WO2017017692A2 - Système de craquage à multiples étages et processus associé de conversion de déchets non dégradables en carburants - Google Patents

Système de craquage à multiples étages et processus associé de conversion de déchets non dégradables en carburants Download PDF

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Publication number
WO2017017692A2
WO2017017692A2 PCT/IN2016/000197 IN2016000197W WO2017017692A2 WO 2017017692 A2 WO2017017692 A2 WO 2017017692A2 IN 2016000197 W IN2016000197 W IN 2016000197W WO 2017017692 A2 WO2017017692 A2 WO 2017017692A2
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WO
WIPO (PCT)
Prior art keywords
reactor
heat exchanger
alumina
silica
tank
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PCT/IN2016/000197
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English (en)
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WO2017017692A3 (fr
Inventor
Suraj MUNDHE
Jan Vink
Yogesh KODE
Original Assignee
Praesto Life Science Private Limited
Nespro Renewable Energy Solutions
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Publication of WO2017017692A2 publication Critical patent/WO2017017692A2/fr
Publication of WO2017017692A3 publication Critical patent/WO2017017692A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING 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
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10—Production 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
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING 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
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/08—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal with moving catalysts
    • C10G1/086—Characterised by the catalyst used

Definitions

  • the present process relates to a field of non-degradable waste processing, and more particularly be used to produce solid, liquid and gaseous energy products form waste plastics by pyrolysis and catalytic cracking.
  • Waste plastics that are synthetic polymer-containing substances, pose an environmental issue because of the problems associated with disposal, a large volume of non-biodegradable material.
  • a study performed by the Environmental Protection Agency (EPA) states that approximately billions tons of waste plastic is generated globally. However, statistics show that ⁇ 10% of waste plastic is recycled, ⁇ 25% is incinerated and the remaining ⁇ 65% is literally dumped in landfills. The estimated cost of end-to-end waste plastic management is ⁇ $ 2800 per ton of waste plastic. Incineration is an alternative to landfill disposal of plastic waste, however this practice result in formation of unacceptable emission of gases viz; nitrous oxide, sulphur oxide, dusts, dioxins and other toxins etc.
  • US patent application 5849964 teaches a process is disclosed for processing used or waste plastic materials in order to recover chemical raw materials and liquid fuel components by depolymerisation of the used materials, which are transformed into a pumpable and into a volatile phase.
  • the volatile phase is separated into a gaseous phase and a condensate or condensable depolymerisation product, which are refined by standard usual procedures.
  • the pumpable phase remaining once the volatile phase is separated is subjected to liquid phase hydrogenation, gasification, low temperature carbonisation or to a combination of said processes.
  • the condensate can be converted into a high- grade synthetic crude oil (syncrude), for example by hydrotreating on fixed-bed commercial Co-Mo or Ni-Mo catalysts, or it can be brought directly into chlorine- tolerating chemico-technical processes or typical oil refinery processes as a hydrocarbon-containing basic substance.
  • syncrude synthetic crude oil
  • the main drawback of this process is that the process is more complicated; number of operation involved is more and involves high pressure and high temperature in the same.
  • Another patent application WO2013087480A4 teaches a process and catalyst system for thermal catalytic cracking of pyrolysis derived organic molecules comprising at least a first organic catalytic material and a second organic catalytic material.
  • the first organic catalytic material has a pyrolysis organic molecule pore absorption volume of at least two times that of the second organic catalytic material and the mass ratio of the first organic catalytic material and the second organic catalytic material is in the range of 10:0.1.
  • the main drawback of this process is that the process is more complicated; number of operation involved is more and involves high temperature in the same. There is no consideration of pressure in the process. Total process is laboratory oriented no commercial viable process available.
  • Another object of the present invention is to prevent adverse impact on the society, environment and surroundings flora and fauna.
  • the present invention provides a multi-stage cracking system and a process for conversion of non-degradable waste into fuels.
  • the system comprises a base, a feeder, a first reactor, a quench drum, a second reactor, a refining column, a first heat exchanger, a second heat exchanger, a first tank and a second tank.
  • the feeder that incorporates a hopper configured on top of a first conveyer that receives shredded and segregated raw materials therein, and a second conveyor placed perpendicularly with the first conveyer to prevent chocking of material during feeding of the raw material.
  • the first reactor is capable of transforming raw material into a hydrocarbon vapor mixture in the presence of catalyst.
  • the first reactor has an inner shell and an outer shell.
  • the quench drum is capable of receiving catalytically cracked hydrocarbon vapor mixture from the gas outlet of the first reactor at one end.
  • the second reactor configured with a vertical shell and a horizontal shell.
  • the horizontal shell adaptably connects the first tank to collect the oil extracted therefrom.
