Waste Plastic to Fuel Conversion via Internal Metal Catalysts

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for generating fuel are energy-intensive and have environmental drawbacks, such as pollution and landfills, and alternative energy sources like bio-fuels divert resources from food production and pose hazards to wildlife.

Innovation Solution

A system and method for converting waste plastic into lower molecular-weight hydrocarbon fuels through thermal decomposition using a reactor with a residue from previously heated plastic, where metals within the plastic act as internal catalysts, producing a hydrocarbon-containing vapor stream that is condensed into liquid fuel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If traditional fuel production methods are used, then fuel can be produced, but energy consumption is high and pollution is generated

Engineering Contradiction:

Improveenergy consumptionVSAvoidpollution

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent converts waste plastic, which is a harmful environmental pollutant, into useful fuel products through thermal decomposition. The process transforms the harmful waste material into beneficial hydrocarbon fuels, simultaneously addressing both the energy production need and the waste pollution problem.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent utilizes metals naturally present within the plastic waste itself as internal catalysts for the decomposition reaction. This eliminates the need for external catalysts or additional chemical agents, allowing the waste material to serve its own conversion process and reducing the energy and materials required for fuel production.

Inventive Principle:

Principle #25Self-service

2Loss of substance

If waste plastic is sent to landfills, then plastic waste is disposed of, but environmental pollution increases

Engineering Contradiction:

Improveplastic wasteVSAvoidenvironmental pollution

Core Design Contradiction:

Loss of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent transforms the harmful environmental pollutant (waste plastic) into a beneficial resource (fuel). By converting the waste material into useful energy products, the process eliminates the need for landfill disposal while simultaneously reducing environmental pollution and providing an alternative energy source.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Quantity of substance

If bio-fuels are produced from crop plants, then alternative fuel is generated, but arable land is diverted from food production

Engineering Contradiction:

Improvefuel productionVSAvoidland use

Core Design Contradiction:

Quantity of substanceVSAdaptability or versatility

Solution Approach 1:

The patent uses waste plastic material that is already present in the environment as the feedstock for fuel production. This eliminates the need to divert arable land from food production, as the process utilizes non-competitive waste materials rather than requiring agricultural resources.

Inventive Principle:

Principle #25Self-service

4Power

If wind generators are deployed, then alternative energy is produced, but wildlife safety is compromised

Engineering Contradiction:

Improveenergy generationVSAvoidwildlife hazard

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent converts harmful waste plastic into beneficial fuel products through thermal decomposition. By utilizing metals naturally present within the plastic as internal catalysts, the process eliminates the need for external catalysts or additional chemical agents, allowing the waste material to serve its own conversion process and reducing the energy and materials required for fuel production.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 reduces energy consumption, minimizes pollution, decreases plastic waste, and provides a sustainable alternative to traditional fuels without diverting resources from food production, while being safer for wildlife.

Implementation Method 1

the decomposition of hydrocarbon polymers of waste plastics, which can have a high molecular weights (i.e., long carbon-chain lengths), to lower molecular-weight hydrocarbons (i.e., shorter carbon-chain lengths) that may be useful as fuels

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

said condenser unit is configured to condense a vapor stream containing one or more chemical components from said reactor into one or more liquid streams

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS11530359B2Methods and systems for converting plastic to fuel

Publication Date: 2022.12.20 WASTE TECHNOLOGIES LLC

AI summary

A method for producing a vapor stream from waste plastic comprises providing a waste plastic feedstock into a reactor containing one or more residues produced from a previously heated source of waste plastic, and heating the waste plastic feedstock in the reactor to a temperature from about 125° C. to 500° C. to generate a vapor containing one or more hydrocarbons. The waste plastic feedstock can have a calcium to sodium mass ratio from about 0.0001 to 400 as measured by inductively-coupled plasma (ICP) spectrometry. The catalytic activity in the reactor may be provided through one or more constituent elements in the waste plastic feedstock or the one or more residues produced from the previously heated source of waste plastic.