Alloyed Zeolite Catalyst for Plastic Recycling
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Solution Overview
Problem
Current methods for recycling mixed waste plastics are inefficient in converting high molecular weight polymers into low molecular weight organic compounds, often resulting in the formation of chlorinated hydrocarbons and requiring complex separation processes.
Innovation Solution
A solid catalyst component comprising a zeolite with a modifier and at least one Group VIII metal alloyed with a transition metal is used in a fluid-bed reactor system for continuous recycling, allowing for the conversion of mixed waste plastics into low molecular weight organic compounds, including the recovery of fillers like glass fibers, and the decomposition of halogenated plastics without forming chlorinated hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to convert high molecular weight polymers into low molecular weight organic compounds, then the conversion process is simple, but the efficiency is low and chlorinated hydrocarbons are formed
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by introducing a specific zeolite composition with modified acidity and pore structure, along with controlled reaction temperature and pressure parameters, to achieve selective conversion that prevents chlorinated hydrocarbon formation while maintaining high conversion efficiency
Solution Approach 2:
The patent uses a composite catalyst system comprising zeolite combined with metal promoters (such as nickel, cobalt, or platinum) and hydroxyapatite, creating a multi-functional material that simultaneously provides cracking activity, hydrogenation capability, and selectivity to prevent harmful byproduct formation
2Ease of operation
If conventional catalysts are used for plastic recycling, then the process is simple to operate, but complex separation processes are required
Solution Approach 1:
The patent applies local quality by designing a catalyst with specific spatial characteristics - the zeolite's uniform pore structure (3-10 angstroms) provides shape-selective catalysis that produces predominantly linear-chain hydrocarbons with narrow molecular weight distribution, enabling straightforward separation without complex downstream processing
Solution Approach 2:
The patent extracts and removes harmful components (chlorine, oxygen, nitrogen-containing groups) from the plastic waste during the catalytic conversion process, producing purified hydrocarbon products that require minimal separation and purification steps
3Productivity
If standard pyrolysis methods are used, then energy consumption is low, but the conversion of high molecular weight polymers into useful products is inefficient
Solution Approach 1:
The patent introduces a catalytic intermediary (the zeolite-based catalyst system) that mediates the conversion process, providing alternative reaction pathways with lower activation energies, thereby achieving high conversion efficiency at moderate temperatures and reducing overall energy consumption compared to thermal pyrolysis
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively converts mixed waste plastics into usable low molecular weight organic compounds, such as fuels and chemical intermediates, while recovering reusable fillers and minimizing the formation of chlorinated hydrocarbons, enhancing the efficiency and sustainability of the recycling process.
Implementation Method 1
catalytically crack the mixed waste plastics so as to convert high molecular weight polymers into volatile compounds having much lower molecular weight
Implementation Method 2
heating the second stream in a regeneration zone in the presence of oxygen at a temperature effective to convert the carbon to carbon dioxide and water
Implementation Method 3
heating the polyether polyol and a zeolite-containing particulate catalyst in a fluidized bed reaction zone
Data Source
AI summary
The presently disclosed and claimed inventive concept(s) generally relates to a solid catalyst component comprising a zeolite with a modifier and at least one Group VIII meal alloyed with at least one transition metal. The presently disclosed and claimed inventive concept(s) further relates to a method of making the solid catalyst component and a process of converting mixed waste plastics into low molecular weight organic compounds using the solid catalyst component.