Continuous Liquefaction and Filtration System for Waste Plastic
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Solution Overview
Problem
Conventional plastic recycling methods are ineffective in treating all types of plastic waste, leading to increased volumes of discarded plastics ending up in landfills or incinerators, and there is a need for an efficient and safe liquefaction and filtration system to process plastic waste for further thermochemical treatments.
Innovation Solution
A continuous liquefaction and filtration system that includes a first device to melt and filter solid waste plastic, with a second device maintaining the plastic in a molten phase, a feeding system, extractors, and a vacuum unit to control pressure, allowing for the efficient breakdown of carbon bonds and removal of residues like metals and stones, enabling the use of the resulting products in further thermochemical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mechanical recycling is used, then some types of plastics can be recycled, but it cannot treat all types of plastic waste effectively
Solution Approach 1:
The patent applies parameter changes by transforming the physical state of plastic waste from solid to liquid through controlled heating and temperature management. The system uses multiple heating zones with different temperature parameters to achieve complete liquefaction of various plastic types, enabling universal treatment regardless of plastic category.
Solution Approach 2:
The core invention utilizes phase transitions by converting solid plastic waste into liquid state through systematic heating. The process maintains plastic in molten phase through controlled temperature zones, allowing residues to separate and be filtered out, thereby enabling treatment of all plastic types through state change rather than mechanical processing.
2Productivity
If liquefaction process is applied to break carbon bonds, then lower molecular weight fractions are produced for further processing, but residues like metals and stones remain in the molten plastic
Solution Approach 1:
The patent implements extraction by removing residues from the molten plastic through a filtration system. A filter is positioned in the path of molten plastic flow to separate and extract unwanted residues such as metals and stones, allowing only the purified liquid plastic to proceed to further processing stages.
Solution Approach 2:
The system applies segmentation by dividing the treatment process into distinct functional zones: heating zones for liquefaction, a filtration zone for residue removal, and collection zones for different products. This segmentation allows each stage to address specific aspects of the problem independently, with filtration specifically targeting residue removal.
3Productivity
If a continuous liquefaction and filtration system is implemented, then efficient treatment of plastic waste is achieved, but the device complexity increases with multiple components
Solution Approach 1:
The patent applies merging by combining multiple functions into integrated components. The heating elements serve both as heat sources and as structural components of the reaction chambers. The filtration system is integrated into the flow path rather than being a separate post-processing unit, reducing overall system complexity while maintaining continuous operation.
Solution Approach 2:
The system employs multi-functionality where a single continuous processing unit performs liquefaction, filtration, and product separation. The same heating zones that melt the plastic also maintain the molten state for filtration, and the filter serves both as a separation device and a protective element for downstream equipment, reducing the need for dedicated single-purpose components.
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 system effectively liquefies and filters plastic waste, breaking carbon bonds to create lower molecular weight fractions suitable for further processing, while removing residues, thus enhancing the efficiency and safety of plastic waste treatment and enabling its utilization in applications like pyrolysis and extrusion systems.
Implementation Method 1
A vacuum unit is in communication with the first device and the second device. The vacuum unit is configured to control a pressure level within the continuous liquefaction and filtration system.
Implementation Method 2
The solid waste plastic material is then heated in the first device, where it melts and forms molten plastic.
Implementation Method 3
A first device configured to melt and filter solid waste plastic material
Data Source
AI summary
A continuous liquefaction and filtration system has a first device configured to melt and filter solid waste plastic material. A second device is in communication with the first device, and configured to melt solid waste plastic material. A feeding system is configured to feed waste plastic material into the first device. A vacuum unit is in communication with the first device and the second device. The vacuum unit configured to control a pressure level within the system. A method of processing solid waste plastic including the steps of providing the system and solid waste plastic; inserting the solid waste plastic into the first device; heating the solid waste plastic material; extracting the molten plastic with one of the extractors; sending a portion of the molten plastic to second device and recirculating another portion in the first device; and extracting the melt polymers.