  • the refining column adaptably connects the first tank to collect the oil extracted therefrom.
  • the first heat exchanger and the second heat adaptably receiving exhaust gas allowing treated fumes to be collected and stored in tanks connected therethrough.
  • the process comprises of: feeding shredded and segregated raw material that has moisture content of less than 5% to the first reactor (200) through the feeder (150) at rate of 5 kg/hr to 45 kg/hr; then partially degrading raw material to 80 to 85 % hydrocarbons in the presence of a catalyst at cracking temperature ranging in between 250 to 450 degree Celsius at atmospheric pressure in absence of oxygen in the first reactor (200); intermediate quenching of the partial degraded raw materials using the quench drum (250) to retain the higher molecular weight hydrocarbons and send back into the first reactor (200); complete cracking of the quenched lower molecular weight hydrocarbons from the quench drum (250) in the presence of a catalyst at cracking temperature ranging in between 200 to 300 deg.
  • Figure 1 shows a schematic view of a multi-stage cracking system.
  • FIG. 2 shows a feeder, in accordance with one aspect of the present invention.
  • Figure 3 shows a first reactor, in accordance with one aspect of the present invention.
  • FIG. 4 shows a quench drum, in accordance with one aspect of the present invention.
  • Figure 5 shows a second reactor, in accordance with one aspect of the present invention.
  • Figure 6 shows a refining column, in accordance with one aspect of the present invention.
  • Figure 7 shows a first heat exchanger / oil condenser, in accordance with one aspect of the present invention.
  • Figure 8 shows a second heat exchanger / gas condenser, in accordance with one aspect of the present invention.
  • Figure 9 shows a first tank / an oil storage tank, in accordance with one aspect of the present invention.
  • FIG. 10 shows a second tank / a gas storage tank, in accordance with one aspect of the present invention. Detailed description of the invention
  • the present invention provides a multi-stage cracking system and process thereof for conversion of non-degradable waste into energy products in all solid, liquid and gaseous form.
  • the non-degradable waste / raw materials for the present particularly includes waste polymers i.e. organic waste plastic in form of polyethylene, polypropylene, polyester, polyvinyl chloride, polystyrene, polyethylene terephthalate, polyvinylidene chloride, low density polyethylene, high density polyethylene, acrylonitrile butadiene styrene, nylon and the like.
  • the present invention provides a multi-stage cracking system (1000) (hereafter referred to as 'the system (1000)').
  • the system (1000) includes a base (Not Shown), a feeder (150), a first reactor / catalytic cracker (200), a quench drum (250), a second reactor / reboiler/ catalytic re-cracker (300), a refining column (400), a first heat exchanger / oil condenser (500), a second heat exchanger / gas condenser (600), a first tank / an oil storage tank (700), a second tank / a gas storage tank (800) and a sludge screw and collection unit (900).
  • the base in the preferred embodiment is a solid ground or a vehicle floor in accordance to the requirement from a user to make the system (1000) erected in a plant or to facilitate a portable unit.
  • the base provides platform securely mounting all the components using a plurality of fixing means.
  • the fixing mean could be screws, nuts and bolts and the like.
  • the second conveyor (140) is placed perpendicularly with the first conveyer (130) to prevent chocking of material during feeding of the raw material.
  • the second conveyor (140) allows the raw material pass therethrough.
  • the second conveyor (140) at a second end is configured to be fixedly secured to the first reactor (200) by a fixing mean (Not Numbered).
  • the second conveyor (140) is provided with a cooling jacket (Not Numbered). Cooling water is circulated through the jacket in order to keep the temperature of the second conveyor (140) low as it is connected directly to first reactor (200) which operates at higher temperature.
  • the first reactor (200) of the present embodiment is shown.
  • the first reactor (200) in the present embodiment is a catalytic cracker.
  • the first reactor (200) is securely mounted on the base using the fixing means.
  • the first reactor (200) is cylindrically shaped container configured to have atleast two chambers that is an inner shell (160) and an outer shell (170).
  • the inner shell (160) of the first reactor (200) is incorporated with an input (Not Numbered) to receive shredded and segregated raw materials from the second conveyor (140).
  • the inner shell (160) includes a rotating scrapper (Not Numbered) connected with a geared motor (Not Numbered) to mix or stir the raw material, a gas outlet (154) and a sludge / carbon outlet (158) further connecting the sludge screw and collection unit (900).
  • the outer shell (170) is configured to enclose of the inner shell (160) therein.
  • the outer shell (170) includes a plurality of stiffening rings (175) a burner (Not shown) and a gas outlet (Not Shown).
  • the raw material is fed to inner shell (160) of first reactor (200) along with a catalyst and the outer shell (170) is then heated by firing of the burner.
  • the raw material is heated and transform into a hydrocarbon vapor mixture in the presence of catalyst.
  • the gas outlet (154) of the inner shell (160) is adaptably connected with the quench drum (250).
  • the quench drum (250) of the present embodiment has a long cylindrical body (210) having a cooling jacket (220) thereon.
  • the quench drum (250) having one end receiving catalytically cracked hydrocarbon vapor mixture from the gas outlet (154) of the first reactor (200). Another end of the quench drum (250) is adaptably connected to the second reactor (300) to pass the quenched vapor therefrom.
  • the second reactor (300) of the present embodiment is shown. Further, the second reactor (300) is an inverted T-shaped structure being firmly secured on the base using the fixing means.
