectroscopy (LIBS). The visual system identifies the color and shape, and a cold plasma gun (10kV) bombards the plastic surface to destroy the chemical bond between the contaminants and the plastic. The parameters are: sorting accuracy ≥99%, processing speed 3 tons / hour (traditional process 1 ton / hour), plasma treatment energy consumption is 0.2kWh / kg plastic, and an engineered PET hydrolase (resistant to 70°C) solution is used to clean mixed plastics, selectively decomposing PET into terephthalic acid (TPA) and ethylene glycol (EG). The remaining PE / PP is cooled to -50°C with liquid nitrogen and then mechanically crushed (particle size ≤ 5mm) to avoid thermal softening and adhesion. The technical effect achieved is a 14% increase in AI multi-spectral sorting accuracy and a 3-fold increase in processing speed; plasma activation reduces the amount of cleaning agent by 80%, and enzymatic cleaning achieves selective decomposition of PET, avoiding cross-contamination of mixed plastics, and the COD of wastewater is less than 50mg / L;

[0040] S2, Nanocatalysis and Conversion Module:

[0041] (1) Microwave-assisted cracking: The crushed material enters a microwave reactor, and a Pt@ZIF-8 catalyst is added to directionally crack PE / PP into α-olefins. The crushed PE / PP enters a microwave reactor (frequency 2.45 GHz), and a Pt@ZIF-8 catalyst (loading amount 1.2 wt%) is added to catalytic cracking at 280 °C. The nano-confinement effect of ZIF-8 guides the directional breakage of the PE / PP molecular chains, and the Pt nanoparticles promote the dehydrogenation reaction to produce α-olefins.

[0042] (2) Photothermal synergy enhancement: Ti3C2Tx MXene photothermal film is integrated on the top of the reactor, and solar energy is focused to increase the local temperature to 500℃. Ti3C2Tx MXene photothermal film is integrated on the top of the reactor. Through the solar concentrator (500suns), the light is focused and the local temperature is increased to 500℃, which accelerates the cracking reaction, improves the cracking efficiency by 40%, reduces the microwave power demand by 30%, and the life of Pt@ZIF-8 catalyst is greater than 500 hours. The selectivity of α-olefins is increased by 20%. Photothermal synergy reduces the demand for fossil energy heating by 80%, and the products are directly used for the synthesis of high-end chemicals (without hydrogenation), which reduces costs.

[0043] S3, Refining and High Value Module:

[0044] (1) Quantum chemical simulation distillation: The cracked gas passes through a quantum computing-optimized distillation tower to separate α-olefins and diesel fractions. The cracked gas enters the distillation tower, and the temperature and pressure gradient of the tower plate are optimized based on the intermolecular force data simulated by IBM Quantum to accurately separate the α-olefins and diesel fractions.

[0045] (2) Microbial synthesis of high-value products: light component gas is introduced into a genetically engineered bacteria reactor to synthesize PHB bioplastics; light component gas (CO / H2) is introduced into a genetically engineered bacteria (such as recombinant Escherichia coli) reactor to synthesize polyhydroxybutyrate (PHB) through metabolic pathways;

[0046] S4, pollution control module:

[0047] (1) Plasma tail gas purification: The uncondensed gas is oxidized by atmospheric pressure plasma. The uncondensed gas passes through the atmospheric pressure plasma reactor to produce hydroxyl radicals (·OH), which decompose pollutants such as dioxins and VOCs. The dioxin decomposition rate is greater than 99.9% (conventional incineration plants are less than 95%), and the energy consumption is 0.15kWh / m 3 exhaust gas;

[0048] (2) Blockchain carbon asset management: All process data is uploaded to the chain, and carbon credits are automatically generated for transactions or tax deductions. All process data (energy consumption, carbon emissions) are uploaded to the chain (Polygon network), and carbon credits are automatically generated (1 ton of plastic reduces emissions by 2.8tCO2e).

