Waste Plastic Pyrolysis Oil Refining via Two-Reactor Hydrotreating
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Solution Overview
Problem
The conventional methods for refining waste plastic pyrolysis oil struggle to convert it into high value-added oils like naphtha and kerosene due to high impurity content and inefficient process conditions, leading to low process efficiency and stability.
Innovation Solution
A method and apparatus involving a two-reactor system where waste plastic pyrolysis oil undergoes primary and secondary hydrotreating reactions followed by a hydrocracking reaction, using heterogeneous catalysts to remove impurities and convert the oil into high value-added hydrocarbon products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional crude oil refining process is applied to waste plastic pyrolysis oil, then the process can be simplified, but the high impurity content (chlorine, nitrogen, metal) makes it difficult to produce high value-added fuel
Solution Approach 1:
The refining process is divided into three distinct sequential stages: hydrotreating to remove impurities, fractionation to separate oil components by boiling point, and hydrocracking to convert heavy components into high-value fuels. This segmentation allows each stage to be optimized independently for its specific function, resolving the contradiction between process simplicity and product quality.
Solution Approach 2:
The hydrotreating stage is performed as a preliminary action before fractionation and hydrocracking to remove chlorine, nitrogen, and metal impurities from the pyrolysis oil. This preliminary purification enables subsequent stages to operate more efficiently and produce higher quality products, addressing the impurity problem before it affects later processing.
2Adaptability or versatility
If conventional hydrotreating method for heavy oil is applied to waste plastic pyrolysis oil, then the method can be used, but process efficiency is lowered and conversion to high value-added oil is difficult
Solution Approach 1:
The patent modifies the hydrotreating parameters (temperature, pressure, catalyst type) specifically for waste plastic pyrolysis oil composition rather than using general heavy oil refining parameters. This parameter optimization enables efficient impurity removal and maintains process applicability while improving productivity for this specific feedstock.
Solution Approach 2:
The patent segments the refining process into three optimized stages rather than using a single conventional hydrotreating method. This segmentation allows each stage to be tailored to the specific needs of pyrolysis oil conversion, improving overall process efficiency and high value-added oil production.
3Manufacturing precision
If severe refining conditions are used to remove impurities, then oil quality improves, but process stability and continuous production capability are compromised
Solution Approach 1:
The patent optimizes operating parameters (temperature, pressure, space velocity) for each refining stage to achieve the minimum necessary conditions for effective impurity removal while maintaining process stability. The hydrotreating stage operates at conditions that remove impurities without compromising continuous operation, resolving the contradiction between quality improvement and process reliability.
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 proposed method achieves a high content of naphtha and kerosene in the refined oil, significantly reduces impurity levels, and operates under milder conditions with improved process efficiency and stability, enabling continuous production of high value-added oil.
Implementation Method 1
a first hydrotreating step of producing first refined oil, from which impurities are primarily removed, by performing a primary hydrotreating reaction on the waste plastic pyrolysis oil in the first reactor under a first hydrotreating catalyst
Implementation Method 2
a hydrocracking step of producing third refined oil containing naphtha and kerosene by performing a hydrocracking reaction on an oil component in a fluid containing the second refined oil introduced from the first region under a hydrocracking catalyst in the second region
Data Source
AI summary
A method and apparatus for refining waste plastic pyrolysis oil has an effect of converting the waste plastic pyrolysis oil into high value-added hydrocarbon oil having a high content of naphtha and kerosene, lowering a content of impurities such as chlorine, nitrogen, oxygen, and metal of the hydrocarbon oil, operating under milder process conditions, having excellent process efficiency, and having high process stability to be able to continuously produce refined oil.