Recycled Polyester Production via Pyrolysis Oil Cracking

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Solution Overview

Problem

There is a global issue with waste disposal, particularly of non-biodegradable consumer products like plastics and polymers, which are not effectively recycled or reused, leading to environmental sustainability concerns and a need for products made from renewable, recycled, and reused materials to reduce waste and carbon emissions.

Innovation Solution

A process is developed to produce recycle polyesters using recycled propylene derived from pyrolysis oil, which involves cracking recycled pyrolysis oil to obtain propylene, using it as a feedstock to produce polyester reactants, and reacting these reactants with depolymerized terephthalate polyesters to create polyesters with significant recycled content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polyesters are made from fossil fuel sources (oil, natural gas, coal), then the production process is simple and well-established, but the environmental sustainability is poor and carbon emissions are high

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidenvironmental harm

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the source parameter of raw materials from fossil fuels to recycled waste plastics through pyrolysis conversion. This transforms the chemical composition and origin of feedstocks while maintaining the polyester production process, thereby reducing environmental harm without significantly complicating manufacturing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts waste plastics (harmful environmental factor) into valuable pyrolysis oil through thermal decomposition, which then serves as feedstock for polyester production. This transforms an environmental problem into a beneficial resource, simultaneously addressing waste disposal and sustainable material production

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Ease of manufacture

If waste plastics are disposed of in landfills, then the disposal process is simple, but the environmental sustainability is poor and carbon emissions are high

Engineering Contradiction:

Improvedisposal simplicityVSAvoidenvironmental harm

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent transforms waste plastics from a disposal problem into a valuable resource through pyrolysis. Instead of simple landfilling, the waste is converted into pyrolysis oil that serves as feedstock for polyester production, creating economic value while eliminating environmental harm

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements a recovery system where waste plastics are collected, pyrolyzed to extract valuable oil components, and the resulting products are reused in polyester manufacturing. This closes the material loop and prevents waste from being simply discarded

Inventive Principle:

Principle #34Discarding and recovering

3Quantity of substance

If recycled pyrolysis oil is used as feedstock for polyester production, then the recycled content in the final product is high, but the process complexity increases

Engineering Contradiction:

Improverecycled contentVSAvoidprocess complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent divides the complex recycling process into distinct segments: waste collection, pyrolysis conversion, oil purification, and polyester synthesis. Each segment can be independently optimized and controlled, managing overall process complexity while achieving high recycled content

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses pyrolysis oil as an intermediary substance that bridges waste plastics and polyester production. This intermediary allows the transformation of incompatible materials (waste plastic to polyester monomers) through controlled chemical conversion, enabling high recycled content while managing process complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

4Quantity of substance

If conventional polyester production methods are used, then the production cost is low, but the recycled content in the final product is low

Engineering Contradiction:

Improverecycled contentVSAvoidmanufacturing simplicity

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the feedstock parameter from virgin fossil fuel-based materials to recycled pyrolysis oil. This parameter change increases recycled content while the established polyester synthesis methodology maintains manufacturing simplicity

Inventive Principle:

Principle #35Parameter changes

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 creation of polyesters with substantial recycled content, promoting waste reduction, environmental sustainability, and lowering carbon emissions by incorporating recycled materials into new products.

Implementation Method 1

obtaining a recycled propylene composition (r-propylene) derived directly or indirectly from cracking a recycle content pyrolysis oil composition (r-pyoil)

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 2

obtaining recycle DMT directly or indirectly from the depolymerization of terephthalate polyesters

Methodology Applied

Scientific EffectDepolymerization: Decomposition (biological)

Implementation Method 3

Polyesters are typically made by polycondensation or polyesterification of dicarboxylic acids with diols

Methodology Applied

Scientific EffectPolycondensation: Chemical Bonding

Data Source

PatentUS20220325036A1Process for the preparation of polyesters with recycled monomers from pyrolysis and methanolysis

Publication Date: 2022.10.13 EASTMAN CHEM CO

AI summary

A process for producing recycle polyesters made from organic compounds, e.g., acids and alcohols, derived from recycled, reused or other environmentally favored raw materials by obtaining a recycle monomer composition derived directly or indirectly from cracking a recycle content pyrolysis oil composition and reacting the recycle monomer with recycle DMT obtained directly or indirectly from the depolymerization of terephthalate polyesters to prepare a recycle polyester.