Plastic Feedstock Blending for Refining Carbon Footprint Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current refining and petrochemical processing systems face challenges in reducing carbon footprints due to the wastage of plastics, which results in increased CO2 emissions and inefficient use of resources.
Innovation Solution
A method and system for blending pulverized plastic feedstock into the feedstock of processing systems, where plastics are crushed to a granule size of 7-10 nanometers, separated to remove larger particles, and then blended with crude or heavy oil to generate a plastic feedstock, reducing waste and carbon emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic is sent to landfill instead of recycled, then waste disposal is simplified, but carbon footprint increases and resources are wasted
Solution Approach 1:
The patent converts waste plastic into a valuable feedstock for refining systems. By pulverizing plastic waste into fine particles (7-10 nanometers) and blending it with crude oil or heavy oil, the system transforms harmful waste into useful chemical feedstock, thereby converting the harm of plastic waste into beneficial petroleum processing feedstock and reducing carbon footprint
Solution Approach 2:
The patent changes the physical parameters of plastic waste by controlling its pulverization to achieve a specific granule size range (7-10 nanometers). This parameter change enables the plastic to be effectively blended with petroleum feedstocks and processed in refining systems, transforming it from unusable waste into processable material
2Productivity
If plastic is pulverized to very fine granule size (7-10 nanometers), then blending efficiency with feedstock increases, but energy consumption and processing complexity increase
Solution Approach 1:
The patent divides the plastic pulverization process into multiple stages using sequential crushers and classifiers. The first stage uses a crusher to reduce plastic to coarse particles, followed by a classifier to separate fine particles (7-10 nanometers) from larger debris. This segmentation allows efficient pulverization while managing energy consumption through staged processing
Solution Approach 2:
The patent employs mechanical classification systems (such as centrifugal classifiers or pneumatic classifiers) to separate plastic particles by size. These mechanical systems efficiently sort particles into the desired 7-10 nanometer range without requiring excessive energy input, replacing purely mechanical pulverization with more efficient mechanical separation processes
3Adaptability or versatility
If plastic feedstock is blended into processing system, then plastic re-use increases and carbon footprint reduces, but system complexity and equipment requirements increase
Solution Approach 1:
The patent designs the plastic conversion unit to be integrated with existing refining systems, making the system universal. The unit can process various types of plastic waste and blend them with different petroleum feedstocks (crude oil, heavy oil), providing multi-functionality. This allows the system to handle diverse inputs while maintaining compatibility with standard refining equipment, thereby reducing overall system complexity
Solution Approach 2:
The patent embeds the plastic pulverization and classification system within the existing refining complex. The plastic conversion unit is nested alongside conventional petroleum processing equipment, allowing plastic waste to be processed through the same infrastructure. This nesting approach enables plastic re-use capability while avoiding the need for completely separate processing systems, thus reducing device complexity
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 carbon footprints, increases operational efficiencies, and extends the life of existing refining and petrochemical processing equipment by reusing plastic, thereby minimizing waste and pollution while lowering costs.
Implementation Method 1
a primary shredder includes an outlet and an inlet coupled to an outlet of the primary hopper. The primary shredder is configured to crush the plastic supply to a first granule size that is less than 5 millimeters
Implementation Method 2
a secondary granulator including an outlet and an inlet coupled to the outlet of the secondary hopper. The secondary granulator is configured to crush the plastic supply to a plastic stock having a second granule size that is within a range of 10 nanometers to 0.1 microns
Implementation Method 3
a secondary classifier including an outlet and an inlet coupled to the outlet of the secondary granulator. The secondary classifier is configured to separate the plastic stock to remove a portion having a granule size that is outside of the range of 10 nanometers to 0.1 microns
Implementation Method 4
blending the plastic feedstock into a feedstock of the processing system to generate a blended feedstock
Data Source
AI summary
Aspects of the present disclosure relate to methods, systems, and apparatus for efficiently reducing carbon footprints in refining systems and petrochemical processing systems. In one aspect, a plastic powder feedstock is blended into a feedstock of a processing system to re-use plastic and reduce carbon footprints. In one implementation, a method of blending plastics into a processing system includes pulverizing a plastic supply to a plastic stock having a granule size that is within a range of 7 nanometers to nanometers. The method includes separating the plastic stock to remove a portion having a granule size that is outside of the range of 7 nanometers to 10 nanometers and generate a plastic feedstock. The method includes blending the plastic feedstock into a feedstock of the processing system to generate a blended feedstock, and processing the blended feedstock.