WO2016175667A1 - Apparatus for processing waste from the polyolefins into liquid fuels and the method for processing waste from polyolefins into liquid fuels - Google Patents

Apparatus for processing waste from the polyolefins into liquid fuels and the method for processing waste from polyolefins into liquid fuels Download PDF

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Publication number
WO2016175667A1
WO2016175667A1 PCT/PL2015/000074 PL2015000074W WO2016175667A1 WO 2016175667 A1 WO2016175667 A1 WO 2016175667A1 PL 2015000074 W PL2015000074 W PL 2015000074W WO 2016175667 A1 WO2016175667 A1 WO 2016175667A1
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Prior art keywords
reactor
premelter
deposits
waste
products
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PCT/PL2015/000074
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French (fr)
Inventor
Piotr Grzybowski
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23 Rs Coras Sp Z O.O.
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Publication of WO2016175667A1 publication Critical patent/WO2016175667A1/en

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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J6/00Heat treatments such as Calcining; Fusing ; Pyrolysis
    • B01J6/008Pyrolysis reactions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/0015Feeding of the particles in the reactor; Evacuation of the particles out of the reactor
    • B01J8/0035Periodical feeding or evacuation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/08Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles
    • B01J8/10Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles moved by stirrers or by rotary drums or rotary receptacles or endless belts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008Controlling the process
    • B01J2208/00017Controlling the temperature
    • B01J2208/00389Controlling the temperature using electric heating or cooling elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008Controlling the process
    • B01J2208/00017Controlling the temperature
    • B01J2208/0053Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00743Feeding or discharging of solids
    • B01J2208/00752Feeding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049Controlling or regulating processes
    • B01J2219/00245Avoiding undesirable reactions or side-effects
    • B01J2219/00252Formation of deposits other than coke

Definitions

  • Apparatus for processing waste from the polyolefins into liquid fuels and the method for processing waste from polyolefins into liquid fuels
  • the present invention relates to the field of polyolefin waste treatment enabling conversion thereof into liquid fuels.
  • the object of the present invention is an apparatus for processing polyolefin waste into liquid fuels and the method conducted with the use of this apparatus.
  • the present waste contains a lot of plastics produced mainly in developed countries.
  • a commonly used polymer is polyethylene and polypropylene. Both of these polymers are polyolefins. They consist solely of carbon and hydrogen and are produced from petroleum.
  • Plastic products have a relatively short life span and end up in the waste stream. In Poland, in about 300 kg of garbage per person per year the plastics consist 1% - 10% by weight. Total production of new polyolefin polymers in the country reaches 600 thousand tons per year and a similar amount of waste from these plastics group can be expected.
  • polyolefin waste is produced in large quantities in certain sectors of the economy, e.g. in the form of used gardening foils, empty fertilizers bags, used packaging (cans) or packaging films.
  • Thermal processing of waste by pyrolysis runs through the decomposition of polymeric macromolecules into short chain products of fuel form.
  • the process of thermal decomposition of polyolefins, a so called thermal cracking is a process known for many years and is used in the processes of refining the crude oil processing.
  • the Polish patent application No. P.332001 describes a method of preparing of liquid fuels from polyolefine wastes, the method comprising heating the particulate polyolefin wastes at a temperature of 180°C to 620°C in the presence of heavy metals silicates as catalyst, used in an amount of from 1% to 30% by weight, calculated on the weight of polyolefin material.
  • Particularly preferred reaction is obtained in the temperature range from 380°C to 450°C, using iron silicate Fe 3+ , cobalt Co 2+ , nickel Ni 2+ , manganese Mn , chromium Cr3 , copper Cu , zinc Zn , cadmium Cd as catalysts. After use the used catalyst can be recycled and reused for the process.
  • a method described in the Polish patent application No. P.342248 involves the catalytic cracking of the molten polymers and separating the resulting products in the rectification column.
  • the gaseous products are used for heating purposes in the installation.
  • Gasoline and oil fractions are received as products and heavy fractions are recycled for re-processing.
  • the process is continuous.
  • the device consists of a premelter connected to the reservoir, wherein a filter and an agitator is arranged, and a valve in a funnel part, wherein the tank is also connected to a rectifying column line, having a valve and a conduit with a tubular reactor filled with a catalyst, under which there is the tank and additionally a pipe reactor is connected by a conduit with a rectifying column which, through the conduit connects to the partial condenser which in turn communicates with the hydraulic closure through the conduit, and in addition the partial condenser is connected by the conduit with the top of the rectification column, wherein the valve for receiving the gasoline fraction is in the conduit and in the middle part of the rectification column there is a valve for discharging oil fraction and the bottom of the rectification column with the conduit containing a valve is connected to the tank.
  • a process for obtaining components of liquid fuels from cracking of polyolefin wastes is described in the Polish patent application No. P.360100.
  • the process consists in that the hydrocarbon products resulting from the cracking of polyolefin wastes are mixed with the mixture of hydrocarbons, wherein the mixture has a temperature of beginning the distillation not lower than 30°C, and a temperature of the end of the distillation not higher than 300°C and substantially does not contain saturated hydrocarbons, and the sulfur content is below 50 ppm and the content of resins in this part of the mixture which corresponds to the gasoline fraction is less than 1 mg/100 ml.
  • the resulting mixture of the cracked products with the mixture of hydrocarbons is submitted to distillation and rectification and separated into patrol fraction, a gas oil fraction and a fraction being an oil component.
  • the weight ratio of mixing cracking products with said mixture of hydrocarbons is from 1 : 4 to 3 : 1.
  • the Polish patent application No. P.371234 discloses a method of obtaining fuel components from waste polyolefms and involves the catalytic cracking of waste polyolefms conducted at atmospheric pressure, at a temperature of about 400°C, with a catalyst of aluminosilicate under such conditions to maintain a constant level in the reactor and a constant temperature. Products leaving the reactor are directed to the condenser so as to maintain a predetermined temperature of the vapor stream after the condenser, and the condensate is separated by distillation so as to obtain the components compliant with the requirements for fuels.
