Recycle Content Pyrolysis Oil Cracking for Mixed Waste
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Solution Overview
Problem
Recycling waste materials, especially non-biodegradable ones, is economically challenging and often requires expensive processing, with different types of waste necessitating distinct recycling processes, making it difficult for large-scale production facilities to efficiently utilize recycle content feedstocks.
Innovation Solution
A process involving the pyrolysis of recycled waste to produce recycle content pyrolysis oil (r-pyoil) and pyrolysis gas (r-pygas), which can be used to crack olefins in a cracking furnace, producing olefin-containing effluents that are then separated to enhance recycling efficiency and produce valuable hydrocarbon products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive physical sorting of waste materials is performed to achieve pure, single-composition waste volumes, then recycling purity is improved, but processing cost increases
Solution Approach 1:
The patent changes the compositional parameters of the feedstock by accepting mixed waste plastic compositions and using catalytic cracking conditions (temperature, pressure, catalyst type) as adjustable parameters to achieve consistent olefin products from variable feedstock, eliminating the need for expensive sorting to achieve pure compositions
Solution Approach 2:
The cracking process is designed to handle multiple types of waste plastic materials (polyethylene, polypropylene, and other polymers) simultaneously in a single reactor system, making the process universal and eliminating the need for separate processing lines for different waste types
2Reliability
If different recycling processes are used for different types of waste materials, then recycling effectiveness is improved, but process complexity increases
Solution Approach 1:
A single catalytic cracking process is designed to effectively process multiple types of waste plastics (polyethylene, polypropylene, and other polymers) simultaneously, eliminating the need for multiple specialized recycling processes and reducing overall process complexity while maintaining recycling effectiveness
3Object-affected harmful factors
If large-scale production facilities use recycle content feedstocks, then environmental impact is improved, but processing efficiency may worsen due to feedstock variability
Solution Approach 1:
The catalytic cracking process uses adjustable parameters (temperature, pressure, catalyst composition, residence time) to optimize processing efficiency regardless of feedstock variability, allowing large-scale facilities to efficiently process recycle content feedstocks while maintaining high productivity and reducing environmental impact
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 efficient production of olefins and hydrocarbon products from recycled waste, improving recycling efficiency and reducing environmental impact by utilizing recycle content feedstocks in non-biodegradable product manufacturing.
Implementation Method 1
cracking a cracker feedstock comprising a recycle content pyrolysis oil composition (r-pyoil) in at least one furnace coil of a cracker furnace to provide an olefin containing effluent
Implementation Method 2
pyrolyzing a feed stream comprising recycle waste material in a first section of a cracking furnace to provide a stream comprising a recycle content pyrolysis composition (r-pyrolysis stream)
Data Source
AI summary
Processes and systems for making recycle content hydrocarbons, including olefins, from recycled waste material. Recycle waste material may be pyrolyzed to form recycle content pyrolysis oil composition (r-pyoil), at least a portion of which may then be cracked to form a recycle content olefin composition (r-olefin). In some cases, a heavy fraction from the cracker effluent may be used to form a recycle content pyrolysis gasoline composition (r-pyrolysis gasoline).