Liquified Waste Plastic Feed for FCC and Hydrocracking Aromatics
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Solution Overview
Problem
Conventional production routes for aromatic compounds like para-xylene rely on fossil fuel-derived feeds, and there is a need for sustainable alternatives that utilize waste plastics in liquid form for refinery unit operations.
Innovation Solution
A chemical recycling process that liquifies waste plastic, optionally dehalogenates it, and introduces it into fluidized catalytic crackers or hydrocracking units to produce recycled content para-xylene and other organic chemical compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If waste plastic is used as feedstock in chemical recycling processes, then sustainable production of aromatic compounds is achieved, but the solid plastic material cannot be utilized in certain unit operations requiring liquified feeds
Solution Approach 1:
The patent applies parameter changes by transforming the physical state of waste plastic from solid to liquid through liquification processes. This enables the plastic to be compatible with existing refinery equipment that requires liquid feedstocks, while maintaining the sustainable production route. The liquified plastic can then be processed through conventional unit operations like fluidized catalytic cracking and hydrocracking.
Solution Approach 2:
The patent introduces an intermediary liquification step between waste plastic collection and refinery processing. This intermediary process converts solid plastic into liquid form, serving as a bridge that allows existing equipment to handle waste plastic without requiring fundamental design changes to the refinery units.
2Ease of operation
If waste plastic is liquified for use in refinery unit operations, then compatibility with existing equipment is achieved, but additional processing steps are required
Solution Approach 1:
The patent applies preliminary action by implementing the liquification step before the waste plastic enters the refinery unit operations. This preliminary processing ensures the feedstock is in the correct form for existing equipment, and the patent integrates this step into the overall process flow to minimize additional complexity.
Solution Approach 2:
The patent merges the liquification process with existing refinery operations by combining the waste plastic liquification unit with conventional processing units. The liquified plastic is introduced into existing streams and processed through conventional equipment, thereby integrating the new functionality into the existing system rather than creating separate isolated processes.
3Manufacturing precision
If dehalogenation is performed on liquified waste plastic, then quality of feedstock for cracking units is improved, but additional processing time and energy are consumed
Solution Approach 1:
The patent converts the harmful halogen content in waste plastic into a beneficial separation process. By performing dehalogenation, the harmful halogen atoms are removed and separated from the useful hydrocarbon components. This allows the harmful aspect (halogen contamination) to be addressed through a separation process that yields both purified feedstock and recoverable halogen byproducts.
Solution Approach 2:
The patent extracts the harmful halogen components from the liquified waste plastic through dehalogenation processes. This extraction removes the harmful substances while leaving the useful hydrocarbon feedstock intact, improving the quality of the feedstock for cracking units. The extracted halogen can be separated and potentially recovered or disposed of through dedicated streams.
4Manufacturing precision
If pyrolysis and catalytic cracking are both performed on waste plastic, then production of high-purity para-xylene is achieved, but process complexity and capital investment increase
Solution Approach 1:
The patent segments the waste plastic conversion process into distinct functional units: pyrolysis unit for initial thermal decomposition, catalytic cracking unit for breaking down molecular structures, and aromatics complex for producing para-xylene. This segmentation allows each unit to be optimized independently and facilitates modular implementation, reducing overall process complexity while maintaining high purity output.
Solution Approach 2:
The patent applies local quality by tailoring specific processing conditions to each unit operation. The pyrolysis unit uses specific temperature and atmosphere conditions, the catalytic cracking unit uses specific catalyst types and temperatures, and the aromatics complex uses specific separation conditions. This localized optimization of parameters at each stage enables high-purity para-xylene production while keeping each individual unit manageable and efficient.
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 high-purity para-xylene and related compounds with substantial recycled content, utilizing existing equipment and facilities, and allows for the efficient recycling of waste plastics.
Implementation Method 1
introducing at least a portion of the liquified waste plastic stream into a fluidized catalytic cracker (FCC) unit and/or a hydrocracking unit
Implementation Method 2
introducing at least a portion of the liquified waste plastic stream into a fluidized catalytic cracker (FCC) unit and/or a hydrocracking unit
Implementation Method 3
pyrolyzing at least a first portion of the liquified waste plastic to thereby provide a recycled content pyrolysis oil (r-pyoil)
Implementation Method 4
dehalogenating at least a portion of the liquified waste plastic stream to form a halogen-depleted liquified waste plastic stream
Data Source
AI summary
Processes and facilities for producing a recycled content organic chemical compound directly or indirectly from waste plastic. Processing schemes are described herein for converting waste plastic (or hydrocarbon having recycled content derived from waste plastic) into useful intermediate chemicals and final products. The waste plastic can be liquified before being introduced to downstream processing. In some aspects, recycled content aromatics (r-aromatics) can be processed to provide recycled content paraxylene (r-paraxylene), which can then be used to provide recycled content terephthalic acid (r-TPA) and/or recycled content polyethylene terephthalate (r-PET).