  • the second reactor (300) is configured with a vertical shell (270) and a horizontal shell (290).
  • the vertical shell (270) includes a cooling tube coil (262), an inlet nozzle (264), a baffle plate (Not Shown) and an outlet nozzle (268).
  • the inlet nozzle (264) is adaptably configured to receive the quenched vapor from the quench drum (250) which is further passed into the horizontal shell (290) of the second reactor (300).
  • the horizontal shell (290) is cylindrical body having a heat exchanger (Not Shown) therein with a storage space (Not Shown).
  • the refining column (400) as shown in the figure 6 is tower shaped column having a water jacket (Not Shown) facilitating continues running water for cooling.
  • the refining column (400) has an inlet (340) at one end to adaptably receive exhaust gas received from the gas outlet (284) and a gas outlet (360) at another end.
  • the refining column (400) includes a bottom outlet nozzle (380).
  • the refining column (400) facilitates rectification of the fumes and extract some traces of oil which is further collected from the bottom outlet nozzle (380) of the refining column (400) and stored in the first tank (700) connected therethrough.
  • the first heat exchanger (500) has an inlet (440) at one end to adaptably receive exhaust gas received from the gas outlet (360) and a gas outlet (460) at another end.
  • the first heat exchanger (500) includes a bottom outlet nozzle (480).
  • In the first heat exchanger (500) mostly all hydrocarbon is condensed and oil is collected from the bottom outlet nozzle (480) and stored in the first tank (700) connected therethrough.
  • the non-condensed fumes from the first heat exchanger (500) are allowed to pass through the second heat exchanger (600) for treatment of the fumes.
  • the second heat exchanger (600) has an inlet (540) at one end to adaptably receive exhaust gas received from the gas outlet (460).
  • the second heat exchanger (600) includes a bottom outlet nozzle (580).
  • the treated fumes from the second heat exchanger (600) in form of gas is collected and stored in the second tank (800) connected therethrough.
  • a multi-stage cracking process (100) hereafter referred to as 'the process (100)'
  • the process (100) facilitates treatment and conversion of non-degradable waste viz; waste polymers or waste plastic into energy products in various form viz; solid, liquid and gaseous form.
  • the process (100) begins with a step (10), where the shredded and segregated raw material like waste polymers / plastic with moisture content and inert material less than 5% is fed to the first reactor (200) via the feeder (150) at constant and desired feed rate.
  • the non-degradable waste is shredded in size of 10-20 mm.
  • the moisture content and inert material concentration of the shredded and segregated raw material is preferably less than 2-3%.
  • the rate of feed in the present embodiment is operable between 5 kg/hr to 45 kg/hr and preferably 15 kg/hr to 30 kg/hr however it understood that feed rate may varies in accordance with the plant requirement.
  • the waste polymers are partially degraded from complex form to simpler form of various hydrocarbons due to the presence of catalyst at atmospheric pressure in absence of oxygen. Further, the catalytically cracked raw material is mixed with predetermined quantity of catalyst is then subjected for further processing.
  • the cracking temperature for this step is ranging in between 250 to 450 degree Celsius is achieved using an external power source like oil / gas burner (Not Numbered). The most preferred cracking temperature for this step is ranging in between 300 to 350 degree Celsius.
  • the first reactor (200) once subjected with raw material temperature starts to rise and initiates the reaction inside the first reactor (200) which results into breakdown of hydrocarbons into partial degraded/polymerized raw materials.
  • the process in this step brings partial breakdown of hydrocarbons upto ⁇ 80 to 85 % by converting complex molecular hydrocarbons into various simpler hydrocarbons in the presence of catalyst.
  • the catalyst of the present embodiment is among various catalysts used such as bentonite, alumina, silica, alumina + silica, zeolite, V205 etc.
  • the present step can also be operated using combination of Alumina + Silica such as (50% Alumina + 50% Silica), (40% Alumina + 60% Silica), (30% Alumina + 70% Silica), (20% Alumina + 80% Silica) and (10% Alumina + 90% Silica) etc.
  • the present step can also be operated using different ratio of with respect to feed from 5 % to 30 %.
  • the present invention delivers best results at 10% feed ratio by using (10% Alumina + 90% Silica).
  • next step (30) the partial degraded/polymerized raw materials are allowed to pass to and are subjected to intermediate quenching using the quench drum (250).
  • the process in this step allows the quench drum (250) to retain the higher molecular weight hydrocarbons and send them back into the first reactor (200). Further the high molecular weight hydrocarbons retained back in the first reactor (200) are again re-cracked / processed at high temperature in presence of catalyst and converted into lower molecular weight hydrocarbons which are further subjected for processing.
  • the partial water cooling provided to quench drum (250) effectively results in separation of higher and lower molecular hydrocarbons due to the difference in their boiling point of the simpler polymerized hydrocarbons.
  • step (40) the quenched lower molecular weight polymerized hydrocarbons obtained from the quench drum (250) are further subjected for the final cracking in the second reactor (300) at temperature between 200 to 300 deg. Celsius.
  • the present step (40) facilitates 100% cracking of the processed material in presence of catalyst to be converted into simpler and extractable forms of hydrocarbons in the form of fumes / gas / vapours.
