Co-Conversion of Waste Plastics in Fluid Catalytic Cracking Unit

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing processes for converting waste plastics to fuel are not economically viable for small-scale operations and do not meet product specifications due to varying plastic qualities, and they do not integrate effectively with petroleum refinery units, while fluid catalytic cracking units face heat management issues and high coke yields.

Innovation Solution

A catalytic cracking process that co-converts waste plastics with petroleum-derived feedstocks in a Fluid Catalytic Cracking Unit, using a synergistic method involving spray feeding of hydrocarbon feed, hot regenerated catalyst, and thermal decomposition of waste plastics within the riser reactor, followed by separation and fractionation to produce lighter distillate products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If waste plastics are converted using stand-alone conversion units, then waste plastic processing capability is achieved, but product treatment facilities become economically unviable at small scales and product specifications are not met

Engineering Contradiction:

Improvewaste plastic processing capabilityVSAvoideconomic viability of treatment facilities

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent combines waste plastic conversion with an existing Fluid Catalytic Cracking Unit in a co-conversion process. The waste plastics are fed along with hydrocarbon feedstocks into the same riser reactor where they undergo catalytic cracking together with the petroleum feedstock. This integration eliminates the need for separate stand-alone conversion units and their associated product treatment facilities, making the process economically viable while ensuring products meet specifications through the refinery's existing treatment infrastructure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The existing Fluid Catalytic Cracking Unit is made multi-functional by enabling it to process both traditional hydrocarbon feedstocks and waste plastics simultaneously. The unit serves dual purposes: maintaining its primary function of cracking petroleum residues while also converting waste plastics into valuable hydrocarbon products, thereby eliminating the need for dedicated waste plastic conversion facilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If Fluid Catalytic Cracking Unit operates at high severities to increase productivity, then coke yield increases, but excess heat generation in regenerator causes reduction in hot regenerated catalyst flow

Engineering Contradiction:

Improvecracking severityVSAvoidregenerator temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent converts the harmful excess heat generated in the regenerator during high-severity operation into a beneficial resource. The excess heat is utilized to provide the thermal energy required for waste plastic decomposition and catalytic cracking in the riser reactor. This approach transforms the heat management problem into an advantage, enabling high-severity operation while maintaining adequate hot regenerated catalyst flow by utilizing the heat in-situ for the co-conversion process

Inventive Principle:

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

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 effectively converts waste plastics into valuable lighter hydrocarbons like light olefins and gasoline, integrates with existing petroleum refinery units, manages heat in the regenerator, and ensures product quality by treating reaction products alongside hydrocarbon cracking products.

Implementation Method 1

These are contacted by the hot regenerated catalyst supplied to the riser bottom section through a regenerated catalyst standpipe (46) & slide valves (47) from a regenerator vessel (45)

Methodology Applied

Scientific EffectCatalytic cracking: Catalysis

Implementation Method 2

Once the comparatively smaller size molecules are produced from thermal decomposition, these molecules then will be able to contact with the catalyst particles effectively

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 3

The hydrocarbon feedstock is injected into a high velocity (>5 m/s) pneumatic flow riser type cracking reactor where it undergoes catalytic cracking upon contact with the hot micro sized catalyst particles coming at a temperature range of 650-750° C.

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Data Source

PatentUS11421162B2Process for co-conversion of waste plastics and hydrocarbon feedstock

Publication Date: 2022.08.23 INDIAN OIL CORP LTD

AI summary

The present invention relates to a process for converting the waste plastics along with the petroleum feedstock in a Catalytic Cracking Unit, in particular a Fluid Catalytic Cracking Unit employed in petroleum refineries. The invention also provides a method and hardware system to enable waste plastic to fuel conversion along with hydrocarbon catalytic cracking. The invented process aims to convert any type of waste plastic including polystyrene, polypropylene, polyethylene, metal containing Polyethylene-Polypropylene multilayer plastics & other metal containing plastics along with the petroleum derived feedstock such as vacuum gas oil, reduced crude oil, vacuum residue etc. in catalytic cracking unit.