Hydroconversion of Plastic Waste and Heavy Hydrocarbons

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Solution Overview

Problem

Existing hydroconversion processes struggle to effectively upgrade heavy hydrocarbon feedstocks and plastic waste, particularly due to the presence of impurities like metals, sulfur, nitrogen, and asphaltenes, which can lead to catalyst deactivation and operational challenges.

Innovation Solution

A process for hydroconversion of a feedstock comprising a mixture of plastic waste and heavy hydrocarbon fractions, using ebullated bed or hybrid ebullated-entrained bed reactors with supported catalysts, allowing for the simultaneous conversion of plastics and heavy hydrocarbons into lighter, more valuable products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If slurry hydroconversion process is used to convert plastic waste, then conversion of plastic waste into hydrocarbons is achieved, but catalyst separation from end products becomes complex and costly

Engineering Contradiction:

Improveconversion of plastic wasteVSAvoidcatalyst separation

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The catalyst system is segmented into two distinct parts: supported catalyst particles that remain in the reactor and entrained catalyst that is carried away with products. This segmentation allows for selective recovery and reuse of the supported catalyst, simplifying the separation process compared to fully entrained catalyst systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The supported catalyst acts as an intermediary carrier that facilitates the hydroconversion reaction while remaining separable from the product stream. The catalyst support structure enables the catalyst to function during the reaction while allowing for its recovery and reuse, thereby reducing separation complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If hydroconversion process is used to upgrade heavy hydrocarbon feedstock, then conversion into lighter products is achieved, but catalyst deactivation occurs due to impurities

Engineering Contradiction:

Improveconversion of heavy hydrocarbonVSAvoidcatalyst deactivation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The harmful impurities (metals, sulfur, nitrogen, asphaltenes) are extracted or removed from the feedstock before it contacts the catalyst. This extraction step protects the catalyst from deactivation by contaminants, thereby maintaining catalyst reliability and extending its operational life during the hydroconversion process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Preliminary treatment steps are implemented to counteract the deactivating effects of impurities before they can reach the catalyst. By pre-removing or neutralizing metals, sulfur, nitrogen, and asphaltenes, the catalyst is protected from premature deactivation, ensuring sustained catalytic activity throughout the process.

Inventive Principle:

Principle #9Preliminary anti-action

3Productivity

If plastic waste is mixed with heavy hydrocarbon fraction, then simultaneous conversion is achieved, but process complexity increases

Engineering Contradiction:

Improvesimultaneous conversionVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The hydroconversion process merges the treatment of plastic waste and heavy hydrocarbon fraction into a single integrated process stream. By combining these feedstocks and using a dual-catalyst system (supported and entrained), the process achieves simultaneous conversion of both materials into lighter hydrocarbon products, reducing the need for separate processing units.

Inventive Principle:

Principle #5Merging (Combining)

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

The process achieves efficient conversion of heavy hydrocarbon feedstocks and plastic waste, producing higher-quality, lower-boiling products while effectively managing impurities and reducing catalyst deactivation, thus enhancing the recycling and upgrading of plastic waste.

Implementation Method 1

using one or more reactors operating in an ebullated bed or a hybrid ebullated-entrained bed, and preferably two successive hydroconversion steps

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

reactors operating in an ebullated bed or a hybrid ebullated-entrained bed

Methodology Applied

Scientific EffectFluidization: Fluidisation

Implementation Method 3

hydroconversion of such a mixed feedstock, including at least one hydroconversion step using one or more reactors

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Data Source

PatentUS20250051659A1Hydroconversion in an ebullated or hybrid ebullated/entrained bed of a feedstock comprising a plastic fraction

Publication Date: 2025.02.13 IFP ENERGIES NOUVELLES

AI summary

The present invention relates to a process for the hydroconversion of a feedstock including a plastic fraction (102), notably derived from plastic waste, and a heavy hydrocarbon fraction (101), notably a heavy hydrocarbon fraction containing a portion of at least 50% by weight, preferably at least 80% by weight, having a boiling temperature of at least 300° C. Hydroconversion involves one or more ebullated bed or hybrid ebullated-entrained bed reactors (20), and preferably two successive hydroconversion steps, in order to produce higher-quality, lower-boiling materials, for example for fuel production purposes, while at the same time allowing waste plastics to be upgraded.