Recycled Dioctyl Adipate Production via Syngas Segmentation
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Solution Overview
Problem
There is no clear commercial path for recycling dioctyl adipate (DOA), a crucial plasticizer used in PVC and other applications, limiting the recycling of this valuable chemical material.
Innovation Solution
A process is developed to produce recycled dioctyl adipate (r-DOA) by reacting propylene with syngas to form n-butyraldehyde, converting it to 2-ethylhexanol, and then reacting it with adipic acid, while attributing recycled content credits along the chemical pathway, allowing for up to 100% recycled content through the use of waste plastic and digital inventory systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical recycling is used for DOA, then recycling process is simple, but recycled DOA cannot be produced due to lack of clear path
Solution Approach 1:
The recycling process is segmented into two distinct pathways: mechanical recycling for simple processing and chemical recycling for producing recycled DOA. This segmentation allows each method to optimize for its specific function, resolving the contradiction between process simplicity and production capability.
Solution Approach 2:
Syngas serves as an intermediary substance in the chemical recycling pathway, converting waste plastics into a form that can be further processed into recycled DOA. This intermediary step enables the production of recycled DOA while maintaining a structured and manageable process flow.
2Productivity
If chemical recycling pathway is implemented, then recycled DOA can be produced, but process complexity increases
Solution Approach 1:
The complex chemical recycling process is divided into sequential stages: waste plastic conversion to syngas, syngas processing, and DOA synthesis. This segmentation makes the overall complex process more manageable and implementable by breaking it into controllable segments.
Solution Approach 2:
The chemical recycling pathway is designed to handle multiple types of waste plastics through a universal conversion process to syngas, which then feeds into the DOA production process. This multi-functionality reduces the need for separate specialized processes for different plastic types.
3Quantity of substance
If waste plastic is converted to syngas, then recycled content is increased, but tracking and allocating recycled content becomes complex
Solution Approach 1:
A digital inventory system with recycled content credits provides feedback tracking throughout the chemical pathway. This system monitors and records the transformation of waste plastic into syngas and subsequently into recycled DOA, maintaining information about recycled content quantity and origin throughout the process.
Solution Approach 2:
The physical transformation of waste plastic into syngas and then into DOA is accompanied by a digital copy or representation in the form of recycled content credits. This digital tracking system mirrors the physical material flow, enabling precise monitoring without interfering with the chemical processes.
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 process enables the production of r-DOA with significant recycled content, promoting waste plastic recycling and efficient use of existing assets, with the potential for 100% total recycled content in the final product.
Implementation Method 1
reacting a propylene with a syngas to thereby provide an n-butyraldehyde
Implementation Method 2
converting at least a portion of the n-butyraldehyde into a 2-ethylhexanol
Implementation Method 3
reacting at least a portion of the 2-ethylhexanol with an adipic acid to thereby provide a DOA
Implementation Method 4
carbon reforming a first carbon-containing feed comprising waste plastic to thereby produce a first syngas
Implementation Method 5
gasifying a second carbon-containing feed comprising a solid hydrocarbon, a liquid hydrocarbon, and/or a gaseous hydrocarbon to thereby produce a second syngas
Data Source
AI summary
Recycled content dioctyl adipate (r-DOA) is produced using a process and system that applies credit-based recycled content from one or more feed materials to DOA produced from the feed materials.