Plastic Waste Co-Processing in Cokers for Low-Nitrogen Jet Fuel
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Solution Overview
Problem
The integration of plastic waste into refinery processes poses challenges due to its composition variability and the potential contamination of refinery products with nitrogen and chlorine compounds, leading to high nitrogen content in kerosene/jet boiling range fractions and disrupting integrated refinery operations.
Innovation Solution
A method for co-processing plastic waste in a coking environment involves controlling the type of plastic waste, using thermal dehalogenation to reduce chlorine content, and employing hydroprocessing to minimize nitrogen content in kerosene/jet boiling range fractions, while utilizing coking to generate liquid products and synthesis gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plastic waste is introduced into refinery processes, then production of jet fuel and other refinery products can be achieved, but nitrogen content in kerosene/jet boiling range fractions increases and product quality deteriorates
Solution Approach 1:
The patent applies preliminary action by conducting thermal dehalogenation and nitrogen removal treatments on plastic waste feedstock before introducing it into the coking process. This pre-treatment removes harmful chlorine and nitrogen compounds that would otherwise contaminate the kerosene/jet fraction, thereby preventing quality deterioration while maintaining productivity
Solution Approach 2:
The patent extracts harmful nitrogen-containing compounds from the kerosene/jet boiling range fraction through selective removal processes. By separating and removing these contaminants after coking but before final product formulation, the patent maintains high jet fuel production while delivering low-nitrogen quality product
2Adaptability or versatility
If plastic waste is co-processed in integrated refinery, then diverse refinery products can be produced, but process complexity and capital costs increase due to need for isolated process trains
Solution Approach 1:
The patent applies universality by designing a coking process that can simultaneously handle plastic waste feedstock and produce multiple refinery products (naphtha, kerosene, diesel, lubricant, fuel oil) within a single integrated process train. This eliminates the need for isolated process trains while maintaining the ability to produce a diverse product slate
Solution Approach 2:
The patent merges plastic waste processing with conventional coking operations in an integrated refinery setting. By combining these previously separate processes into a unified flow, the patent achieves both process simplification and product diversity without requiring capital-intensive isolated process trains
3Loss of substance
If plastic waste is introduced into refinery, then carbon from polymers can be recovered, but contamination with chlorine and nitrogen compounds occurs
Solution Approach 1:
The patent converts the harmful chlorine and nitrogen compounds present in plastic waste into removable byproducts through thermal dehalogenation and controlled coking. These contaminants are transformed into separable forms that can be removed in downstream processing, allowing carbon recovery while eliminating contamination in the final jet fuel product
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 approach effectively reduces contaminants in kerosene/jet fuel boiling fractions, allowing for the efficient production of jet fuel blending components with low nitrogen content and increased production of liquid products.
Implementation Method 1
exposing at least a portion of the combined feed to coking conditions to form a conversion effluent
Implementation Method 2
employing hydroprocessing to minimize nitrogen content in kerosene/jet boiling range fractions
Implementation Method 3
using thermal dehalogenation to reduce chlorine content
Data Source
AI summary
Systems and methods are provided for co-processing plastic waste in a coker as part of an integrated refinery environment that produces kerosene, jet fuel, and/or jet fuel blending components as a product. The co-processing can be performed in a fluidized coker, a delayed coker, or a combination of fluidized cokers and delayed cokers. After coking, hydroprocessing can be performed on one or more portions of the coker effluent that contribute to formation of the kerosene, jet fuel, and/or jet fuel blending component product(s). The hydroprocessing can be used to reduce or minimize the presence of unexpected nitrogen contaminants in the resulting kerosene, jet fuel, and/or jet fuel blending component product(s).