Embedded Slurry-Phase Catalyst Particles From Waste Plastics
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Solution Overview
Problem
Slurry-phase hydrocracking catalysts are single-use and become deactivated by high concentrations of sulfur, nitrogen, and metal compounds, leading to environmental and economic challenges in disposal and requiring new methods to recycle waste plastics effectively.
Innovation Solution
Development of embedded slurry-phase hydrocracking catalyst particles with catalytic material embedded in a plastic carrier, utilizing waste plastic materials to form catalysts suitable for slurry-phase hydrocracking processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional slurry-phase hydrocracking catalysts are used, then heavy hydrocarbon conversion is achieved, but catalyst deactivation occurs due to sulfur, nitrogen, and metal compounds requiring disposal
Solution Approach 1:
The patent converts harmful waste plastics into beneficial catalyst carriers. Waste plastics containing sulfur, nitrogen, and metal compounds are pyrolyzed to produce carbonaceous material that serves as the catalyst carrier, transforming environmental pollutants into functional catalytic support structures that can withstand and utilize these impurities without deactivation
Solution Approach 2:
The patent changes the physical and chemical parameters of the catalyst system by using highly porous carbonaceous material with specific surface area and pore structure characteristics. This porous structure provides high dispersion of active metal species while resisting deactivation from sulfur and nitrogen compounds, maintaining catalytic activity under severe processing conditions
2Ease of manufacture
If spent catalyst is disposed of as waste, then catalyst deactivation is accepted, but substantial disposal expenses and environmental impact occur
Solution Approach 1:
The patent recovers valuable materials from waste streams by pyrolyzing waste plastics to produce carbonaceous catalyst carriers. This process recovers carbon and converts associated impurities into useful catalyst support material, eliminating the need to discard catalyst materials and instead transforming waste into a functional resource
Solution Approach 2:
The patent creates a multi-functional system where waste plastics serve dual purposes: as the carbon source for catalyst carrier synthesis and as the structural foundation for active catalytic sites. This universal utilization of waste material eliminates disposal needs while providing essential catalyst functions
3Productivity
If unsupported catalyst particles are used in slurry-phase hydrocracking, then catalytic activity is achieved, but catalyst recovery and removal becomes necessary when activity falls below efficacy
Solution Approach 1:
The patent creates composite catalyst particles consisting of active metal species dispersed on highly porous carbonaceous material derived from waste plastics. This composite structure combines the catalytic activity of metal particles with the structural stability and porosity of the carbon carrier, enabling both high reaction efficiency and simplified separation due to the robust particulate form
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 waste plastics into effective hydrocracking catalysts, reducing environmental impact and operational costs while maintaining high conversion rates of heavy hydrocarbons into lighter fuels.
Implementation Method 1
catalytic material effective for slurry-phase hydrocracking embedded in a plastic carrier
Implementation Method 2
the molten plastic materials are formed by melting solid waste plastic materials
Data Source
AI summary
The present disclosure relates to methods for manufacturing embedded slurry-phase hydrocracking catalyst particles having catalytic material embedded in a plastic carrier. Catalytic material effective for slurry-phase hydrocracking, and molten plastic materials, are mixed, and the embedded slurry-phase hydrocracking catalyst particles are formed from the mixture.