Plastic Pyrolysis Reactor for Mixed Polyolefin Feedstock Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There are few effective options for recycling mixed polyolefin streams of post-consumer and post-industrial plastics into value-added chemical and refinery feedstock products at an industrially significant scale.
Innovation Solution
A reactor system is used to pyrolyze post-consumer and post-industrial plastics, applying heat to convert them into hydrocarbon-based compositions, with specific energy densities and temperatures to produce usable products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pyrolysis is applied to mixed polyolefin streams at industrially significant scale, then value-added chemical and refinery feedstock products can be produced, but effective recycling options remain limited
Solution Approach 1:
The patent applies parameter changes by optimizing pyrolysis temperature ranges (typically 300-700°C), residence time, and heating rates to maximize hydrocarbon yield from mixed polyolefin streams. These parameter adjustments enable effective processing at industrial scale while maintaining product quality suitable for chemical and refinery feedstock applications.
Solution Approach 2:
The patent implements local quality by creating specific zones within the pyrolysis reactor with different temperature profiles and residence times. This allows different regions of the mixed polyolefin feedstock to undergo optimized decomposition conditions, improving overall recycling effectiveness and product distribution for value-added chemicals.
2Quantity of substance
If heating is applied to convert plastics into hydrocarbon products, then useful chemical feedstocks are produced, but energy consumption increases
Solution Approach 1:
The patent merges the pyrolysis process with energy recovery systems where the heat generated from hydrocarbon product combustion or condensation is recirculated to preheat incoming plastic feedstock. This integration reduces external energy input requirements while maintaining high hydrocarbon product yield from the mixed polyolefin streams.
Solution Approach 2:
The patent utilizes phase transitions of hydrocarbon products during condensation and cooling stages to recover latent heat. This recovered thermal energy is then applied to the pyrolysis process, reducing the net energy density required while maintaining effective conversion of plastics to valuable hydrocarbon feedstocks.
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 converts plastics into valuable hydrocarbon products, addressing the recycling challenge and enabling the production of improved chemical and refinery feedstocks.
Implementation Method 1
a reactor for pyrolysis of plastic feedstock comprising post-consumer and/or post-industrial plastics
Implementation Method 2
heating the feedstock in the reactor vessel's internal volume to a temperature of 200° C. or more
Data Source
AI summary
Disclosed herein are reactors for pyrolysis of plastic feedstock comprising post-consumer and/or post-industrial plastics. In various implementations, the reactors include a reactor vessel for receiving and pyrolyzing the plastic feedstock, and one or more heaters for heating the feedstock in the reactor vessel's internal volume.