  • polish patent application No. P. 382405 discloses a method for processing waste polyolefin of plastics, which results in obtaining a mixture of liquid hydrocarbons, which may be a component of fuel or after re-distillation, the solvent for the production of waterproof asphalt masses and ecological sulfur- free fuel oil, characterized in that disintegration process is carried out in two stages, wherein the raw material after the sorting and crushing is melted in two sections premelter and then the melted raw material is collected in the heated buffer tank of the melted material, maintained at a temperature of 250°C, where initial sedimentation of solid impurities of the raw material is carried out, these impurities are removed by means of a screw, and then the molten material in powder form is fed after it is mixed with the catalyst into the first stage depolymerization reactors, and then after the depolymerization at a temperature of 300 to 400°C, the vapors pass into the second stage decomposition reactor, wherein further processes of the cracking and reforming of hydrocarbons
  • a method and apparatus system for the thermal catalytic processing of polyolefms to hydrocarbons is described in the Polish patent application No. P.398135.
  • the object of this invention is a method for thermal catalytic processing of polyolefin wastes into hydrocarbons in the dosage forms of components for motor fuels and fuel oils and/or solvents.
  • the method consists in that the particulate and dried feed material and the catalyst slurry with a heavy fraction from the preliminary column separator is subjected to liquefaction, and the resulting feed mixture is fed continuously into the cracking reactor, from which by preliminary separator column the products of thermal degradation of the feedstock in the form of the gaseous fraction and a heavy fraction are taken, then so obtained fractions are subjected to separation in the preliminary column separator and in turn in the fractional column separator to obtain final products.
  • the present invention also provides an apparatus system for the thermal catalytic processing of polyolefins to hydrocarbons, consisting of a series of interconnected devices, namely the storage of the raw material, the crushing device, the separator, the drier, the liquefaction reactor, the catalytic cracking reactor, the preliminary column separator and the fractional column separator with outlet of the final products.
  • the preliminary column separator is connected by a static mixer with the liquefaction reactor, which is equipped with a catalyst feed.
  • the separator is connected with one supply and one discharge opening, and in addition the light fraction and/or solvent tank, the medium fraction tank and the heavy fraction tank are connected to the fractional column separator.
  • a method described in the Polish patent application No. P. 399600 is that the waste is ground and pre-dried, after which it is preheated and melted, and passed to the reaction chamber (Rl, R2), where it is heated by the liquid-metallic jacket heated from the outside, liquefied and cracked at a temperature of 350°C to 450°C, with moderate overpressure.
  • the resulting gas-steam fraction is drained continuously and it partially melts the waste supplied to the inlet of the reactor, and then it subjected to distillation, then cooled in two stages, first in a cooler, where first the fuel oil fraction is withdrawn and the heat recovered from cooling is used to pre-drying of waste.
  • the petrol fraction is discharged to the tank, and water from cooling is used to heat the oil fraction tank with part of non-condensing gases is consumed together with the petrol fraction for heating the reactor, where in a single operation a liquid metal almost completely fills the inner space of the mantle, wherein the process of liquefaction and cracking is preferably carried out simultaneously and parallel in two production lines, and the cracking waste resulting in the process - the quick coke is discharged periodically from the reactor (Rl, R2).
  • the exhaust gases from the combustion of the petrol fraction and not condensable gases are after-burnt in the catalytic afterburner.
  • a gas and steam fraction is discharged through the annular outlet of the reactor (Rl, R2) and to improve the cracking the known catalysts aer used.
  • the present application discloses also a device for processing plastics waste, especially polyolefins.
  • the solution described in WO2010106009 relates to an apparatus for heat treatment, in particular for thermal decomposition of mixtures of oils or waste fractions for recycling which may be mixed with the waste or waste oil, bitumen, tar or the like in a state similar to the paste and shredded plastics of polyolefin type
  • the device is equipped with a heated tank reactor, in which a mixture of oil waste is arranged to a certain height above the gas chamber and the cover above the height of the filling, the reactor has an inlet of mixtures of waste oils which are heat-treated and an outlet for exhaust gas products.
  • the apparatus further comprises at least two mixing tools arranged in vertical position inside a reactor mounted in a rotational manner, wherein each of which has a shaft with a helical stirrer.
  • the bolts of adjacent mixing tools partly overlap each other and are arranged in the reactor in such a way that the stirrers are from the bottom of the reactor to the height of the filling, wherein the reactor has a peripheral wall having a curved inner wall substantially in accordance with the outer contour of the mixing tool coils.
  • the apparatus further includes a drive assembly for driving the shaft of the mixing tools in a rotational manner.
  • the process of thermal decomposition of polyolefins, with the skillful pyrolytic processing of polyolefins may lead to obtaining about 85% of liquid products. They consist of half of the gasoline fraction having a boiling point up to 200°C and half of the oil fraction with a boiling point in a range of 200-340°C.
  • the byproducts are non-condensable gases such as methane, ethane, ethylene, etc., and coke.
  • the entire apparatus performs all the functions such as pre-melting of the raw material, pyrolysis, cleaning of the reactor, and heating the mass streams in such a way as to ensure that effective continuous operation.
  • the object of the present invention the apparatus for polyolefin waste pyrolytic conversion-into liquid fuel products
  • the horizontal reactor connected with the polyethylene waste premelter by the two-way filter on the outlet from the premelter, (1), which has the walls of cylindrical shape, equipped with means for external, diaphragmatic electric or flame heating (4), the agitator (3) is arranged inside this reactor connected with the scraper and the deposits extractor is attached to this reactor (1) such that at its inner side over the surface of its walls there is a fitted ribbon scraper (72) for removing deposits accumulating on the reactor's surface, the drip trough for compacting deposits discharged from the reactor and the ram scraper bucket (75) for removing deposits from the inside of the reactor cooperating with the lock (73) ensuring tightness of the reactor, wherein the reactor (1) is equipped with a feeder with molten polymer from the dispenser and the apparatus also comprises the condenser for condensing products with a zone cooling.
  • the reactor is equipped with an electric mantle (4) with a temperature control system, the thermocouple is preferably arranged by the reactor's surface which controls the heater operation regulator.
  • the reactor is equipped with means for controlling of feeding of the processed molten polymer, which include the molten polymer feeder including rotating (31) cylindrical fitting (32) having slots (33), which in the upper position forms an opening for feeding molten polymer with the premelter and after the rotation, in the lower position forms an opening for discharging to the reactor's space.
  • the apparatus comprises means for controlling rotation of the fitting (32) for controlling the amount of molten polymer fed into the reactor.
  • the premelter is a tank apparatus fed by the processed waste polymer (41), wherein the tubes (42) are arranged by the side walls of the premelter and above its bottom on which the melting of polyolefms takes places, and the premelter has a bottom slightly inclined towards the feeder, which is arranged at the bottom of the premelter.
