Plastic Pyrolysis Reactor Heating for Scalable Polyolefin Recycling
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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 system for pyrolyzing plastic feedstock comprising post-consumer and/or post-industrial plastics using energy transfer apparatuses, including pyrolysis reactors that heat the feedstock to temperatures between 200° C. and 1,000° C. at an average rate of 0.80 kW per pound of product per hour or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pyrolysis methods are used to recycle mixed polyolefin streams, then plastic waste can be converted into hydrocarbon products, but the energy consumption is high and industrial scalability is limited
Solution Approach 1:
The patent applies parameter changes by optimizing the pyrolysis temperature range (200-1,000°C) and controlling heating rates to achieve efficient plastic decomposition. The system adjusts operational parameters such as residence time, temperature profiles, and energy input rates to maximize product yield while minimizing energy consumption, enabling industrial-scale recycling of mixed polyolefin streams
Solution Approach 2:
The patent implements dynamic control of the pyrolysis process through variable heating rates and temperature profiles. The system dynamically adjusts energy input based on feedstock composition and desired product specifications, allowing flexible operation across different plastic types and scales, thereby improving both productivity and energy efficiency
2Ease of manufacture
If pyrolysis reactors heat plastic feedstock to high temperatures, then plastic waste is effectively converted into hydrocarbon-based compositions, but energy consumption increases
Solution Approach 1:
The patent replaces conventional thermal heating systems with microwave energy transfer apparatuses. This substitution enables direct volumetric heating of the plastic feedstock throughout the reactor, significantly improving heating efficiency and reducing overall energy consumption while maintaining effective conversion of mixed polyolefin streams into hydrocarbon products
Solution Approach 2:
The patent employs periodic heating cycles with controlled temperature ramps and holding periods. The system alternates between heating phases and maintenance phases, optimizing energy utilization by applying heat only when and where needed during the pyrolysis process, thereby reducing total energy consumption while ensuring complete conversion
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 plastic waste into hydrocarbon-based compositions, addressing the challenge of recycling mixed polyolefin streams and producing industrially significant products.
Implementation Method 1
one or more pyrolysis reactors configured for receiving and pyrolyzing the plastic feedstock
Implementation Method 2
heating the feedstock in the reactor vessel's internal volume to a temperature between 200° C. and 1,000° C.
Implementation Method 3
one or more energy transfer apparatuses configured for receiving the plastic feedstock and applying energy to the plastic feedstock
Data Source
AI summary
Disclosed herein are methods for pyrolysis of plastic feedstock comprising post-consumer and/or post-industrial plastics. In various implementations, the methods include directing the plastic feedstock into an internal volume of a reactor vessel, and pyrolyzing the plastic feedstock in the internal volume of the reactor vessel.