Dynamic Pressure Control for Variable Composition Plastic Pyrolysis
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Solution Overview
Problem
Current pyrolysis processes for plastics materials are limited in treating complex polymeric mixtures, particularly those with variable compositions, as they often require specific operating conditions and are ineffective in handling undesirable components like PVC and PET, leading to inefficiencies and environmental concerns.
Innovation Solution
A process that adjusts reaction conditions, specifically pressure, according to the composition of the plastics material, allowing for the pyrolysis of variable composition plastics at temperatures between 330° C and 580° C in the substantial absence of oxygen, and regulating pressure between atmospheric and 13 bar to produce high-quality liquid hydrocarbons, including those with undesirable components without fouling or blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pyrolysis is carried out at fixed operating conditions (pressure and temperature), then the process is simple to operate, but it cannot effectively treat plastics materials of variable composition
Solution Approach 1:
The patent implements dynamic adjustment of operating parameters (pressure and temperature) based on the composition of plastics fed to the pyrolysis reactor. The system continuously monitors plastic composition and automatically adjusts pressure between atmospheric and 13 bar, and temperature between 330-580°C, allowing the process to adapt to variable composition inputs while maintaining efficient pyrolysis conditions for different polymer types
Solution Approach 2:
The invention changes physical parameters (pressure and temperature) of the pyrolysis process to match the composition of plastics being treated. By varying pressure from atmospheric to 13 bar and temperature from 330-580°C based on feed composition, the system optimizes pyrolysis efficiency for different plastic types including vinyl and non-vinyl polymers, resolving the contradiction between adaptability and operational simplicity
2Quantity of substance
If pyrolysis is carried out at reduced pressure (0.1-0.9 atm), then volatile products are better separated, but the liquid hydrocarbon yield decreases significantly
Solution Approach 1:
The patent optimizes pressure parameters within the range of atmospheric to 13 bar to maximize liquid hydrocarbon yield while maintaining effective product separation. This pressure range prevents the significant yield loss observed at reduced pressures (0.1-0.9 atm) while still allowing for proper separation of volatile pyrolysis products through controlled condensation and fractionation
3Adaptability or versatility
If pyrolysis process treats complex polymeric mixtures with undesirable components (PVC, PET), then total plastic recovery is achieved, but fouling and blocking occur in the reactor
Solution Approach 1:
The patent adjusts pressure (atmospheric to 13 bar) and temperature (330-580°C) parameters based on the composition of plastics including those with undesirable components like PVC and PET. These optimized parameters promote complete decomposition of complex polymers while controlling condensation conditions to prevent fouling and blocking in the reactor and downstream equipment
Solution Approach 2:
The system implements monitoring and control mechanisms that detect the composition of plastics fed to the reactor and adjust operating conditions accordingly. This feedback approach allows the system to handle variable composition inputs including complex mixtures with PVC and PET while maintaining stable operation and preventing fouling through real-time parameter optimization
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
Enables the recycling of plastics multiple times without property loss, treats a wide range of plastics including vinyl and non-vinyl polymers, and produces high-quality pyrolysis oil with a high hydrocarbon content, effectively managing variable composition plastics and reducing environmental impact.
Implementation Method 1
a process for the pyrolysis of substantially plastics material to obtain at least liquid hydrocarbons
Implementation Method 2
subjecting a substantially plastics material to a specific pyrolytic process... in the substantial absence of oxygen, and at a pressure of between atmospheric pressure and 13 bar
Implementation Method 3
regulating the pressure in the pyrolysis reactor in relation to characteristic parameters defined by the composition of said substantially plastics material and/or characteristic parameters defined by the products of said pyrolysis process
Data Source
AI summary
This invention relates to the processing of plastics materials for re-use and valorisation in chemical recycling processes for the re-use of substantially plastics materials otherwise destined for disposal.In particular the invention relates to a process for the pyrolysis of substantially plastics material to obtain at least liquid hydrocarbons that are in the liquid state at 25° C. comprising the following steps:a) feeding the substantially plastics material optionally already in the molten and/or preheated state to a pyrolysis reactor;b) bringing said material in said pyrolysis reactor to a temperature of between 330° C. and 580° C. in the substantial absence of oxygen and at a pressure of between atmospheric pressure and 13 bar (a);c) holding said material in said pyrolysis reactor at a temperature of between 330° C. and 580° C. for a time sufficient to produce at least one effluent in the gaseous state in said pyrolysis reactor;d) adjusting the pressure in said pyrolysis reactor in relation to characteristic parameters defined by the composition of said substantially plastics material and/or characteristic parameters defined by the products of said pyrolysis process, while maintaining said pressure at a value of between atmospheric pressure and 13 bar (a);e) partly or totally condensing said effluent in the gaseous state so as to form at least one fluid comprising liquid hydrocarbons that are in the liquid state at 25° C. which quantitatively is at least 10% by mass with respect to the mass of substantially plastics material fed;f) the process being characterized by the fact that the pressure adjustment of step d) has low latency.