  • the premelter underneath the bottom has additionally the heating mantle powered by a heat carrier, preferably hot products from the reactor, additionally the premelter comprises the weight (44) to press down loose polymer waste covered from the top, preferably the premelter is equipped with the lift system (45) for lifting and lowering the weight (44).
  • the dispenser At the outlet of the premelter a upstream the dispenser there is the basket filter with a metal mesh (51) with fine mesh arranged in a tight tank (52), wherein the basket filter also comprises an access flap (53) for periodic cleaning.
  • the deposits extractor is a horizontal cylinder heated from the outside or by the heating mantle or by the means of the electric heater (71).
  • the deposits extractor is equipped with a ribbon scraper (72) moving slowly just above the walls of the extractor and scraping the accumulated deposits towards the lock (73).
  • a lock (73) for removing deposits from inside the reactor.
  • the apparatus is equipped with the ram (75) performing a periodic downward movement and crushing gradually deposits accumulated in the lock, wherein the apparatus is also equipped with a damper (76) in the bottom of the lock which clears the lock, wherein the ram (75) pushes outside the portions of the compacted deposits and provides a sealing means for the lock and prevents escaping through the cleared lock any combustible gaseous products from inside the reactor.
  • the present invention also provides a method of polyolefin waste pyrolytic conversion into liquid fuel products, in which the waste is introduced into the premelter where they are heated and where they are melted, then they are passed in a controlled manner from the premelter to the reactor by means of a feeder which provides stabilization of the filling level of the reactor with a treated polymer mass, the pyrolysis reaction is carried in the reactor and gas and steam reaction products are removed from the reactor and directed back to the premelter where while cooling they heat, pre-dry and melt the polyolefin waste while coke deposits are removed from the reactor gradually and ballast impurities existing in the processed waste, using a suitable treatment system - the deposits extractor.
  • a structure of a new type of apparatus for polyolefin waste pyrolytic conversion into liquid fuel products comprising the horizontal reactor, connected with the polyethylene waste premelter by the two-way filter on the outlet with the premelter, which has the walls of cylindrical shape, equipped with means for external diaphragm electric or flame heating, inside this reactor the agitator is connected with the scraper and the deposits extractor is attached to this reactor such that at its inner side over the surface of its walls there is a fitted ribbon scraper for removing deposits accumulating on the reactor's surface, the drip trough for compacting deposits discharged from the reactor and the worm scraper for removing deposits from inside the reactor cooperating with the lock ensuring tightness of the reactor, wherein the reactor is equipped with molten polymer feeder with the dispenser and the apparatus also comprises the condenser for condensing products with zone cooling.
  • the reactor constituting the core of the production plant has a cylindrical shape is electrically or flame diaphragm heated.
  • the ribbon scraper On the inner side of the apparatus just above the surface of its walls the ribbon scraper is moving which removes from the inner surface of the reactor, the accumulating coke deposits and ensures effective heat transfer from the walls of the apparatus to the molten polymer.
  • the ribbon scraper further scrapes any deposits from the inside of the reactor and throws them to the drip trough from which the deposits are continuously removed from the interior of the reactor through a special lock.
  • Such a design solution ensures maintaining continuous operation of the reactor for processing polyolefin waste, stabilization of thermal conditions on the walls of the apparatus which improves homogenization and improvement of the performance of major products, mixing the same reaction mixture and safe disposal of solid waste from inside the reactor.
  • This design solution ensures maintaining continuous operation of the reactor for processing waste polyolefins, stabilization of thermal conditions on the sides of the apparatus which is reflected in the homogenization and improving the performance of the main products, mixing the raw material in the reactor and safe disposal of the solid waste inside the reactor.
  • Fig. 1 shows a block diagram of functions of the apparatus for processing waste poly olefins into liquid fuels
  • Fig. 2 shows a construction scheme of the construction of the reactor for pyrolysis of polyolefin waste
  • Fig. 3 shows a feeder of the raw material drawn from the premelter and fed to the reactor
  • Fig. 4 shows a construction scheme of the premelter
  • Fig. 5 shows a construction scheme of the basket filter
  • Fig. 6 shows the products cooling system
  • Fig. 7 shows a construction scheme of the deposits extractor.
  • the apparatus for processing waste polyolefins into liquid fuels consists of the following connected elements.
  • the main one is the horizontal cylindrical reactor (1) shown in Fig. 2. It is fed with molten polymer.
  • the method of feeding the processed molten polymer is not included in Fig. 2.
  • An agitator (3) rotates on a horizontal axis (2) inside the reactor which performs two functions. This agitator provides maintenance of a layer of molten polymer on the entire inner surface of the reactor and at the same time removes increasing coke layer from the reactor's walls.
  • the reactor is heated by any means, but most conveniently by means of an electric mantel (4) with a temperature control system. It is important to ensure temperature stabilization of the reactor walls.
  • the operation control system of the heater and temperature control of the reactor's walls is not shown in Fig. 2. This is achieved for example by placing at its surface thermocouple controlling the operation of the heater regulator.
  • the same reactor there is a process of depolymerizing of the polymer waste and the formation of low molecular weight products, which leave the reactor in a steam-gas stream.
  • the output of the product stream from the reactor is not illustrated in Fig. 2.
  • the molten polymer feeder shown in Fig. 3 is provided.
  • the cylindrical fitting (32) rotates in the cylindrical space (31) having slots (33). The molten polymer from the premelter flows in To the slot when it is in the upper position.
  • the molten polymer feeder is fed with a molten polymer stream coming from the polymer premelter shown in Fig. 4.
  • the premelter is a tank apparatus fed with a processed waste polymer (41), optionally prepared in advance, for example by grinding, into a form suitable for convenient feeding of the premelter.
  • the pre-treatment of the waste consists in its separation and removal of visible impurities, e.g. metals, glass, wood and products of polymers of a different type. While the removal of the processed waste polyolefins of other types of plastics, PVC in particular, it is recommended that especially difficult to separate the fine solid impurities may be introduced into the premelter because it ensures their separation.
  • the tubes (42) are arranged at the side walls of the premelter and on its bottom, on which there is melting of the polyolefin. The molten polyolefin drip into the space (43) between the tubes and the wall of the premelter where they get warmer and thus liquefy further and then flow gravitationally towards the feeder since the premelter has a bottom slightly inclined towards the feeder.
  • the feeder is positioned at the bottom of the premelter.
  • the feeder is not shown in Fig. 4.
  • the premelter underneath its bottom may also have a heating mantel supplied with a heat carrier, e.g. hot products from the reactor. Such a mantel is not shown in Fig. 4.
