Recycled Plastic Syngas Cellulose Ester Compositions

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Solution Overview

Problem

There is a global issue with waste disposal of non-biodegradable consumer products like plastics and polymers, which poses environmental sustainability challenges, and there is a market need for products made from renewable, recycled, and biodegradable materials to reduce waste and carbon emissions.

Innovation Solution

The development of cellulose esters made from cellulose and organic compounds derived from recycled materials, where recycled plastic content syngas is used to produce cellulose esters with substituents on anhydroglucose units, enabling the creation of biodegradable and compostable products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cellulose esters are made from conventional organic acids derived from fossil fuels, then the material properties and performance are maintained, but the environmental sustainability and renewable content are reduced

Engineering Contradiction:

Improvematerial performanceVSAvoidfossil fuel content

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent changes the source parameter of the organic acid from fossil fuel-based to syngas-derived (from recycled plastics and biomass). This parameter change maintains the chemical functionality needed for cellulose ester performance while improving sustainability metrics by reducing fossil fuel dependence and increasing renewable content.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The syngas production process serves multiple functions: it converts recycled plastic waste into useful chemical feedstocks, produces organic acids for cellulose ester synthesis, and simultaneously reduces landfill waste and fossil fuel consumption. This multi-functionality addresses both material performance and environmental sustainability goals.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of substance

If recycled plastics are incorporated into syngas feedstock, then the recycled content and waste reduction are improved, but the process complexity and feedstock handling requirements increase

Engineering Contradiction:

Improverecycled contentVSAvoidgasification process

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent combines recycled plastic waste with traditional biomass feedstocks in the gasification process. This merging approach allows the system to handle diverse feedstock types through a single integrated gasification unit, simplifying overall waste management infrastructure while maximizing recycled content incorporation and syngas production efficiency.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If cellulose esters are designed to be biodegradable and compostable, then the environmental sustainability is improved, but the application range and material durability may be reduced

Engineering Contradiction:

Improveenvironmental impactVSAvoidapplication range

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent creates cellulose esters with specific substituent patterns and molecular weight distributions that provide controlled biodegradability. By adjusting the degree of substitution and chain length, the material can be tailored to exhibit appropriate durability for its intended application while maintaining the capacity for biodegradation under specific environmental conditions, thus balancing performance with sustainability.

Inventive Principle:

Principle #3Local quality

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 approach allows for the production of biodegradable and compostable cellulose ester products that incorporate recycled content, reducing waste and environmental impact while meeting market demands for sustainable materials.

Implementation Method 1

preparing a recycled plastic content syngas in a synthesis gas operation by gasifying a feedstock containing a solid fossil fuel source and at least some content of recycled plastics

Methodology Applied

Scientific EffectGasification:

Implementation Method 2

reacting said at least one cellulose reactant to prepare at least one cellulose ester

Methodology Applied

Scientific EffectEsterification: Chemical Bonding

Data Source

PatentUS11447576B2Cellulose ester compositions derived from recycled plastic content syngas

Publication Date: 2022.09.20 EASTMAN CHEM CO

AI summary

A process for preparing a recycle cellulose ester and a recycle cellulose ester composition and articles made with such recycle cellulose esters comprising at least one cellulose ester having at least one substituent on an anhydroglucose unit (AU) derived from recycled plastic content syngas are provided. The recycled plastic content syngas can be obtained by gasifying feedstocks containing a solid fossil fuel such as coal, a plastic, and water. The plastic can be post-consumer or postindustrial plastic.