Polymeric Waste Coker Processing for Circular Polymer Production
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Solution Overview
Problem
Existing processing systems for polymeric waste recycling require substantial initial capital costs and a constant supply of waste feedstock, and coker gas derived from polymeric waste presents challenges due to high sulfur, paraffin, and halide content, necessitating extensive pre-treatment and fractionation.
Innovation Solution
Integrate polymeric waste co-processing in cokers to produce coker gas with reduced sulfur and paraffin content, followed by olefin recovery and polymerization to form circular chemical products such as olefins and polymers, utilizing existing coking units to reduce capital costs and pre-treatment needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dedicated processing systems are used for polymeric waste recycling, then production of circular chemical products is achieved, but substantial initial capital costs are required
Solution Approach 1:
The patent combines polymeric waste recycling with an existing coking unit to produce circular chemical products. By merging the waste recycling function with the coking process, the system leverages existing infrastructure and processing capabilities, thereby reducing the need for substantial new capital investment while still achieving the production of circular chemical products from polymeric waste.
Solution Approach 2:
The coking unit is designed to handle multiple feedstocks including polymeric waste alongside traditional coking operations. This multi-functionality allows the existing unit to serve dual purposes: conventional coking and polymeric waste recycling, thereby avoiding the need for dedicated separate processing systems and reducing initial capital costs.
2Ease of manufacture
If dedicated processing systems are used for polymeric waste recycling, then production of circular chemical products is achieved, but a constant supply of waste feedstock is required
Solution Approach 1:
The coking unit's multi-functionality allows it to process both polymeric waste and traditional coking feedstocks. This versatility ensures that the system can maintain operation even when waste feedstock supply is intermittent, as the unit can switch between or combine different feedstock types, thereby reducing dependency on a constant waste supply.
3Productivity
If coker gas is used for chemical production, then production of circular chemical products is achieved, but high sulfur, paraffin, and halide content necessitates extensive pre-treatment
Solution Approach 1:
The patent converts the harmful sulfur, paraffin, and halide content in the coker gas into beneficial aspects of the circular chemical production process. By integrating the coking unit with the chemical production system, these contaminants are managed within the integrated process flow, reducing the need for extensive external pre-treatment while still enabling productive chemical synthesis.
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
This approach enhances the value of coker gas for chemical production by increasing olefin content, reducing pre-treatment requirements, and producing circular chemical products with improved economics and efficiency.
Implementation Method 1
converting the coker gas into at least a polymer
Implementation Method 2
coker gas has an olefin content of about 10 wt % to about 30 wt %
Data Source
AI summary
Systems and methods are provided for integration of polymeric waste co-processing in cokers to produce circular chemical products from coker gas, including a method of producing circular chemical products comprising: providing a coker gas that is at least partially derived from polymeric waste, wherein the coker gas has an olefin content of about 10 wt % to about 30 wt %, a sulfur content of about 0.5 wt % to about 5 wt %, and a total halide content of about 1 wppm to about 150 wppm; and oxygen-containing compounds in an amount of about 0.5 wt % to about 15 wt %; and converting the coker gas into at least a polymer.