Waste Plastic Transport in Recycled Carrier Fluid for Catalytic Cracking

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Solution Overview

Problem

Existing methods for recycling waste plastics, such as polyethylene and polypropylene, into valuable chemical and fuel products are inefficient, with conventional recycling methods producing low-quality products and high disposal costs, and current pyrolysis operations yield fuel components of poor quality that cannot be blended in significant amounts.

Innovation Solution

A continuous process using a recycled inert carrier fluid to transport waste plastic feedstocks to a refinery processing unit under catalytic cracking conditions, allowing for the separation and recycling of the carrier fluid, which enhances the dissolution and conversion of waste plastics into higher-quality hydrocarbon products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional pyrolysis methods are used to recycle waste plastics, then fuel products can be produced, but the product quality is poor and cannot be blended in significant amounts

Engineering Contradiction:

Improveproduct qualityVSAvoidblending capacity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the processing parameters by using catalytic cracking instead of conventional pyrolysis, operating at lower temperatures (450-650°C) with catalysts to achieve high-quality hydrocarbon products that meet blending specifications while maintaining high productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a carrier fluid as an intermediary medium to dissolve waste plastics before catalytic cracking, enabling better control over the reaction process and producing higher quality products that can be blended in significant amounts

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If waste plastics are incinerated or landfilled, then disposal is achieved, but environmental harm and loss of valuable resources occur

Engineering Contradiction:

Improvedisposal simplicityVSAvoidenvironmental harm

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful waste plastic problem into a beneficial resource by chemically recycling it into valuable hydrocarbon fuel products through catalytic cracking, eliminating environmental harm while creating economic value

Inventive Principle:

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

Solution Approach 2:

The patent recovers valuable hydrocarbon products from waste plastics through catalytic cracking, preventing them from being discarded as harmful waste while maintaining the simplicity of a continuous processing operation

Inventive Principle:

Principle #34Discarding and recovering

3Productivity

If a continuous processing system is implemented, then productivity increases, but process complexity increases

Engineering Contradiction:

Improverecycling throughputVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements a multi-functional continuous processing system where the catalytic cracking unit simultaneously performs dissolution, cracking, and product separation, increasing productivity while managing complexity through integrated design

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent establishes continuous operation of the catalytic cracking process with continuous feed of waste plastics in carrier fluid and continuous removal of hydrocarbon products, maintaining high productivity through uninterrupted processing

Inventive Principle:

Principle #20Continuity of useful action

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 increases the hydrocarbon yield from waste plastics to up to 98% and reduces the carbon footprint, providing positive economic benefits and thermal energy savings.

Implementation Method 1

forming a solution comprising (i) about 1 to about 40 wt. %, based on the total weight of the solution, of one or more waste plastic feedstocks and (ii) a recycled inert carrier fluid

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

processing the solution comprising the one or more waste plastic feedstocks and the recycled inert carrier fluid in the presence of a catalyst under catalytic cracking conditions

Methodology Applied

Scientific EffectCatalytic cracking: Catalysis

Implementation Method 3

separating the recycled inert carrier fluid from the processed first solution

Methodology Applied

Scientific EffectPhase separation: Density Gradient

Data Source

PatentUS12473496B2Processes for transporting waste plastics to a refinery processing unit

Publication Date: 2025.11.18 CHEVRON USA INC

AI summary

A continuous process for transporting a waste plastic feedstock to a refinery processing unit, includes forming a solution containing (i) about 1 to about 40 wt. %, based on the total weight of the solution, of one or more waste plastic feedstocks and (ii) a recycled inert carrier fluid received from a refinery processing unit, and processing the solution comprising the one or more waste plastic feedstocks and the recycled inert carrier fluid in the presence of a catalyst under catalytic cracking conditions.