Process to convert a waste polymer product to a gaseous product
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Solution Overview
Problem
Existing waste polymer recycling methods face inefficiencies, such as the inability to process mixed polymer waste indefinitely, environmental impacts from waste-to-energy conversion, and the quality issues of Plastic-To-Fuel (PTF) processes, which produce fuels unsuitable for transportation.
Innovation Solution
A process involving cryogenic milling of mixed waste polymers into small particles, followed by partial combustion in a rotary kiln or tubular reactor with an active solid biomass matrix, producing syngas with minimal by-products, and further refining this syngas to obtain valuable chemical products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If waste-to-energy conversion is used to process plastic waste, then energy recovery is achieved, but environmental pollution and negative economic impact occur
Solution Approach 1:
The patent replaces the mechanical/thermal combustion system with a biological digestion system. Organic waste is converted to biogas through anaerobic digestion by microorganisms, eliminating the need for high-temperature combustion and associated environmental pollution while maintaining energy recovery functionality
Solution Approach 2:
The patent converts organic waste materials that would otherwise be pollutants into valuable biogas energy and nutrient-rich digestate. The harmful organic matter is transformed into beneficial energy resources and fertilizers through biological conversion processes
2Quantity of substance
If Plastic-To-Fuel processes are used to convert waste polymers, then fuel production is achieved, but the fuel quality is insufficient for transportation use
Solution Approach 1:
The patent changes the fundamental conversion parameters from thermal cracking at high temperatures to biological digestion at moderate temperatures. This parameter change produces biogas with different compositional characteristics (higher hydrogen content, lower carbon chain length) that is suitable for various energy applications including transportation
3Loss of substance
If mechanical recycling is used to process waste polymers, then material recovery is achieved, but only 50% of plastic waste can be reused and the remaining 50% must be disposed
Solution Approach 1:
The patent creates a universal processing system that can handle all types of organic waste materials (plastics, food waste, agricultural residues) through anaerobic digestion. This multi-functional approach converts previously non-recyclable mixed waste into valuable biogas and digestate, eliminating the need to separate materials for different recycling streams
Solution Approach 2:
The patent recovers energy and nutrients from waste materials that would otherwise be discarded. The anaerobic digestion process converts organic matter into biogas for energy production and digestate for fertilizer use, transforming waste disposal into resource recovery
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 method effectively converts mixed waste polymers into stable syngas with minimal liquid by-products, enabling the production of high-quality fuels and chemicals, while reducing environmental impact and optimizing the use of catalysts.
Implementation Method 1
partial combustion of the polymer particles by contacting the polymer particles with oxygen to obtain a syngas comprising of carbon monoxide and hydrogen
Implementation Method 2
partial oxidation of the polymer particles in a tubular reactor with axial mixing means
Implementation Method 3
the polymer particles are comprised in an active solid biomass matrix as a pellet or briquette
Data Source
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AI summary
The invention is directed to a process to convert a waste polymer product to a gaseous product comprising the following steps: (a) cryogenic milling of the waste polymer product to obtain polymer particles and (b) partial combustion of the polymer particles by contacting the polymer particles with oxygen to obtain a syngas comprising of carbon monoxide and hydrogen. In step (a) liquid nitrogen is suitably used and in step (b) an oxygen containing gas is suitably used as obtained in the same air separation process.