Recycle-Content Alpha Olefins via Pyrolysis Without Feed Segregation
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Solution Overview
Problem
Existing methods for recycling waste materials into alpha olefins and fatty alcohols are costly, require complex segregation, and lack flexibility in sourcing and incorporating recycle content without additional equipment, posing challenges for large-scale production and infrastructure integration.
Innovation Solution
A method of processing pyrolysis recycle content alpha olefins and fatty alcohols derived from recycled waste, involving pyrolysis and hydrogenation or oxidation processes, allowing for flexible integration into existing manufacturing systems and enabling the tracking and adjustment of recycle content values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methanolysis technologies are used to recycle waste materials, then recycle content can be obtained, but the process requires high purity stream of PET and complex segregation, increasing processing cost
Solution Approach 1:
The patent changes the chemical parameters of the recycling process by using pyrolysis instead of conventional methanolysis. This allows acceptance of a broader range of waste materials including mixed plastics, flexible plastics, and materials with dyes or inks, eliminating the need for complex segregation while reducing processing costs. The pyrolysis process operates under different temperature and atmospheric conditions that enable direct conversion of diverse waste streams into useful chemical feedstocks.
Solution Approach 2:
The pyrolysis-based recycling system provides universality by being able to process multiple types of waste materials through a single integrated process. The system can handle mixed plastics, flexible plastics, and materials containing dyes or inks that would require separate processing in conventional systems. This multi-functional approach consolidates what would otherwise require multiple specialized facilities into one cost-effective operation.
2Ease of manufacture
If waste materials with dyes and inks are recycled, then recycle content can be obtained, but pretreatment and removal of dyes and inks contributes to increased costs
Solution Approach 1:
The patent converts the harmful presence of dyes and inks in waste materials into a benefit by using pyrolysis to directly convert these contaminated materials into useful chemical feedstocks. Instead of requiring costly pretreatment to remove dyes and inks, the pyrolysis process breaks down all organic components including dyes and inks into valuable chemical building blocks, thereby eliminating the need for complex pretreatment facilities and reducing overall processing costs.
3Productivity
If large-scale production facilities process diverse recycle content feedstocks, then productivity increases, but existing equipment cannot handle varied feedstocks without additional expensive equipment
Solution Approach 1:
The pyrolysis-based system provides universality that enables large-scale production facilities to process diverse recycle content feedstocks using existing equipment. The pyrolysis process is inherently flexible and can handle varied feedstock types including mixed plastics, flexible plastics, and materials with contaminants without requiring specialized equipment for each material type. This allows facilities to maintain high productivity while avoiding the need for expensive additional equipment.
4Adaptability or versatility
If gas infrastructure is used to distribute recycle content gas, then distribution capability is achieved, but gas infrastructure commingles gas streams from various sources making dedicated segregation difficult
Solution Approach 1:
The patent uses an intermediary approach by converting recycle content gas into liquid or solid forms for storage and transport, or by using it as fuel directly. This intermediary conversion avoids the need to maintain separate gas infrastructure systems, as the liquid or solid forms can be stored in conventional tanks and transported using existing logistics networks. The intermediary conversion layer enables dedicated tracking and distribution of recycle content without requiring complex segregation in the gas infrastructure.
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
Enables efficient and cost-effective recycling of waste materials into alpha olefins and fatty alcohols, providing flexibility in sourcing and reducing dependency on natural gas or petroleum, while maintaining product quality and environmental sustainability.
Implementation Method 1
pyrolysis of a recycled waste to form a pyrolysis effluent
Implementation Method 2
hydrogenation or oxidation processes
Implementation Method 3
hydrogenation or oxidation processes
Data Source
AI summary
A composition having a recycle content value is obtained by reacting a recycle content feedstock to make a recycle content alpha olefin or by deducting from a recycle inventory a recycle content value applied to an alpha olefin composition. At least a portion of the recycle content value in the feedstock or in an allotment obtained by an alpha olefin manufacturer has its origin in recycled waste and/or pyrolysis of recycled waste and/or in thermal steam cracking of recycle content pyoil.