Dual-Reactor Plastic-Derived Oil Decontamination and Cracking
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Solution Overview
Problem
Plastic derived oils contain halogen-containing compounds and wide boiling point ranges, posing challenges in direct use for catalytic cracking due to corrosion, catalyst poisoning, and environmental contamination, which hinder the production of high-value chemical products and intermediates.
Innovation Solution
A dual reactor system with a mixed catalyst comprising a decontamination catalyst and a cracking catalyst in separate reactors, along with dedicated regenerators, to remove halogen-containing compounds and convert plastic derived oils into higher-value chemicals and intermediates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plastic derived oil is directly used for catalytic cracking, then the process is simple and fast, but halogen-containing compounds cause corrosion, catalyst poisoning, and environmental contamination
Solution Approach 1:
The patent divides the processing system into two separate reactors: a first reactor for decontamination and a second reactor for catalytic cracking. This segmentation allows the decontamination catalyst to remove halogen-containing compounds before the oil enters the catalytic cracking stage, preventing catalyst poisoning and corrosion while maintaining processing efficiency.
Solution Approach 2:
The decontamination catalyst acts as an intermediary between the plastic derived oil and the cracking catalyst. It removes harmful halogen-containing compounds through adsorption and chemical reaction, protecting the downstream cracking catalyst from poisoning and corrosion while enabling the cracking process to proceed effectively.
2Reliability
If decontamination and cracking are performed in separate reactors, then catalyst degradation is minimized and product quality is improved, but system complexity increases
Solution Approach 1:
The patent employs two separate reactors with dedicated catalysts for decontamination and cracking functions. This segmentation protects the expensive cracking catalyst from halogen poisoning, extends catalyst life, and improves product quality, justifying the increased system complexity through enhanced reliability and reduced operational costs.
Solution Approach 2:
The decontamination reactor serves the cracking reactor by removing harmful contaminants before the oil enters the cracking stage. This self-service arrangement protects the cracking catalyst without requiring additional complex protection systems, making the increased reactor count worthwhile for the reliability gained.
3Manufacturing precision
If halogen-containing compounds are removed before cracking, then catalyst poisoning is prevented and product value is increased, but processing time and system complexity increase
Solution Approach 1:
The patent performs decontamination in a first reactor before the catalytic cracking in a second reactor. This preliminary removal of halogen-containing compounds prevents catalyst poisoning and ensures high product purity, with the added processing time justified by the significant increase in product value and quality.
Solution Approach 2:
By segmenting the process into decontamination and cracking stages in separate reactors, the patent achieves high product purity through selective removal of contaminants before cracking, with the processing time investment yielding superior circular chemical products.
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-containing compounds, minimizing catalyst degradation and environmental impact, enabling the production of light olefins, light aromatic compounds, and low carbon footprint fuel components.
Implementation Method 1
The decontamination catalyst converts halogen-containing compounds to hydrogen halides and organic compounds
Implementation Method 2
adsorbs the hydrogen halides onto the surface of the decontamination catalyst
Implementation Method 3
catalytic cracking the first reactor effluent to produce the greater value circular chemical products and intermediates
Implementation Method 4
removes halogen-containing compounds from the plastic derived oil
Data Source
AI summary
A process for upgrading plastic derived oil includes contacting the plastic derived oil with a mixed catalyst in a first reactor, where the mixed catalyst includes a decontamination catalyst and a cracking catalyst different from the decontamination catalyst. The first reactor reduces concentrations of halogen-containing compounds in the plastic derived oil. The process includes passing the first reactor effluent to a second reactor and contacting the first reactor effluent with the cracking catalyst to produce a second effluent comprising light olefins and naphtha range hydrocarbons. The process includes separating used mixed catalyst from the first reactor to produce a used decontamination catalyst and a second used cracking catalyst, and regenerating the decontamination catalyst and cracking catalyst in separate regenerators to reduce exposure of the cracking catalyst to halogen-containing compounds produced during regeneration of the used decontamination catalyst.