Recycle-Content (C4)Alkanal via Pyrolysis-Oil Cracking
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Solution Overview
Problem
Recycling non-biodegradable waste materials is challenging due to the need for complex segregation, high costs, and dependence on specific recycling processes, and there is a lack of infrastructure for utilizing recycle content in the production of chemical compounds like (C4)alkanal, which is often dependent on natural gas or petroleum.
Innovation Solution
A method of hydroformylating a recycle propylene composition derived from cracking pyrolysis oil to produce (C4)alkanal, integrating propylene manufacturing and (C4)alkanal production facilities, and introducing a recycle content identifier for (C4)alkanal, allowing flexibility in incorporating recycle content without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methanolysis technologies are used to recycle waste materials, then high purity streams can be obtained, but the process requires complicated and detailed segregation of waste streams and high costs
Solution Approach 1:
The patent changes the chemical parameters by using hydroformylation reaction conditions (high pressure, temperature, catalyst system) to convert propylene directly into (C4)alkanal, avoiding the need for physical segregation and purification steps required in conventional methanolysis processes
Solution Approach 2:
The patent extracts only the essential step of propylene conversion to (C4)alkanal from the complex waste recycling process, using hydroformylation to directly produce the desired chemical compound without requiring complete waste stream segregation and purification
2Manufacturing precision
If conventional methanolysis technologies are used to recycle waste materials, then high purity streams can be obtained, but the process costs increase significantly
Solution Approach 1:
The patent changes the chemical parameters by using hydroformylation reaction conditions (high pressure, temperature, catalyst system) to convert propylene directly into (C4)alkanal, avoiding the need for physical segregation and purification steps required in conventional methanolysis processes
Solution Approach 2:
The patent uses a catalyst system that can be easily replaced or regenerated, avoiding the need for expensive, complex purification equipment and processes, thereby reducing overall manufacturing costs while maintaining product quality
3Adaptability or versatility
If gas infrastructure is used to distribute recycle content gas, then existing infrastructure can be utilized, but the gas streams from various sources commingle and cannot be segregated
Solution Approach 1:
The patent uses an intermediary chemical transformation process (hydroformylation) that converts gaseous propylene into liquid (C4)alkanal, which can then be stored and transported using existing liquid infrastructure, avoiding the problem of gas stream commingling while utilizing existing distribution networks
Solution Approach 2:
The patent utilizes phase transition by converting propylene from gaseous state to liquid state through hydroformylation reaction, enabling the use of existing liquid storage and transport infrastructure while avoiding gas stream segregation issues
4Productivity
If additional expensive equipment is installed to establish recycle content in chemical compound manufacture, then recycle content can be maximized, but the equipment investment increases
Solution Approach 1:
The patent uses a universal hydroformylation process that can handle various feedstock types (propylene from different sources including recycle content) through a single reaction system, maximizing recycle content utilization without requiring separate equipment for different feedstocks
Solution Approach 2:
The patent adjusts reaction parameters (pressure, temperature, catalyst concentration) to optimize recycle content incorporation, allowing flexible adjustment of recycle content levels without adding equipment, thereby maximizing productivity within existing 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 recycling of waste materials into (C4)alkanal production, reducing costs and infrastructure requirements, and providing flexibility in using recycle content, independent of natural gas or petroleum sources.
Implementation Method 1
hydroformylating a recycle propylene composition (r-propylene) to thereby produce a hydroformylation effluent comprising (C4)alkanal
Implementation Method 2
r-propylene is derived directly or indirectly from cracking recycle pyoil
Data Source
AI summary
A recycle content ethylene is fed to a reactor to make propionaldehyde having recycle content. The recycle ethylene feedstock is derived directly or indirectly from the cracking of recycle content pyrolysis oil. The cracking of the pyrolysis oil can be conducted in a gas furnace or a split furnace.