  • the second reactor (300) plays a vital role in improvement of better quality and quantity of extractable hydrocarbons.
  • the second reactor (300) being provided with partial water cooling unit allows some vapor traces to be extracted, condensed, and converted into oil. The traces of extracted oil are collected from the bottom of the second reactor (300) and stored in the first tank (700).
  • the extracted oil in this step is crude oil (A) having various applications such as burner fuel, furnace fuel, raw material for oil refinery various industrial and domestic heating applications, raw material for extraction of various industrial chemicals, industrial and domestic heating applications production of grease and the like.
  • step (50) the fumes of hydrocarbons along with cracked simpler hydrocarbons other than condensate are further allowed to pass through refining column (400) that facilitates rectification of the fumes using cooling water continuously circulated around the rectified column (400). Also, traces of extracted oil are collected from the bottom of the refining column (400) and stored in the first tank (700). The extracted oil in this step is better in terms of quality and quantity as compared to earlier crude oil (A).
  • the oil collected at this stage is referred as crude oil (B) having various applications such as burner fuel, furnace fuel, raw material for oil refinery, raw material for extraction of various chemicals, industrial and domestic heating applications and the like.
  • first heat exchanger (500) includes a cooling tower (Not Numbered) that facilitates condensation of the rectified fumes into crude oil or fuel oil or high calorific oil (C) by passage of cold water there around.
  • the cooling water plays a vital role in condensation of extracted or cracked fumes converting them in better quality of oil.
  • the crude oil or fuel oil or high calorific oil (C) is also collected and stored in the first tank (700).
  • the extracted oil in this step is best in terms of quality and quantity as compared to earlier crude oil (A) and (B).
  • the crude oil (C) collected at this stage has various applications such as burner fuel, furnace fuel, raw material for oil refinery, various industrial and domestic heating applications, raw material for extraction of various industrial chemicals, production of grease and the like.
  • the non-condensed fumes from the first heat exchanger (500) are allowed to pass through the second heat exchanger (600).
  • the second heat exchanger (600) is a gas cooler which includes a cooling tower that facilitates re-condensation of the treated fumes into as crude oil or fuel oil or high calorific oil (D) and gases by passing cold water.
  • the crude oil or fuel oil or high calorific oil (D) is collected and stored in the first tank (700).
  • the vapours which are not condensed at this stage i.e. other than oil traces are extracted and collected from top of second heat exchanger (600) in the form of gas.
  • the gas is compressed at desired pressure of 6 bar (kg/cm 2 ), and stored in the second tank (800).
  • next step (80) the crude oils (A), (B), (C) and (D) extracted, condensed and collected at from various steps (40), (50), (60) and (70) stored in the first tank (700) has found to be of similar properties to LDO (Low Density Oil), Furnace Oil and hence can be safely used an alternative fuel for various industrial applications thus conserving depleting natural resources.
  • LDO Low Density Oil
  • Furnace Oil Furnace Oil
  • the un-cracked polymers i.e. which are neither converted into gas nor oil are converted into solid fuel viz; sludge or semi-solid carbon.
  • the physical appearance of this semi-solid carbon may vary from powder, lumps, semi-solid, slurry and the like depending upon the type of raw material and process operational conditions.
  • any of the form of carbon or sludge can be effectively used as solid fuel for boilers or any other solid heating applications for various industrial applications from case to case.
  • the present method and system converts organic waste viz; waste polymers / plastic into various energy products in different form viz; 60% liquid, 30% gas and 10% solid.
  • the gas stored in the second tank (800) is used as process fuel for various heating application especially in the preferred embodiment as a fuel for the first reactor (200) at step (10) making process economically feasible in terms of energy consumption as well thereby minimizing air pollution too.
  • the gas produced in the process is compressed at 6 bar (kg/cm2), stored in gas storage , tank as further used as a process fuel for the catalytic cracker at 200-300 mbar which make the process almost self-sufficient (80 - 90%) in terms of energy requirements. If the produced gas is insufficient as process fuel then in that case produced process crude oil is used partially viz; around 10% of the produced quantity as process fuel.
  • the produced fuel in various forms viz. gas and liquid facilitates self-sustainable energy requirement of the system (1000).
  • Table 1 details data collected for conversion of 1000 kg per day of Waste Plastic / Polymer in various products for the present invention:
  • Table no. 3 shows approximate flammable gas composition obtained:
  • Table no. 4 shows approximate sludge / carbon composition obtained:
  • the system (1000) and method (100) facilitates a self-sustainable energy treatment method for non-degradable wastes.
  • the system (1000) and method (100) provides 100% decomposition of waste plastic.
  • the system (1000) facilitates continuous process along with compact design thereby resulting in effective utilization of required space and machinery for process plant.
  • the system (1000) has customized best effective design based on earlier field experience for ease of maintenance and operation process.
  • the system (1000) and method (100) provides better product efficiency in terms of quality and quantity of produced end energy products.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

