Integrated Pyrolysis Cracking Waste Plastic Recycling
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Solution Overview
Problem
The reliance on additional downstream processing facilities, such as cracking facilities, increases operation costs and complicates logistics for waste plastic pyrolysis processes, especially when these facilities are not located in close proximity.
Innovation Solution
A chemical recycling process that involves melting solid waste plastic in a plastic liquification system to form a pyrolysis effluent stream, which is then pyrolyzed in a reactor at high temperatures to produce a pyrolysis vapor stream, thereby eliminating the need for downstream cracking facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If waste plastic pyrolysis is performed using conventional methods requiring downstream cracking facilities, then heavy components and pyrolysis oil can be produced, but operation costs increase and logistics are complicated
Solution Approach 1:
The patent combines the pyrolysis process and cracking process into a single integrated reactor system. The pyrolysis reactor directly cracks plastic waste at high temperatures (650-900°C) to produce vaporized hydrocarbons, eliminating the need for separate downstream cracking facilities. This merging of functions reduces device complexity and operational costs while maintaining product yield.
Solution Approach 2:
The pyrolysis reactor is designed to perform multiple functions: it conducts both pyrolysis of plastic waste and subsequent cracking of pyrolysis oil in one unit. This multi-functionality allows the single facility to produce both pyrolysis oil and cracked hydrocarbon products, reducing the need for multiple specialized facilities and simplifying logistics.
2Ease of manufacture
If pyrolysis facilities and downstream processing facilities are located close to each other, then integration is feasible, but location constraints increase and logistics are complicated
Solution Approach 1:
By merging pyrolysis and cracking operations into a single facility, the patent eliminates the need for geographic proximity between separate facilities. The integrated design allows the process to be implemented at any location with appropriate feedstock supply, significantly improving location flexibility and reducing logistics complications.
3Manufacturing precision
If additional downstream processing facilities are used, then product processing can be achieved, but operation costs increase
Solution Approach 1:
The integration of pyrolysis and cracking in one reactor reduces the number of processing steps and intermediate handling operations. This consolidation decreases energy consumption for pumping, heating, and cooling between separate facilities, thereby reducing operational costs while maintaining product quality through direct in-reactor 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 process achieves process efficiencies and logistical simplicity by integrating plastic liquification and pyrolysis within a single facility, allowing for the direct production of recycle content products without the need for additional downstream processing.
Implementation Method 1
melting a solid waste plastic in a plastic liquification system to thereby form a pyrolysis effluent stream
Implementation Method 2
pyrolyzing at least a portion of the pyrolysis effluent stream in a pyrolysis reactor at a temperature of at least 650° C. to thereby form a pyrolysis vapor stream
Implementation Method 3
each of the plastic liquification vessel, the heating vessel, and the pyrolysis reactor are heated via an electrical heat source
Data Source
AI summary
It has been discovered that the reliance of additional chemical processing facilities downstream of a waste plastic pyrolysis facility may be avoided by utilizing a pyrolysis facility that can both pyrolyse and crack a waste plastic feedstock to thereby form various recycle content products. More specifically, a plastic liquification system and a pyrolysis reactor operating at more severe temperatures and conditions may effectively pyrolyze and crack a waste plastic so that additional downstream processing in a cracking facility may be avoided. Consequently, the waste plastic pyrolysis configuration and process disclosed herein can obtain process efficiencies and logistical simplicity not obtainable in previous waste plastic pyrolysis scheme iterations.