Recycled Cyclobutane Diol Polyester from Pyrolysis-Derived Propylene
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Solution Overview
Problem
There is a global issue with waste disposal of non-biodegradable plastics and polymers, and there is a market need for consumer products containing renewable, recycled, and re-used materials to reduce carbon emissions and environmental impact.
Innovation Solution
The production of polyesters is enhanced by using recycled propylene derived from pyrolysis oil to create cyclobutane diol residues, which are then used as reactants in a reaction scheme to produce polyesters, incorporating recycled content into the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyesters are made from fossil fuel sources (oil, natural gas, coal), then the manufacturing process is simple and well-established, but the environmental sustainability and carbon emissions are poor
Solution Approach 1:
The patent changes the source parameter of raw materials from fossil fuels to recycled plastic waste, transforming the chemical composition and origin of feedstocks while maintaining the polyesterification process. This parameter change enables the production of polyesters with recycled content that reduces carbon emissions and improves environmental sustainability.
Solution Approach 2:
The patent converts harmful plastic waste that would otherwise be disposed of in landfills or incinerated into valuable polyester raw materials. By pyrolyzing recycled plastic waste to produce pyrolysis oil, which is then converted to cyclic olefin and subsequently to diol reactants, the process transforms environmental harm into economic and environmental benefit.
2Object-affected harmful factors
If recycled plastic waste is pyrolyzed to produce pyrolysis oil and then converted to polyester reactants, then the recycled content and environmental sustainability are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent segments the complex recycling process into distinct modular stages: (1) pyrolysis of plastic waste to produce pyrolysis oil, (2) conversion of pyrolysis oil to cyclic olefin, (3) conversion of cyclic olefin to diol reactants, and (4) polyesterification. This segmentation allows each stage to be optimized independently and facilitates integration with existing polyester manufacturing infrastructure.
Solution Approach 2:
The patent uses pyrolysis oil as an intermediary substance that bridges recycled plastic waste and polyester production. The pyrolysis oil serves as a versatile intermediate that can be converted to various chemical feedstocks including cyclic olefin, which then becomes the precursor for diol reactants. This intermediary approach enables flexible integration of recycling into existing polyester manufacturing processes.
3Object-affected harmful factors
If significant amounts of recycled material are incorporated into polyesters, then the environmental sustainability and waste reduction are improved, but the manufacturing precision and product consistency may be affected
Solution Approach 1:
The patent performs preliminary pyrolysis and purification steps to convert recycled plastic waste into standardized pyrolysis oil with consistent chemical composition. This preliminary processing ensures that the downstream polyesterification process receives uniform feedstocks, thereby maintaining product consistency and manufacturing precision despite the use of recycled materials.
Solution Approach 2:
The patent controls and standardizes critical parameters throughout the recycling process, including pyrolysis temperature, residence time, and chemical conversion conditions. By maintaining precise control over these parameters, the process produces diol reactants with consistent molecular weight, purity, and composition, ensuring that the final polyester product meets quality specifications regardless of the recycled content.
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 method allows for the production of polyesters with significant recycled content, reducing waste and carbon emissions by utilizing environmentally friendly raw materials.
Implementation Method 1
cracking a recycle content pyrolysis oil composition
Implementation Method 2
preparing a recycled propylene composition derived directly or indirectly from cracking a recycle content pyrolysis oil composition
Implementation Method 3
Polyesters are typically made by polycondensation or polyesterification of dicarboxylic acids with diols
Implementation Method 4
reacting said at least one polyester reactant to prepare at least one polyester
Data Source
AI summary
Described is a process for preparing a recycle content polyester, the process comprising obtaining a recycled propylene composition derived from cracking a recycle content pyrolysis oil composition made from a waste plastic-containing stream, using the recycled propylene as a feedstock in a reaction scheme to produce a polyester reactant, and reacting the polyester reactant to prepare at least one polyester.