  • the heating mantle as well as the tubes arranged at the sides and above the bottom of the premelter are supplied with the hot products stream leaving the reactor. These products from the reactor cool down and condense releasing heat to the heated and melting polymer.
  • Loose polymer waste poured into the premelter are pressed from the top of the weight (44) lifted and lowered e.g. by the lift system (45). The waste pressure from above ensures their better contact with the heating surfaces and their more efficient melting.
  • the tubes (42) with a bonding medium are supplied by the power collector (46) and condensed products together with the condensate leave the heating tube system (42) by means of the exhaust manifold (47).
  • Both the tubes which transfer heat to the melted polyolefin waste and the mantle beneath the premelter have access for periodic maintenance relying on their cleaning and removal of the accumulated deposits such as coke particles. These deposits must be removed because they block the uniform flow of the product stream from the reactor and cause uneven operation of the premelter and reduce the efficiency of heat transfer from the product stream from the reactor to the melted polyolefins waste.
  • the premelter is additionally coated with a thermal insulation from the outside in order to increase its efficiency.
  • the polyolefin layer introduced into the premelter is pressed down toward the bottom of the premelter by the 'means of a ram or the weight.
  • the premelter has a vent through which it any volatile gases and water vapor contained in the waste can escape. Venting the premelter also allows for emergency discharge of large amounts of steam which might arise when a greater amount of water will be introduced to the premelter, e.g., bound earlier in the processed waste.
  • the premelter provides for removal of the water at the stage of melting the raw material to the reactor and protects the reactor from access of water to it in liquid form. Products leaving the reactor and heating diaphragmatic the premelter condense in contact with the colder walls of the premelter forming a liquid phase.
  • Products from the reactor, which did not condensate in the heating portion of the premelter are directed to the diaphragmatic condenser shown in Fig. 6 supplied with hot water and then to the second part of the condenser supplied with cold water.
  • Such a construction constitutes protection against blocking tubes with the products which, after cooling, have a solid form e.g. waxes which are also in the product stream from the reactor. All the condensed products are bonded in the collector and are directed to the storage tank.
  • a basket filter shown in Fig. 5 constructed of a metal mesh (51) with a fine mesh placed in a tight tank (52). This filter stops contaminants present in the processed waste polyolefins.
  • the filter is periodically cleaned by the access flap (53) as it is filling up.
  • the filter is a two-way filter, and during a cleaning work the other one of its parts is working.
  • the valve (53) over it is closed.
  • the filter can be additionally diaphragmaly heated by a products stream from the reactor and/or electric heater to prevent the stream of molten polyolefins from solidifying inside it.
  • a certain amount of solids in the form of coke are also formed.
  • the agitator removes them from the reactor walls. These particles remain in the layer of molten polymer in the reactor and together with the molten polymer from the reactor get in a small stream into the deposits extractor shown in Fig. 7.
  • It is a horizontal cylinder heated from outside or by a heating mantel or by an electric heater (71) as a main reactor.
  • a ribbon scraper (72) is positioned in the deposits extractor moving slowly just above the walls of the extractor and scraping the accumulating deposits in the direction of the lock (73). This direction is the same as the direction (74) the stream of products from the main reactor and passing the deposits extractor to the premelter.
  • a lock (73) for removing the deposits from inside the reactor At the end of the deposits extractor there is a lock (73) for removing the deposits from inside the reactor.
  • This lock at the same time ensures the tightness and prevents the escape of the gaseous products filling the deposits extractor.
  • the ram (75) performs periodic downward movement and crushes gradually the deposits accumulating in the lock.
  • a latch (76) shifts in the bottom of the lock and clears the blockage in the lock and the ram (75) pushes outside the portions of the compacted deposits
  • the ram (75) serves at this moment as a sealant of the lock and prevents escaping through the cleared lock combustible gaseous products from inside the reactor.
  • the apparatus provides the safe operation of the process, controlled pyrolysis reaction of waste polyolefins conditions and thus achievement of better yields of liquid products, provides tightness (lock for the deposits), enables continuous operation for a very long period of time (lock, the deposits extractor, the two-way filter), maximum utilization of heat by supplying the premelter with gaseous products from the main reactor.

Abstract

The present invention relates to a construction of a new type apparatus for polyolefin waste pyrolytic conversion into liquid fuel products comprising a horizontal reactor connected with the polyethylene waste premelter through the two-way filter at the outlet from the premelter, which has the walls of cylindrical shape, equipped with means for external electric or flame diaphragm heating, wherein the agitator connected with the scraper is arranged inside this reactor and a deposits extractor is attached to this reactor such that at its inner side over the surface of its walls there is a fitted ribbon scraper for removing deposits accumulating on the reactor's surface, the drip trough for compacting deposits discharged from the reactor and the worm scraper for removing deposits from inside the reactor cooperating with the lock ensuring tightness of the reactor, wherein the reactor is equipped with molten polymer feeder with a dispenser and the apparatus also comprises the condenser with zone cooling for condensing products. The invention also relates to the method of polyolefin waste pyrolytic conversion into liquid fuel products.

Description

Apparatus for processing waste from the polyolefins into liquid fuels and the method for processing waste from polyolefins into liquid fuels
The present invention relates to the field of polyolefin waste treatment enabling conversion thereof into liquid fuels. The object of the present invention is an apparatus for processing polyolefin waste into liquid fuels and the method conducted with the use of this apparatus.
The present waste contains a lot of plastics produced mainly in developed countries. A commonly used polymer is polyethylene and polypropylene. Both of these polymers are polyolefins. They consist solely of carbon and hydrogen and are produced from petroleum. Plastic products have a relatively short life span and end up in the waste stream. In Poland, in about 300 kg of garbage per person per year the plastics consist 1% - 10% by weight. Total production of new polyolefin polymers in the country reaches 600 thousand tons per year and a similar amount of waste from these plastics group can be expected. Besides scattered throughout the municipal waste stream polyolefin waste is produced in large quantities in certain sectors of the economy, e.g. in the form of used gardening foils, empty fertilizers bags, used packaging (cans) or packaging films. Thermal processing of waste by pyrolysis runs through the decomposition of polymeric macromolecules into short chain products of fuel form. The process of thermal decomposition of polyolefins, a so called thermal cracking is a process known for many years and is used in the processes of refining the crude oil processing.
