Waste Plastic Hydrocarbon Upgrading via Hydrotreatment and Hydrocracking
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Solution Overview
Problem
Existing methods for upgrading waste plastic to high-quality hydrocarbon components, such as base oils, are hindered by the presence of impurities like chlorine, sulfur, and nitrogen, which affect the refining process and product quality.
Innovation Solution
A method involving the hydrotreatment of a mixture of liquefied waste plastic (LWP) and vacuum gas oil (VGO) or heavy gas oil (HGO) streams, followed by hydrocracking and fractionation, to produce a mixture of purified hydrocarbons with improved viscosity and cold flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If waste plastic is used as feedstock for producing hydrocarbon components, then the production of valuable hydrocarbons is enabled, but impurities such as chlorine, sulfur, and nitrogen are introduced that hinder the refining process and affect product quality
Solution Approach 1:
The patent applies preliminary action by implementing hydrotreatment as a pre-processing step before hydrocracking. This preliminary hydrotreatment step specifically targets the removal of harmful impurities (chlorine, sulfur, nitrogen) from the waste plastic feedstock, thereby preparing the feedstock for subsequent hydrocracking and enabling the production of high-quality hydrocarbon products
Solution Approach 2:
The patent converts the harmful impurities (chlorine, sulfur, nitrogen) present in waste plastic into beneficial outcomes by using hydrotreatment to remove these impurities. The harmful factors are transformed into a cleaning process that produces high-purity hydrocarbons suitable for base oil production, effectively turning the problem of impurity removal into a solution for producing high-quality fuels and chemicals
2Manufacturing precision
If impurities are removed from liquefied waste plastic to improve product quality, then the quality of hydrocarbon components is improved, but the refining process becomes more complex and challenging
Solution Approach 1:
The patent applies segmentation by dividing the refining process into distinct functional steps: hydrotreatment for impurity removal, hydrocracking for hydrocarbon production, and fractionation for product separation. This segmentation allows each step to be optimized independently and simplifies the overall process control while maintaining high product quality
Solution Approach 2:
The patent uses hydrotreatment as an intermediary step between the raw waste plastic feedstock and the final hydrocracking process. This intermediary step removes harmful impurities that would otherwise interfere with the hydrocracking process, thereby simplifying the subsequent refining steps and enabling high-quality product production
3Adaptability or versatility
If base oils are produced from waste plastic to replace fossil oil feedstock, then sustainability is improved, but the viscosity and cold flow properties must meet high demands that are difficult to achieve
Solution Approach 1:
The patent applies parameter changes by using hydrotreatment to modify the chemical composition and molecular structure of the hydrocarbons produced from waste plastic. This process adjusts key parameters such as molecular weight distribution, saturation level, and purity, thereby achieving the required viscosity and cold flow properties for high-quality base oils that meet API Group III+ standards
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
The method effectively removes impurities and enhances the production of high-quality hydrocarbons suitable for base oils and middle distillate fuels, achieving a viscosity index of over 130, which meets API Group III+ standards, while maintaining yield and improving cold flow properties.
Implementation Method 1
subjecting said mixed stream to hydrotreatment for removal of impurities
Implementation Method 2
subjecting the hydrotreated stream to hydrocracking to produce a hydrocracked stream comprising a mixture of purified hydrocarbons
Implementation Method 3
fractionating the hydrocracked stream comprising a mixture of purified hydrocarbons
Data Source
AI summary
A method of upgrading liquefied waste plastic (LWP) to a mixture of purified hydrocarbons is hereby provided. The method includes the steps of providing a feed including liquefied waste plastic (LWP) and a vacuum gas oil (VGO) stream and/or a heavy gas oil (HGO) stream to form a mixed stream, subjecting the mixed stream to hydrotreatment for removal of impurities and to produce a hydrotreated stream, subjecting the hydrotreated stream to hydrocracking to produce a hydrocracked stream including a mixture of purified hydrocarbons and fractionating the hydrocracked stream.