Aviation Fuel from Waste Plastic Pyrolysis Oil
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Solution Overview
Problem
The production of aviation fuel from waste plastic pyrolysis oil is hindered by its deteriorated low-temperature properties and high content of impurities, which makes it difficult to meet the aviation fuel standards JET A-1 or JP-8 with a high yield.
Innovation Solution
A method and apparatus for refining waste plastic pyrolysis oil through a series of processes: olefin migration reaction, olefin branching reaction, hydrotreating, and hydrocracking, using specific catalysts and conditions to improve low-temperature properties and reduce impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If dewaxing process using noble metal catalyst or strong acid site catalyst is performed, then low-temperature properties are improved, but catalyst deactivation occurs due to excessive impurities, resulting in significant decrease in reaction yield
Solution Approach 1:
The patent divides the refinery process into multiple sequential stages: first hydrotreating to remove impurities, then dewaxing to improve low-temperature properties, and finally hydrocracking. This segmentation allows each process to be optimized independently, preventing catalyst deactivation while achieving the desired freezing point improvement.
Solution Approach 2:
The patent performs hydrotreating as a preliminary step before dewaxing and hydrocracking. This preliminary removal of impurities (chlorine, nitrogen, sulfur) protects subsequent catalysts from deactivation, ensuring high reaction yield while still achieving the required low-temperature properties.
2Temperature
If dewaxing and hydrocracking are induced simultaneously at high temperature reaction condition of 450° C. or higher, then low-temperature properties are further improved, but yield decreases by 50% or more due to excessive reaction conditions
Solution Approach 1:
The patent separates dewaxing and hydrocracking into distinct sequential steps rather than combining them in a single high-temperature step. This allows milder reaction conditions for each individual process, preventing excessive cracking that would reduce yield while still achieving the required freezing point improvement through cumulative effects.
Solution Approach 2:
The patent optimizes reaction parameters for each step: controlling temperature, pressure, and catalyst type for dewaxing, then adjusting parameters for hydrocracking. This parameter optimization prevents excessive reaction intensity that would cause yield loss while achieving the desired low-temperature properties.
3Productivity
If waste plastic pyrolysis oil is used directly as fuel, then high-value-added fuel production is achieved, but impurities such as chlorine, nitrogen, and metals cause catalyst deactivation and fail to meet aviation fuel standards
Solution Approach 1:
The patent performs hydrotreating as a preliminary purification step before the fuel can be used or further processed. This removes harmful impurities (chlorine, nitrogen, sulfur, metals) from the pyrolysis oil, protecting downstream catalysts and enabling the fuel to meet aviation fuel standards while maintaining high production value.
Solution Approach 2:
The patent converts the harmful impurities in waste plastic pyrolysis oil into removable byproducts through hydrotreating. The harmful chlorine, nitrogen, and sulfur compounds are transformed and removed, turning a problematic feedstock into a viable fuel source that meets strict aviation fuel specifications.
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
The method achieves aviation fuel with a freezing point of −45° C. or lower and a yield of 75% or more, while minimizing impurities such as chlorine and nitrogen, thus meeting the aviation fuel standards and ensuring stable catalyst operation for a long period.
Implementation Method 1
a first operation of subjecting waste plastic pyrolysis oil to an olefin migration reaction
Implementation Method 2
a second operation of subjecting a product obtained in the first operation to an olefin branching reaction
Implementation Method 3
a third operation of hydrotreating a product obtained in the second operation in the presence of a hydrotreating catalyst
Implementation Method 4
a fourth operation of hydrocracking a product obtained in the third operation in the presence of a hydrocracking catalyst
Implementation Method 5
waste plastic pyrolysis oil
Data Source
AI summary
The present disclosure provides a method for producing aviation fuel, the method including: a first step of subjecting waste plastic pyrolysis oil to an olefin migration reaction; a second step of subjecting a product obtained in the first step to an olefin branching reaction; a third step of hydrotreating a product obtained in the second step in the presence of a hydrotreating catalyst; and a fourth step of hydrocracking a product obtained in the third step in the presence of a hydrocracking catalyst.