Waste Plastic Pyrolysis Oil Refining via Sulfur-Modified Catalyst
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Solution Overview
Problem
The existing methods for producing refined hydrocarbons from waste plastic pyrolysis oil face challenges such as the formation of ammonium salt, catalyst deactivation, and adhesion of impurity particles in reactors, leading to reduced process efficiency and durability due to high contents of chlorine, nitrogen, and other impurities.
Innovation Solution
A method involving dehydration of waste plastic pyrolysis oil using a mixed solution with washing water and a demulsifier, followed by hydrotreating with a sulfur source in the presence of a molybdenum-based catalyst, and dewaxing to minimize impurities and maintain catalyst activity, while applying alternating current voltage to prevent particle adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If waste plastic pyrolysis oil is hydrotreated with hydrogen in the presence of a hydrotreating catalyst, then impurities such as chlorine, nitrogen, and oxygen are removed, but ammonium salt (NH4Cl) is formed causing corrosion and process issues
Solution Approach 1:
The patent extracts and removes nitrogen-containing compounds from waste plastic pyrolysis oil through a specific hydrotreating process using a sulfur-containing catalyst. This prevents nitrogen from reacting with HCl to form ammonium salt, thereby eliminating the harmful effect while still removing other impurities like chlorine and oxygen.
Solution Approach 2:
The patent converts the harmful chlorine impurity into beneficial use by having it react with hydrogen to form HCl, which then reacts with the sulfur-containing catalyst to form sulfur chloride compounds that enhance catalyst activity. This transforms chlorine from a harmful impurity into a component that maintains catalyst performance.
2Manufacturing precision
If conventional hydrotreating is performed to remove impurities, then refined oil is produced, but catalyst activity decreases over time due to adhesion of impurity particles
Solution Approach 1:
The patent performs preliminary treatment of waste plastic pyrolysis oil to remove particles and large impurities before the hydrotreating process. This preliminary filtration prevents impurity particles from adhering to the catalyst during hydrotreating, maintaining catalyst activity and extending its operational life while still achieving high refined oil quality.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst by incorporating sulfur compounds, which alter the catalyst's surface properties and resistance to impurity adhesion. This parameter change enables the catalyst to maintain its activity for longer periods while continuously producing high-quality refined oil.
3Loss of time
If waste plastic pyrolysis oil is directly refined without preliminary treatment, then processing time is reduced, but impurity content in refined hydrocarbons remains high
Solution Approach 1:
The patent merges multiple treatment functions into a single integrated hydrotreating process. The sulfur-containing catalyst simultaneously performs multiple tasks: removing impurities (chlorine, nitrogen, oxygen), preventing ammonium salt formation, and maintaining catalyst activity. This consolidation achieves high refined hydrocarbon quality without requiring separate preliminary treatment steps, thus minimizing processing time.
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 effectively reduces the content of impurities like chlorine, nitrogen, and olefins, maintains catalyst activity for long-term operation, and prevents particle adhesion, resulting in refined hydrocarbons with improved quality and process efficiency.
Implementation Method 1
hydrotreating with a sulfur source in the presence of a molybdenum-based catalyst
Implementation Method 2
applying alternating current voltage to prevent particle adhesion
Data Source
AI summary
The present disclosure relates to a method and system for producing refined hydrocarbons from waste plastic pyrolysis oil. The method and system for producing refined hydrocarbons from waste plastic pyrolysis oil according to the embodiments of the present disclosure may minimize formation of an ammonium salt (NH4Cl) and may prevent an adhesion phenomenon of impurity particles in a reactor in a refining process of waste plastic pyrolysis oil containing impurities including chlorine and nitrogen. In addition, the method and system for producing refined hydrocarbons according to the embodiments of the present disclosure may have excellent refining efficiency and may implement a long-term operation of a process because deactivation of a catalyst used in the process is prevented, and may produce refined hydrocarbons having a low content of impurities and a low content of olefins from waste plastic pyrolysis oil.