Dual Reactor Plastic-Derived Oil Decontamination and Cracking
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Solution Overview
Problem
Plastic derived oils contain halogen-containing compounds and contaminants that pose challenges in direct use for catalytic cracking due to corrosion, catalyst poisoning, and environmental impact, necessitating effective decontamination and conversion processes.
Innovation Solution
A dual reactor system utilizing a mixed metal oxide catalyst in a first reactor to remove halogens, followed by an adsorption unit and a cracking catalyst in a second reactor for catalytic cracking to produce valuable chemical products and intermediates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plastic derived oil is directly used in catalytic cracking, then fuel blending components and chemical feedstocks can be produced, but halogenated compounds cause corrosion, catalyst poisoning, and environmental problems
Solution Approach 1:
The system divides the processing into two separate reactors: a first reactor for decontamination of halogenated compounds and a second reactor for catalytic cracking. This segmentation allows each reactor to be optimized for its specific function, enabling high productivity while eliminating harmful effects through dedicated treatment stages.
Solution Approach 2:
The first reactor extracts and removes halogenated compounds from the plastic derived oil before the oil enters the second reactor for catalytic cracking. This extraction of harmful components prevents catalyst poisoning and corrosion while maintaining the ability to produce fuel blending components and chemical feedstocks.
2Object-affected harmful factors
If decontamination processes are implemented to remove halogenated compounds, then environmental and equipment issues are mitigated, but processing complexity and cost increase
Solution Approach 1:
The first reactor serves as an intermediary unit between the raw plastic derived oil and the catalytic cracking reactor. It mediates by removing halogenated compounds through contact with a catalyst bed, thereby protecting downstream equipment and the environment while maintaining relatively simple processing architecture.
Solution Approach 2:
The decontamination process is integrated into the existing catalytic cracking system rather than being a separate standalone process. The first reactor uses the same catalytic bed concept and operates under similar conditions, allowing the system to self-manage decontamination as part of its normal operation without requiring entirely separate processing infrastructure.
3Manufacturing precision
If a dual reactor system is used for decontamination and conversion, then halogen levels are reduced to refinery specifications and high-value chemicals are produced, but system complexity and capital investment increase
Solution Approach 1:
The system segments the processing function into two distinct reactors with specific roles: the first reactor for precise decontamination to achieve refinery specification halogen levels, and the second reactor for high-value chemical production. This segmentation enables manufacturing precision in halogen removal while maintaining a relatively simple overall system architecture.
Solution Approach 2:
Both reactors use similar catalytic bed technology and operate under comparable conditions, allowing the system to achieve multiple functions (decontamination and conversion) using proven, standardized equipment designs. This universality reduces capital investment and operational complexity compared to using entirely different processing technologies.
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 system effectively reduces halogen levels to refinery specifications, enabling the production of high-value chemicals like light olefins and low carbon footprint fuels, while mitigating environmental and equipment issues.
Implementation Method 1
contacting the plastic derived oil with a mixed metal oxide catalyst (MMO catalyst) in a first reactor at reaction conditions, where contacting the plastic derived oil with the MMO catalyst at reaction conditions may remove halogens from the plastic derived oil
Implementation Method 2
contacting the first reactor effluent with an adsorbent in an adsorption unit disposed downstream of the first reactor to produce a treated first reactor effluent
Implementation Method 3
contacting at least a portion of the treated first reactor effluent with a cracking catalyst in the second reactor. The cracking catalyst is different from the mixed metal oxide catalyst, and the contacting with the cracking catalyst may cause hydrocarbons in the at least a portion of the treated first reactor effluent to undergo catalytic cracking
Data Source
AI summary
A process for upgrading a plastic derived oil includes providing the plastic derived oil comprising hydrocarbons and greater than or equal to 100 ppmw halogen-containing compounds and contacting the plastic derived oil with an MMO catalyst in a first reactor at reaction conditions to remove halogens from the plastic derived oil to produce a first reactor effluent with less than 100 ppmw halogen-containing compounds. The process includes contacting the first reactor effluent with an adsorbent to produce a treated first reactor effluent, passing the treated first reactor effluent to a second reactor, and contacting the treated first reactor effluent with a cracking catalyst in the second reactor. Contacting with the cracking catalyst may cause hydrocarbons in the treated first reactor effluent to undergo catalytic cracking to produce a second reactor effluent comprising light olefins, naphtha range hydrocarbons, or combinations thereof.