The Polish patent application No. P.332001 describes a method of preparing of liquid fuels from polyolefine wastes, the method comprising heating the particulate polyolefin wastes at a temperature of 180°C to 620°C in the presence of heavy metals silicates as catalyst, used in an amount of from 1% to 30% by weight, calculated on the weight of polyolefin material. Particularly preferred reaction is obtained in the temperature range from 380°C to 450°C, using iron silicate Fe3+, cobalt Co2+, nickel Ni2+, manganese Mn , chromium Cr3 , copper Cu , zinc Zn , cadmium Cd as catalysts. After use the used catalyst can be recycled and reused for the process.
A method described in the Polish patent application No. P.342248 involves the catalytic cracking of the molten polymers and separating the resulting products in the rectification column. The gaseous products are used for heating purposes in the installation. Gasoline and oil fractions are received as products and heavy fractions are recycled for re-processing. The process is continuous. The device consists of a premelter connected to the reservoir, wherein a filter and an agitator is arranged, and a valve in a funnel part, wherein the tank is also connected to a rectifying column line, having a valve and a conduit with a tubular reactor filled with a catalyst, under which there is the tank and additionally a pipe reactor is connected by a conduit with a rectifying column which, through the conduit connects to the partial condenser which in turn communicates with the hydraulic closure through the conduit, and in addition the partial condenser is connected by the conduit with the top of the rectification column, wherein the valve for receiving the gasoline fraction is in the conduit and in the middle part of the rectification column there is a valve for discharging oil fraction and the bottom of the rectification column with the conduit containing a valve is connected to the tank.
A process for obtaining components of liquid fuels from cracking of polyolefin wastes is described in the Polish patent application No. P.360100. The process consists in that the hydrocarbon products resulting from the cracking of polyolefin wastes are mixed with the mixture of hydrocarbons, wherein the mixture has a temperature of beginning the distillation not lower than 30°C, and a temperature of the end of the distillation not higher than 300°C and substantially does not contain saturated hydrocarbons, and the sulfur content is below 50 ppm and the content of resins in this part of the mixture which corresponds to the gasoline fraction is less than 1 mg/100 ml. The resulting mixture of the cracked products with the mixture of hydrocarbons is submitted to distillation and rectification and separated into patrol fraction, a gas oil fraction and a fraction being an oil component. The weight ratio of mixing cracking products with said mixture of hydrocarbons is from 1 : 4 to 3 : 1.
The Polish patent application No. P.371234 discloses a method of obtaining fuel components from waste polyolefms and involves the catalytic cracking of waste polyolefms conducted at atmospheric pressure, at a temperature of about 400°C, with a catalyst of aluminosilicate under such conditions to maintain a constant level in the reactor and a constant temperature. Products leaving the reactor are directed to the condenser so as to maintain a predetermined temperature of the vapor stream after the condenser, and the condensate is separated by distillation so as to obtain the components compliant with the requirements for fuels.
Moreover, the Polish patent application No. P. 382405 discloses a method for processing waste polyolefin of plastics, which results in obtaining a mixture of liquid hydrocarbons, which may be a component of fuel or after re-distillation, the solvent for the production of waterproof asphalt masses and ecological sulfur- free fuel oil, characterized in that disintegration process is carried out in two stages, wherein the raw material after the sorting and crushing is melted in two sections premelter and then the melted raw material is collected in the heated buffer tank of the melted material, maintained at a temperature of 250°C, where initial sedimentation of solid impurities of the raw material is carried out, these impurities are removed by means of a screw, and then the molten material in powder form is fed after it is mixed with the catalyst into the first stage depolymerization reactors, and then after the depolymerization at a temperature of 300 to 400°C, the vapors pass into the second stage decomposition reactor, wherein further processes of the cracking and reforming of hydrocarbons occur on the solid catalyst at a temperature of 260 to 300°C, the fumes are formed which pass through a two-stage liquefaction system and condense in the tank, and then in the liquid form flow into the finished product tank.
A method and apparatus system for the thermal catalytic processing of polyolefms to hydrocarbons is described in the Polish patent application No. P.398135. The object of this invention is a method for thermal catalytic processing of polyolefin wastes into hydrocarbons in the dosage forms of components for motor fuels and fuel oils and/or solvents. The method consists in that the particulate and dried feed material and the catalyst slurry with a heavy fraction from the preliminary column separator is subjected to liquefaction, and the resulting feed mixture is fed continuously into the cracking reactor, from which by preliminary separator column the products of thermal degradation of the feedstock in the form of the gaseous fraction and a heavy fraction are taken, then so obtained fractions are subjected to separation in the preliminary column separator and in turn in the fractional column separator to obtain final products. The present invention also provides an apparatus system for the thermal catalytic processing of polyolefins to hydrocarbons, consisting of a series of interconnected devices, namely the storage of the raw material, the crushing device, the separator, the drier, the liquefaction reactor, the catalytic cracking reactor, the preliminary column separator and the fractional column separator with outlet of the final products. The preliminary column separator is connected by a static mixer with the liquefaction reactor, which is equipped with a catalyst feed. The separator is connected with one supply and one discharge opening, and in addition the light fraction and/or solvent tank, the medium fraction tank and the heavy fraction tank are connected to the fractional column separator.
A method described in the Polish patent application No. P. 399600 is that the waste is ground and pre-dried, after which it is preheated and melted, and passed to the reaction chamber (Rl, R2), where it is heated by the liquid-metallic jacket heated from the outside, liquefied and cracked at a temperature of 350°C to 450°C, with moderate overpressure. The resulting gas-steam fraction is drained continuously and it partially melts the waste supplied to the inlet of the reactor, and then it subjected to distillation, then cooled in two stages, first in a cooler, where first the fuel oil fraction is withdrawn and the heat recovered from cooling is used to pre-drying of waste. The petrol fraction is discharged to the tank, and water from cooling is used to heat the oil fraction tank with part of non-condensing gases is consumed together with the petrol fraction for heating the reactor, where in a single operation a liquid metal almost completely fills the inner space of the mantle, wherein the process of liquefaction and cracking is preferably carried out simultaneously and parallel in two production lines, and the cracking waste resulting in the process - the quick coke is discharged periodically from the reactor (Rl, R2). The exhaust gases from the combustion of the petrol fraction and not condensable gases are after-burnt in the catalytic afterburner. In contrast, a gas and steam fraction is discharged through the annular outlet of the reactor (Rl, R2) and to improve the cracking the known catalysts aer used. The present application discloses also a device for processing plastics waste, especially polyolefins.
