Hydrothermal Carbonization of Polyurethane and Polyester for Coal-Like Solid Production
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Solution Overview
Problem
Current hydrothermal carbonization methods primarily focus on converting biomass into coal-like materials, limiting the development of alternative processes that do not rely on biomass as a starting material.
Innovation Solution
A method involving an aqueous reaction mixture with hydrolyzable plastics such as polyurethanes and polyesters, combined with biological materials, under controlled pressure and temperature conditions, to produce coal-like solid particles, which can then be processed to create a carbon black substitute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydrothermal carbonization is used to convert biomass into coal-like materials, then coal-like products can be produced, but the process is limited to biomass-based starting materials only
Solution Approach 1:
The patent extends the hydrothermal carbonization process to accept multiple types of starting materials including both biomass and plastic materials (particularly polyurethanes and polyesters). This universal approach allows the same process conditions and equipment to produce coal-like particles from diverse feedstocks, thereby resolving the limitation of biomass-only starting materials while maintaining process versatility
2Adaptability or versatility
If plastic materials are used as starting material instead of biomass, then alternative carbon sources are available, but the process conditions and material ratios must be precisely controlled
Solution Approach 1:
The patent establishes specific parameter ranges for plastic material conversion including temperature (180-250°C), pressure (2-60 bar), reaction time (0.5-48 hours), and catalyst selection (acids, bases, or metal-based catalysts). These optimized parameters enable effective conversion of plastic materials while maintaining control over the hydrothermal carbonization process, resolving the tension between material diversity and process control precision
3Productivity
If the reaction temperature is increased to 195-225°C for plastic material conversion, then hydrothermal carbonization efficiency improves, but energy consumption increases
Solution Approach 1:
The patent employs continuous hydrothermal carbonization processing where plastic materials are continuously converted to coal-like particles under optimized temperature and pressure conditions. This continuous operation maximizes the efficiency of energy input by maintaining steady-state reaction conditions, thereby improving carbonization efficiency while minimizing energy waste compared to batch processing
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
This method enables the production of coal-like solid particles that can serve as a carbon black replacement, offering a resource-saving alternative for various applications, including fillers, UV stabilizers, and conductivity agents, while reducing greenhouse gas emissions.
Implementation Method 1
an aqueous reaction mixture which comprises a plastic material containing one or more hydrolyzable plastics selected from polyurethanes and/or polyesters
Implementation Method 2
in the presence of a catalyst selected from an acid, a base and/or a metal-based or sulfur-based catalyst
Data Source
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AI summary
The invention relates to particles of a carbon-like solid, their uses, and processes for their production. In the process, an aqueous reaction mixture comprising a plastic material containing one or more hydrolyzable plastics selected from polyurethanes and/or polyesters, and further biological material, wherein the weight ratio of plastic material to biological material is 750:1 to 1.5:1, is reacted at a pressure of 2 to 60 bar and a temperature of 195°C to 225°C in the presence of a catalyst selected from an acid, a base, and/or a metal-based or sulfur-based catalyst, for a period of 0.1 to 48 hours, and the resulting slurry of particles of a carbon-like solid is obtained, wherein at least one comminution step and optionally measures to reduce the water content of the slurry and/or size fractionation steps are carried out.