[0049] S5. Intelligent management and control module: AI collects data such as reaction temperature, pressure, and product composition in real time, dynamically adjusts parameters through machine learning, and puts the entire process from waste plastic recycling to product sales on the chain, generates carbon footprint labels, and synchronizes the 3D model of factory equipment to the Metaverse platform. AI algorithms analyze sensor data in real time, predict faults and generate maintenance instructions. Operation and maintenance personnel view equipment status through AR glasses, and remote experts guide maintenance. The fault response time is ≤15 minutes (traditional>4 hours), and equipment utilization has been greatly improved.

[0050] In S1, a Langmuir probe can be used to monitor the plasma electron density and dynamically adjust the power. The particle size of PE / PP after low-temperature crushing in S1 is ≤5mm. The photothermal film in S2 uses Ti3C2Tx MXene photothermal film. The quantum computing-optimized distillation tower in S3 is based on IBMQuantum simulation data. The uncondensed gas in S4 will generate OH free radicals after atmospheric pressure plasma oxidation.

[0051] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A low-value waste plastic resource utilization system, characterized in that: It includes intelligent sorting and pretreatment module, nanocatalysis and conversion module, refining and high value module, pollution control module and intelligent management and control module.

2. A process for resource utilization of low-value waste plastics, based on the system for resource utilization of low-value waste plastics according to claim 1, characterized in that: The following steps are involved: S1, intelligent sorting and pre-processing module: (1) AI multi-spectral sorting + plasma activation: waste plastics enter the AI ​​multi-spectral sorting line via a conveyor belt, with a sorting accuracy of ≥99%. At the same time, a cold plasma gun bombards the surface to destroy the binding force of pollutants; (2) Enzymatic cleaning: Using an engineered PET hydrolase solution to clean mixed plastics, selectively decompose PET into TPA monomers, and the remaining PE / PP is crushed at low temperature; S2, Nanocatalysis and Conversion Module: (1) Microwave-assisted cracking: The crushed material enters a microwave reactor and is added with a Pt@ZIF-8 catalyst to directionally crack PE / PP into α-olefins; (2) Photothermal synergistic enhancement: A Ti3C2Tx MXene photothermal film is integrated on the top of the reactor, and solar energy is focused to increase the local temperature to 500°C; S3, Refining and High Value Module: (1) Quantum chemical simulation distillation: cracked gas is separated into α-olefins and diesel fractions through a quantum computing optimized distillation tower; (2) Microbial synthesis of high-value products: light component gas is introduced into the genetically engineered bacteria reactor to synthesize PHB bioplastics; S4, pollution control module: (1) Plasma tail gas purification: uncondensed gas is oxidized by atmospheric pressure plasma; (2) Blockchain carbon asset management: full-process data is uploaded to the blockchain, and carbon credits are automatically generated for transactions or tax deductions; S5. Intelligent management and control module: AI collects data such as reaction temperature, pressure, and product composition in real time, dynamically adjusts parameters through machine learning, and puts the entire process from waste plastic recycling to product sales on the chain to generate a carbon footprint label.

3. The process for resource utilization of low-value waste plastics according to claim 2, characterized in that: In the S1 , a Langmuir probe can be used to monitor the plasma electron density and dynamically adjust the power.

4. The process for resource utilization of low-value waste plastics according to claim 1, characterized in that: The particle size of the PE / PP in S1 after low-temperature crushing is ≤5 mm.

5. The process for resource utilization of low-value waste plastics according to claim 1, characterized in that: The photothermal film in S2 is Ti3C2Tx MXene photothermal film.

6. The process for resource utilization of low-value waste plastics according to claim 1, characterized in that: The quantum computing-optimized distillation column in S3 is based on IBM Quantum simulation data.

7. The process for resource utilization of low-value waste plastics according to claim 1, characterized in that: The uncondensed gas in S4 generates OH radicals after being oxidized by atmospheric pressure plasma.

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