The solution described in WO2010106009 relates to an apparatus for heat treatment, in particular for thermal decomposition of mixtures of oils or waste fractions for recycling which may be mixed with the waste or waste oil, bitumen, tar or the like in a state similar to the paste and shredded plastics of polyolefin type where the device is equipped with a heated tank reactor, in which a mixture of oil waste is arranged to a certain height above the gas chamber and the cover above the height of the filling, the reactor has an inlet of mixtures of waste oils which are heat-treated and an outlet for exhaust gas products. The apparatus further comprises at least two mixing tools arranged in vertical position inside a reactor mounted in a rotational manner, wherein each of which has a shaft with a helical stirrer. The bolts of adjacent mixing tools partly overlap each other and are arranged in the reactor in such a way that the stirrers are from the bottom of the reactor to the height of the filling, wherein the reactor has a peripheral wall having a curved inner wall substantially in accordance with the outer contour of the mixing tool coils. The apparatus further includes a drive assembly for driving the shaft of the mixing tools in a rotational manner.
The above described methods have several drawbacks, including the need to use a catalyst in the two-stage processing of molten polymer.
The process of thermal decomposition of polyolefins, with the skillful pyrolytic processing of polyolefins may lead to obtaining about 85% of liquid products. They consist of half of the gasoline fraction having a boiling point up to 200°C and half of the oil fraction with a boiling point in a range of 200-340°C. The byproducts are non-condensable gases such as methane, ethane, ethylene, etc., and coke.
Polyolefins thermal cracking process is carried out in various types of reactors and in different technological regimes. It is the simplest to use atmospheric pressure as the apparatuses are simpler in design. In any process carried out in the diaphragmatic heated reactor there is the occurrence of coke which is deposited on the surface of the reactor blocking the flow of heat. Permanent removal of coke deposits from the reactor and any impurities present in the treated waste such as, e.g. sand, glass, metals, etc. is the Achilles heel of these reactors. There is therefore a need for a device in which the impurities accumulating in the reactor will be discharged continuously.
The entire apparatus performs all the functions such as pre-melting of the raw material, pyrolysis, cleaning of the reactor, and heating the mass streams in such a way as to ensure that effective continuous operation.
The object of the present invention the apparatus for polyolefin waste pyrolytic conversion-into liquid fuel products comprising the horizontal reactor connected with the polyethylene waste premelter by the two-way filter on the outlet from the premelter, (1), which has the walls of cylindrical shape, equipped with means for external, diaphragmatic electric or flame heating (4), the agitator (3) is arranged inside this reactor connected with the scraper and the deposits extractor is attached to this reactor (1) such that at its inner side over the surface of its walls there is a fitted ribbon scraper (72) for removing deposits accumulating on the reactor's surface, the drip trough for compacting deposits discharged from the reactor and the ram scraper bucket (75) for removing deposits from the inside of the reactor cooperating with the lock (73) ensuring tightness of the reactor, wherein the reactor (1) is equipped with a feeder with molten polymer from the dispenser and the apparatus also comprises the condenser for condensing products with a zone cooling. Preferably, the reactor is equipped with an electric mantle (4) with a temperature control system, the thermocouple is preferably arranged by the reactor's surface which controls the heater operation regulator. Preferably, the reactor is equipped with means for controlling of feeding of the processed molten polymer, which include the molten polymer feeder including rotating (31) cylindrical fitting (32) having slots (33), which in the upper position forms an opening for feeding molten polymer with the premelter and after the rotation, in the lower position forms an opening for discharging to the reactor's space. Preferably the apparatus comprises means for controlling rotation of the fitting (32) for controlling the amount of molten polymer fed into the reactor. In a preferred embodiment the premelter is a tank apparatus fed by the processed waste polymer (41), wherein the tubes (42) are arranged by the side walls of the premelter and above its bottom on which the melting of polyolefms takes places, and the premelter has a bottom slightly inclined towards the feeder, which is arranged at the bottom of the premelter. Preferably the premelter underneath the bottom has additionally the heating mantle powered by a heat carrier, preferably hot products from the reactor, additionally the premelter comprises the weight (44) to press down loose polymer waste covered from the top, preferably the premelter is equipped with the lift system (45) for lifting and lowering the weight (44). At the outlet of the premelter a upstream the dispenser there is the basket filter with a metal mesh (51) with fine mesh arranged in a tight tank (52), wherein the basket filter also comprises an access flap (53) for periodic cleaning.
The deposits extractor is a horizontal cylinder heated from the outside or by the heating mantle or by the means of the electric heater (71). Preferably the deposits extractor is equipped with a ribbon scraper (72) moving slowly just above the walls of the extractor and scraping the accumulated deposits towards the lock (73). At the end of the deposits extractor there is a lock (73) for removing deposits from inside the reactor.
Preferably the apparatus is equipped with the ram (75) performing a periodic downward movement and crushing gradually deposits accumulated in the lock, wherein the apparatus is also equipped with a damper (76) in the bottom of the lock which clears the lock, wherein the ram (75) pushes outside the portions of the compacted deposits and provides a sealing means for the lock and prevents escaping through the cleared lock any combustible gaseous products from inside the reactor.
The present invention also provides a method of polyolefin waste pyrolytic conversion into liquid fuel products, in which the waste is introduced into the premelter where they are heated and where they are melted, then they are passed in a controlled manner from the premelter to the reactor by means of a feeder which provides stabilization of the filling level of the reactor with a treated polymer mass, the pyrolysis reaction is carried in the reactor and gas and steam reaction products are removed from the reactor and directed back to the premelter where while cooling they heat, pre-dry and melt the polyolefin waste while coke deposits are removed from the reactor gradually and ballast impurities existing in the processed waste, using a suitable treatment system - the deposits extractor.
More particularly, there is disclosed a structure of a new type of apparatus for polyolefin waste pyrolytic conversion into liquid fuel products comprising the horizontal reactor, connected with the polyethylene waste premelter by the two-way filter on the outlet with the premelter, which has the walls of cylindrical shape, equipped with means for external diaphragm electric or flame heating, inside this reactor the agitator is connected with the scraper and the deposits extractor is attached to this reactor such that at its inner side over the surface of its walls there is a fitted ribbon scraper for removing deposits accumulating on the reactor's surface, the drip trough for compacting deposits discharged from the reactor and the worm scraper for removing deposits from inside the reactor cooperating with the lock ensuring tightness of the reactor, wherein the reactor is equipped with molten polymer feeder with the dispenser and the apparatus also comprises the condenser for condensing products with zone cooling.
