Hydrocracking Catalyst Composition for One-Pot Plastic Hydrogenation
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Solution Overview
Problem
Current processes for converting plastics to chemicals face inefficiencies due to the generation of unsaturated hydrocarbons and require multiple stages, including thermal cracking and hydrogenation, which are cumbersome and do not fully convert aromatic hydrocarbons to saturated hydrocarbons, and result in inconsistent product quality.
Innovation Solution
A catalyst system comprising transition metal or transition metal sulfides supported on an oxide-containing support with low acidity and an acidic zeolite is used to convert carbon-containing feedstocks into alkane-containing products through a one-pot process, enhancing the yield and quality of liquid hydrocarbon products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-stage process (thermal cracking followed by hydrogenation) is used to convert plastics to chemicals, then the conversion of unsaturated hydrocarbons to saturated hydrocarbons is achieved, but the process becomes cumbersome and requires additional pyrolysis units
Solution Approach 1:
The patent combines thermal cracking and hydrogenation functions into a single integrated reaction system. The catalyst system simultaneously performs both cracking and hydrogenation activities, eliminating the need for separate pyrolysis units and subsequent hydrogenation stages, thus reducing process complexity while maintaining reliable conversion of unsaturated hydrocarbons to saturated hydrocarbons
Solution Approach 2:
The catalyst system is designed with multi-functionality, incorporating both cracking and hydrogenation capabilities in a single catalyst formulation. This universal catalyst can handle multiple reaction functions that traditionally required separate processing units, thereby simplifying the overall process structure while ensuring complete conversion of hydrocarbons
2Productivity
If conventional thermal cracking and hydrogenation processes are used, then plastic waste is converted to chemical products, but large amounts of unsaturated, aromatic, and polyaromatic hydrocarbons are generated that are not completely converted
Solution Approach 1:
The patent modifies the chemical parameters of the reaction system by using a specific catalyst system with optimized composition and properties. This changes the reaction pathway and selectivity, enabling complete conversion of unsaturated and aromatic hydrocarbons to saturated products, thereby increasing productivity while eliminating harmful unsaturated and aromatic hydrocarbon byproducts
Solution Approach 2:
The catalyst system converts the previously harmful unsaturated and aromatic hydrocarbons into beneficial saturated hydrocarbon products. By transforming these unwanted byproducts into valuable saturated chemicals, the process turns what were harmful factors into useful products, thereby increasing overall yield and product quality
3Reliability
If a multi-stage process is employed for plastic conversion, then conversion of polymer feedstock is achieved, but the process requires additional pyrolysis units and results in inconsistent product quality
Solution Approach 1:
The patent merges multiple processing functions into a single integrated reaction unit, eliminating the need for separate pyrolysis units and subsequent processing stages. This integration ensures consistent product quality by controlling all reaction parameters in a unified system, while reducing the number of processing units and simplifying the overall process structure
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 catalyst system effectively produces a high yield of alkane-containing products, with at least 50% naphtha-like products, while minimizing unsaturated hydrocarbons, in a single-stage process, improving efficiency and product quality.
Implementation Method 1
a catalyst system comprising at least one transition metal or transition metal sulfide supported on an oxide-containing support having a low acidity, and an acidic zeolite
Implementation Method 2
contacting the carbon-containing feedstock with a hydrogen-containing stream in the presence of a catalyst system
Data Source
AI summary
This invention relates to a process for chemically treating a carbon-containing feedstock (e.g., a polymer-based feedstock), comprising contacting (e.g., by a hydrocracking reaction) the carbon-containing feedstock and a hydrogen stream in the presence of at least one hydrocracking catalyst to produce an alkane-containing product stream. The hydrocracking catalyst comprises at least one transition metal or transition metal sulfide supported on an oxide-containing support. This invention also relates to an alkane-containing mixture obtained by the process described herein and a system/apparatus for carrying out the process described herein.