Pyrolysis Oil Upgrading With Polar Solvent Phase Separation

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Solution Overview

Problem

Existing pyrolysis oils derived from plastic and rubber have high olefin content, solid residue, and heteroatom content, which make them unsuitable for direct use as transportation fuels due to instability, blockage risks, and emission concerns, necessitating costly filtration and hydrogenation processes.

Innovation Solution

A process involving treatment of pyrolysis oil with a polar organic solvent to separate into an extract phase and a raffinate phase, reducing unwanted substances like olefins, solid residues, and heteroatoms, thereby upgrading the oil quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pyrolysis oil is used directly as transportation fuel, then high yield (60-70% of feedstock) is achieved, but the quality is low due to high olefin content, solid residue, and heteroatom content causing instability and blockage risks

Engineering Contradiction:

ImproveyieldVSAvoidquality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies extraction by treating pyrolysis oil with a polar organic solvent to separate and remove unwanted substances (olefins, solid residues, heteroatoms) from the oil, thereby improving quality while maintaining high yield

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical composition parameters of pyrolysis oil by reducing olefin content through extraction with polar organic solvents, transforming the oil from unstable to stable for fuel use

Inventive Principle:

Principle #35Parameter changes

2Reliability

If filtration or centrifugation is used to remove solid residue, then solid residue content is reduced, but capital and operation cost significantly increase

Engineering Contradiction:

Improvesolid residue removalVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent introduces a polar organic solvent as an intermediary substance that facilitates the removal of solid residues, olefins, and heteroatoms through chemical interaction, replacing costly mechanical filtration or centrifugation processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces mechanical separation methods (filtration, centrifugation) with a chemical extraction method using polar organic solvents, eliminating the need for expensive mechanical equipment and operations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If hydrogenation is used to reduce olefin level, then olefin content is reduced and stability improved, but capital cost and operation cost are heavily increased

Engineering Contradiction:

ImprovestabilityVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and removes olefins from pyrolysis oil using polar organic solvents, achieving stability improvement without requiring expensive hydrogenation reactions

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses cost-effective polar organic solvents instead of expensive hydrogenation catalysts and equipment, providing an economical approach to reducing olefin content and improving oil stability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If polar organic solvent treatment is applied to reduce olefin content, then olefin level decreases by 10-80% and stability increases, but additional processing step is added

Engineering Contradiction:

ImprovestabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (removal of solid residues, olefins, and heteroatoms) into a single extraction step using polar organic solvents, simplifying the overall process despite adding a treatment step

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 effectively reduces olefin content by 10-80%, solid residue, and heteroatom content, producing a stable pyrolysis oil suitable for use as transportation fuel or chemical feedstock, avoiding costly filtration and hydrogenation.

Implementation Method 1

treating the pyrolysis oil with an upgrading solution to provide a mixture comprising an extract phase and a raffinate phase, wherein the upgrading solution comprises a polar organic solvent

Methodology Applied

Scientific EffectLiquid-liquid extraction: Liquid-Liquid Extraction

Data Source

PatentUS12492347B2Process of upgrading a pyrolysis oil and upgrading solution used therein

Publication Date: 2025.12.09 OXFORD SUSTAINABLE FUELS LIMITED

AI summary

A process for upgrading a pyrolysis oil comprising treating the pyrolysis oil with an upgrading solution to provide a mixture comprising an extract phase and a raffinate phase, wherein the upgrading solution comprises a polar organic solvent, and wherein the pyrolysis oil is a derived from the pyrolysis of plastic or rubber, or a combination thereof, and an upgraded pyrolysis oil prepared by said process.