The reactor constituting the core of the production plant has a cylindrical shape is electrically or flame diaphragm heated. On the inner side of the apparatus just above the surface of its walls the ribbon scraper is moving which removes from the inner surface of the reactor, the accumulating coke deposits and ensures effective heat transfer from the walls of the apparatus to the molten polymer. The ribbon scraper further scrapes any deposits from the inside of the reactor and throws them to the drip trough from which the deposits are continuously removed from the interior of the reactor through a special lock. Such a design solution ensures maintaining continuous operation of the reactor for processing polyolefin waste, stabilization of thermal conditions on the walls of the apparatus which improves homogenization and improvement of the performance of major products, mixing the same reaction mixture and safe disposal of solid waste from inside the reactor.
This design solution ensures maintaining continuous operation of the reactor for processing waste polyolefins, stabilization of thermal conditions on the sides of the apparatus which is reflected in the homogenization and improving the performance of the main products, mixing the raw material in the reactor and safe disposal of the solid waste inside the reactor.
The invention is illustrated in the drawing, in which:
Fig. 1 shows a block diagram of functions of the apparatus for processing waste poly olefins into liquid fuels
Fig. 2 shows a construction scheme of the construction of the reactor for pyrolysis of polyolefin waste
Fig. 3 shows a feeder of the raw material drawn from the premelter and fed to the reactor,
Fig. 4 shows a construction scheme of the premelter,
Fig. 5 shows a construction scheme of the basket filter,
Fig. 6 shows the products cooling system,
Fig. 7 shows a construction scheme of the deposits extractor. Example
The apparatus for processing waste polyolefins into liquid fuels consists of the following connected elements. The main one is the horizontal cylindrical reactor (1) shown in Fig. 2. It is fed with molten polymer. The method of feeding the processed molten polymer is not included in Fig. 2. An agitator (3) rotates on a horizontal axis (2) inside the reactor which performs two functions. This agitator provides maintenance of a layer of molten polymer on the entire inner surface of the reactor and at the same time removes increasing coke layer from the reactor's walls. The reactor is heated by any means, but most conveniently by means of an electric mantel (4) with a temperature control system. It is important to ensure temperature stabilization of the reactor walls. The operation control system of the heater and temperature control of the reactor's walls is not shown in Fig. 2. This is achieved for example by placing at its surface thermocouple controlling the operation of the heater regulator. In the same reactor there is a process of depolymerizing of the polymer waste and the formation of low molecular weight products, which leave the reactor in a steam-gas stream. The output of the product stream from the reactor is not illustrated in Fig. 2. To uniformly operate the reactor it is equipped with for controlling of feeding processed molten polymer. For this purpose, the molten polymer feeder shown in Fig. 3 is provided. The cylindrical fitting (32) rotates in the cylindrical space (31) having slots (33). The molten polymer from the premelter flows in To the slot when it is in the upper position. When the fitting is rotated and the slot is in the lower position the polymer flows out of it into the reactor's space. This construction of the feeder ensures the leakproofness, prevents uncontrolled flow of the molten polymer from the premelter to the reactor and prevents the flow of vapors from the reactor into the open part of the premelter. Rotation speed of the fitting (32) can be adjusted by the amount of molten polymer fed into the reactor. The molten polymer feeder is fed with a molten polymer stream coming from the polymer premelter shown in Fig. 4. The premelter is a tank apparatus fed with a processed waste polymer (41), optionally prepared in advance, for example by grinding, into a form suitable for convenient feeding of the premelter. The pre-treatment of the waste consists in its separation and removal of visible impurities, e.g. metals, glass, wood and products of polymers of a different type. While the removal of the processed waste polyolefins of other types of plastics, PVC in particular, it is recommended that especially difficult to separate the fine solid impurities may be introduced into the premelter because it ensures their separation. The tubes (42) are arranged at the side walls of the premelter and on its bottom, on which there is melting of the polyolefin. The molten polyolefin drip into the space (43) between the tubes and the wall of the premelter where they get warmer and thus liquefy further and then flow gravitationally towards the feeder since the premelter has a bottom slightly inclined towards the feeder. The feeder is positioned at the bottom of the premelter. The feeder is not shown in Fig. 4. The premelter underneath its bottom may also have a heating mantel supplied with a heat carrier, e.g. hot products from the reactor. Such a mantel is not shown in Fig. 4. The heating mantle as well as the tubes arranged at the sides and above the bottom of the premelter are supplied with the hot products stream leaving the reactor. These products from the reactor cool down and condense releasing heat to the heated and melting polymer. Loose polymer waste poured into the premelter are pressed from the top of the weight (44) lifted and lowered e.g. by the lift system (45). The waste pressure from above ensures their better contact with the heating surfaces and their more efficient melting. The tubes (42) with a bonding medium are supplied by the power collector (46) and condensed products together with the condensate leave the heating tube system (42) by means of the exhaust manifold (47). Both the tubes which transfer heat to the melted polyolefin waste and the mantle beneath the premelter have access for periodic maintenance relying on their cleaning and removal of the accumulated deposits such as coke particles. These deposits must be removed because they block the uniform flow of the product stream from the reactor and cause uneven operation of the premelter and reduce the efficiency of heat transfer from the product stream from the reactor to the melted polyolefins waste. The premelter is additionally coated with a thermal insulation from the outside in order to increase its efficiency. The polyolefin layer introduced into the premelter is pressed down toward the bottom of the premelter by the 'means of a ram or the weight. The premelter has a vent through which it any volatile gases and water vapor contained in the waste can escape. Venting the premelter also allows for emergency discharge of large amounts of steam which might arise when a greater amount of water will be introduced to the premelter, e.g., bound earlier in the processed waste. The premelter provides for removal of the water at the stage of melting the raw material to the reactor and protects the reactor from access of water to it in liquid form. Products leaving the reactor and heating diaphragmatic the premelter condense in contact with the colder walls of the premelter forming a liquid phase. Products from the reactor, which did not condensate in the heating portion of the premelter are directed to the diaphragmatic condenser shown in Fig. 6 supplied with hot water and then to the second part of the condenser supplied with cold water. Such a construction constitutes protection against blocking tubes with the products which, after cooling, have a solid form e.g. waxes which are also in the product stream from the reactor. All the condensed products are bonded in the collector and are directed to the storage tank.
