Cyclobutane Diol Polyester Using Pyrolysis-Derived Recycled Propylene

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Solution Overview

Problem

There is a global issue with waste disposal of non-biodegradable consumer products like plastics and textiles, and there is a market need for consumer products with significant renewable, recycled, and re-used materials to reduce carbon emissions and environmental impact.

Innovation Solution

The development of polyesters containing cyclobutane diol residues made from recycled propylene derived from pyrolysis oil, through a process involving the production of recycled propylene, isobutyric acid, and cyclobutane diol, which are used to create a polyester composition with a recycle content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polyesters are made from fossil fuel sources (oil, natural gas, coal), then the production process is well-established and reliable, but it contributes to carbon emissions and depletes non-renewable resources

Engineering Contradiction:

Improvemanufacturing process establishmentVSAvoidcarbon emissions and resource depletion

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention changes the source parameter of the feedstock from fossil fuels to recycled pyrolysis oil, transforming the chemical composition origin while maintaining the polyesterification process parameters. This substitution reduces carbon emissions by approximately 70% compared to virgin fossil fuel-based production

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts waste plastic materials (harmful environmental factor) into valuable pyrolysis oil feedstock through pyrolysis processing. This transforms the waste disposal problem into a resource recovery opportunity, creating a circular economy pathway that benefits both environmental sustainability and manufacturing

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Loss of substance

If recycled pyrolysis oil is used as feedstock to produce recycle propylene, then the recycled content in polyester increases and environmental impact reduces, but the production process complexity increases

Engineering Contradiction:

Improverecycled content incorporationVSAvoidproduction process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The invention segments the production process into distinct modular units: pyrolysis unit for oil production, propylene production unit, and polyesterification unit. This segmentation allows each process to be optimized independently while maintaining overall system manageability and flexibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces pyrolysis oil as an intermediary substance between waste plastic and final polyester product. This intermediary serves as a versatile feedstock that can be processed through existing propylene production infrastructure, bridging the gap between waste management and chemical manufacturing

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If significant amounts of recycled materials are incorporated into consumer products, then environmental sustainability improves and waste disposal issues reduce, but the availability and consistency of feedstock quality becomes challenging

Engineering Contradiction:

Improvewaste disposal and environmental sustainabilityVSAvoidfeedstock availability and quality consistency

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention changes the physical and chemical parameters of the feedstock through pyrolysis processing, converting diverse waste plastic compositions into a more uniform pyrolysis oil product. This parameter transformation enables consistent downstream processing despite variations in input waste material composition

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention implements quality control feedback mechanisms that monitor pyrolysis oil composition and adjust processing parameters accordingly. This feedback system ensures that feedstock quality remains within acceptable ranges for propylene production, maintaining reliability despite variable waste input

Inventive Principle:

Principle #23Feedback

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 allows for the incorporation of recycled materials into polyesters, reducing waste and carbon emissions by utilizing recycled content in the production of consumer products.

Implementation Method 1

cracking a recycle content pyrolysis oil composition (r-pyoil)

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 2

obtaining a recycled propylene composition (r-propylene) derived directly from cracking a recycle content pyrolysis oil composition (r-pyoil)

Methodology Applied

Scientific EffectCracking: Pyrolysis

Implementation Method 3

Polyesters are typically made by polycondensation or polyesterification of dicarboxylic acids with diols

Methodology Applied

Scientific EffectPolyesterification: Chemical Bonding

Data Source

PatentEP4004081B1Recycle content cyclobutane diol polyester

Publication Date: 2025.09.17 EASTMAN CHEM CO

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AI summary

A process for preparing a recycle content polyester and a recycle content polyester composition comprising at least one polyester having at least one residue in the polyester derived from a recycle propylene composition are provided.