La présente invention concerne un système de craquage à multiples étages (1000) et un processus (100) associé de conversion de déchets non dégradables en produits énergétiques. Le système et le procédé selon l'invention convertissent des déchets organiques, c'est-à-dire des déchets polymères/plastiques, en divers produits énergétiques sous différentes formes, c'est-à-dire 60 % liquide, 30 % gaz et 10 % solide. Les produits énergétiques produits par le processus ont une bonne valeur calorifique et peuvent être utilisés pour diverses applications industrielles de chauffage, c'est-à-dire chaudières, chauffages, générateurs diesel, et en tant que matériaux de remplacement/substitut pour fuel de chauffage, etc.
PCT/IN2016/000197 2015-07-29 2016-07-28 Système de craquage à multiples étages et processus associé de conversion de déchets non dégradables en carburants WO2017017692A2 (fr)

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IN2866MU2015 2015-07-29
IN2866/MUM/2015 2015-07-29

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WO2017017692A3 WO2017017692A3 (fr) 2017-03-09

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113546946A (zh) * 2021-07-23 2021-10-26 浙江中蓝环境科技有限公司 医疗废物的无氧干馏处置方法

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* Cited by examiner, † Cited by third party
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ATE57479T1 (de) * 1983-06-17 1990-11-15 Newest Inc Verfahren zur umwandlung von festem abfall und klaerschlamm in brennstoff.

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113546946A (zh) * 2021-07-23 2021-10-26 浙江中蓝环境科技有限公司 医疗废物的无氧干馏处置方法

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