At the outlet of the premelter and before the feeder there is a basket filter shown in Fig. 5 constructed of a metal mesh (51) with a fine mesh placed in a tight tank (52). This filter stops contaminants present in the processed waste polyolefins. The filter is periodically cleaned by the access flap (53) as it is filling up. The filter is a two-way filter, and during a cleaning work the other one of its parts is working. At the time of cleaning of the basket the valve (53) over it is closed. The filter can be additionally diaphragmaly heated by a products stream from the reactor and/or electric heater to prevent the stream of molten polyolefins from solidifying inside it.
During the pyrolysis reaction occurring in the reactor a certain amount of solids in the form of coke are also formed. The agitator removes them from the reactor walls. These particles remain in the layer of molten polymer in the reactor and together with the molten polymer from the reactor get in a small stream into the deposits extractor shown in Fig. 7. It is a horizontal cylinder heated from outside or by a heating mantel or by an electric heater (71) as a main reactor. In addition, a ribbon scraper (72) is positioned in the deposits extractor moving slowly just above the walls of the extractor and scraping the accumulating deposits in the direction of the lock (73). This direction is the same as the direction (74) the stream of products from the main reactor and passing the deposits extractor to the premelter. At the end of the deposits extractor there is a lock (73) for removing the deposits from inside the reactor. This lock at the same time ensures the tightness and prevents the escape of the gaseous products filling the deposits extractor. The ram (75) performs periodic downward movement and crushes gradually the deposits accumulating in the lock. At a certain period of time a latch (76) shifts in the bottom of the lock and clears the blockage in the lock and the ram (75) pushes outside the portions of the compacted deposits The ram (75) serves at this moment as a sealant of the lock and prevents escaping through the cleared lock combustible gaseous products from inside the reactor.
The apparatus provides the safe operation of the process, controlled pyrolysis reaction of waste polyolefins conditions and thus achievement of better yields of liquid products, provides tightness (lock for the deposits), enables continuous operation for a very long period of time (lock, the deposits extractor, the two-way filter), maximum utilization of heat by supplying the premelter with gaseous products from the main reactor.

Claims

Claims
1. An apparatus for pyrolytic conversion of polyolefin waste into liquid fuel products, characterized in that said apparatus comprises a horizontal reactor (1) connected with a polyethylene waste premelter by a two-way filter at the outlet of the premelter, which has the walls of cylindrical shape, equipped with means for external, diaphragmatic electric or flame heating (4), wherein an agitator (3) connected with a scraper is arranged inside this reactor, and a deposit extractor is attached to this reactor (1) such that there is a ribbon scraper (72) at its inner side over the surface of its walls fitted for removing deposits accumulating on the reactor's surface, a drip trough for compacting deposits discharged from the reactor and a ram scraper bucket (75) for removing deposits from the inside of the reactor cooperating with a lock (73) ensuring tightness of the reactor, wherein the reactor (1) is equipped with a molten polymer feeder with a dispenser, and the apparatus also comprises the condenser for condensing products with zone cooling.
2. The apparatus according to claim 1 characterized in that the reactor is equipped with an electric mantle (4) with a temperature control system, preferably the thermocouple is arranged at the reactor surface controlling the controller of the heater operation.
3. The apparatus according to claim 1 or claim 2 characterized in that the reactor is equipped with means for controlling of feeding the processed molten polymer.
4. The apparatus according to claim 3 characterized in that means for controlling of feeding with processed molten polymer include the molten polymer feeder including a rotating (31) cylindrical fitting (32) having slots (33), which forms an opening in the upper position for flowing in of the molten polymer from the premelter and after the rotation, forms an opening in the lower position for flowing out into the reactor's space.
5. The apparatus according to claim 4 characterized in that said apparatus comprises means for controlling the rotation of the fitting (32) for controlling the amount of molten polymer fed into the reactor.
6. The apparatus according to claims 1-5 characterized in that the premelter is a tank apparatus fed by processed waste polymer (41), wherein the tubes (42) are arranged at the side walls of the premelter and over its bottom on which the melting of the polyolefins occurs, and the premelter has the bottom slightly inclined towards the feeder arranged at the bottom of the premelter.
7. The apparatus according to claim 1-6 characterized in that underneath its bottom the premelter has additionally a heating mantle supplied by a heat transfer medium preferably hot products from the reactor.
8. The apparatus according to claim 1-7 characterized in that the premelter comprises a weight (44) to press down loose polymer waste poured from the top, preferably the premelter is equipped with a lift system (45) for lifting and lowering the weight (44) .
9. The apparatus according to claim 1-8 characterized in that a basket filter made from a metal mesh (51) with fine mesh is at the outlet of the premelter and upstream the dispenser arranged in a tight tank (52), wherein the basket filter also comprises an access flap (53) for periodic cleaning.
10. The apparatus according to claim 1-9 characterized in that the deposits extractor is a horizontal cylinder heated from the outside or by the heating mantle or by the means of the electric heater (71).
1 1. The apparatus according to claim 1-10 characterized in that the deposits extractor is equipped with the ribbon scraper (72) moving slowly just above the walls of the extractor and scraping the accumulated deposits towards the lock (73).
12. The apparatus according to claim 1-1 1 characterized in that the lock (73) for removing of deposits from the inside of the reactor is at the end of the deposits extractor.
13. The apparatus according to claim 1-12 characterized in that the deposits extractor is equipped with a ram (75) performing a periodic downward movement and crushing gradually deposit accumulated in the lock, wherein the apparatus is also equipped with a damper (76) in the bottom of the lock for clearing the lock, wherein the ram (75) pushes outside the portions of the compacted deposits and is means for sealing the lock and prevents escaping combustible gaseous products from the inside of the reactor through the cleared lock.
14. The method of pyrolytic conversion of polyolefm waste into liquid fuel products using the apparatus according to claim 1-13, in which the waste material is fed to the premelter, where it is heated and where it is melted, and then it is passed in a controlled way from the premelter into the reactor by the means of the feeder, which provides stabilization of the level of the reactor's filling with the processed polymer mass, the pyrolysis reaction is conducted in the w reactor and the gaseous and steam reaction products are removed from the reactor and directed back to the premelter, where the polymer waste whole cooling heat, dry and melt the polyolefm waste, coke deposits and impurities present in the processed waste are gradually removed from the reactor using the appropriate deposits extractor.
PCT/PL2015/000074 2015-04-28 2015-04-30 Apparatus for processing waste from the polyolefins into liquid fuels and the method for processing waste from polyolefins into liquid fuels WO2016175667A1 (en)

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