WO2022213021A1 - Compositions mélangées de carburant comprenant de l'huile de pyrolyse de plastique et procédés pour leur fabrication - Google Patents

Compositions mélangées de carburant comprenant de l'huile de pyrolyse de plastique et procédés pour leur fabrication Download PDF

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Publication number
WO2022213021A1
WO2022213021A1 PCT/US2022/071191 US2022071191W WO2022213021A1 WO 2022213021 A1 WO2022213021 A1 WO 2022213021A1 US 2022071191 W US2022071191 W US 2022071191W WO 2022213021 A1 WO2022213021 A1 WO 2022213021A1
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Prior art keywords
liquid product
total liquid
plastic pyrolysis
vol
fuel
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PCT/US2022/071191
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English (en)
Inventor
Timothy J. Anderson
Kenneth C.H. KAR
Sheryl B. RUBIN-PITEL
Cody M. DIAZ
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Exxonmobil Research And Engineering Company
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Priority to EP22714759.2A priority Critical patent/EP4314198A1/fr
Publication of WO2022213021A1 publication Critical patent/WO2022213021A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/04—Liquid carbonaceous fuels essentially based on blends of hydrocarbons
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/02—Gasoline
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/04—Diesel oil
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/06—Gasoil
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/08—Jet fuel

Definitions

  • the present disclosure relates to blended fuel compositions that include plastic pyrolysis oil including the total liquid product or a traction thereof as a blending fuel and methods of making thereof.
  • plastic waste For high quality recycling that leads to plastic products that can again be mechanically recycled, plastic waste must be separated by polymer type and thoroughly cleaned. Typically, plastic waste is not properly segregated and is, consequently, downgraded into inferior products that then cannot be mechanically recycled further and often will later be incinerated (Waste-to- Energy) or discarded into a landfill or the environment.
  • pyrolysis An alternative to discarding plastic waste into landfills or mechanically recycling plastic waste is pyrolysis.
  • Pyrolysis of plastic waste typically involves heating the plastic waste and entrained organic material in a low oxygen environment.
  • a plastic pyrolysis oil having a broad boiling range can be obtained.
  • Said plastic pyrolysis oil typically with additional purification processing, can be used as at least a portion of a blendstock for upgrading to plastic polymer. This pyrolysis processing provides a plastic blendstock for a more circular plastic economy.
  • the present disclosure relates to blended fuel compositions that include plastic pyrolysis oil including the total liquid product or a fraction thereof as a blending fuel.
  • a first nonlimiting example method of making a blended fuel composition of the present disclosure comprises: blending a plastic pyrolysis oil with a blendstock fuel to produce a blended fuel composition, wherein the blended fuel composition comprises about 1 vol% to about 20 vol% of the plastic pyrolysis oil and about 80 vol% to about 99 vol% of the blendstock fuel, and wherein a combination of the plastic pyrolysis oil and the blendstock fuel is selected from the group consisting of: a naphtha fraction of the plastic pyrolysis total liquid product and gasoline; a distillate fraction of the plastic pyrolysis total liquid product and diesel; the distillate fraction of the plastic pyrolysis total liquid product and a marine fuel; a heavy pyrolysis fuel fraction of the plastic pyrolysis total liquid product and the marine fuel; and the plastic pyrolysis total liquid product and the marine fuel.
  • a nonlimiting example of a blended fuel composition of the present disclosure comprises: about 1 vol% to about 20 vol% of a plastic pyrolysis oil and about 80 vol% to about 99 vol% of the blendstock fuel, and wherein a combination of the plastic pyrolysis oil and the blendstock fuel is selected from the group consisting of: a naphtha fraction of the plastic pyrolysis total liquid product and gasoline; a distillate fraction of the plastic pyrolysis total liquid product and diesel; the distillate fraction of the plastic pyrolysis total liquid product and a marine fuel; a heavy pyrolysis fuel fraction of the plastic pyrolysis total liquid product and the marine fuel; and the plastic pyrolysis total liquid product and the marine fuel.
  • the present disclosure relates to blended fuel compositions that include plastic pyrolysis oil including the total liquid product or a fraction thereof as a blending fuel.
  • the plastic pyrolysis oil described herein has a low oxygen content, a low sulfur content, and a high hydrocarbon content.
  • blendstock fuels e.g., marine fuel, gasoline, diesel, and the like
  • the plastic pyrolysis oil described herein can be used as-produced (the total liquid product) or as a distilled fraction thereof depending on the end-product fuel.
  • blending hydrocarbons e.g., light cycle oil and straight run automotive diesel
  • the present disclosure proposes to use plastic pyrolysis oil (total liquid product or fractions thereof) as the blending hydrocarbon.
  • Blending hydrocarbons produced from crude oil and other fossil fuels can have high sulfur concentrations (depending on the source of the crude oil) but a lower cetane index, higher viscosity, and higher density as compared to the plastic pyrolysis oils described herein.
  • the plastic pyrolysis oils described herein provide low-sulfur advantages (e.g., more can be added, if needed, without exceeding the final composition sulfur specifications) as well as high cetane index, lower viscosity, and lower density advantages (e.g., less plastic pyrolysis oil can be used to achieve the desired fuel properties).
  • plastic pyrolysis oil All additional benefit of the use of plastic pyrolysis oil is that the rigorous requirements for mechanical recycling (e.g., separation of each plastic type and stringent pre-cleaning) are not required. Rather, several types of plastic can be pyrolyzed simultaneously with little to no precleaning because the organic matter (e.g., food) carried along with the plastic waste is also pyrolyzed.
  • a reference to a “C x ” fraction, stream, portion, feed, or other quantity is defined as a fraction (or other quantity) where 50 wt% or more of the fraction corresponds to hydrocarbons having “x” number of carbons.
  • a range is specified, such as “Cx-Cy,” 50 wt% or more of the fraction conesponds to hydrocarbons having a number of carbons from “x” to “y.”
  • a specification of “C x +” (or “Cx-”) corresponds to a fraction where 50 wt% or more of the fraction corresponds to hydrocarbons having the specified number of carbons or more (or the specified number of carbons or less).
  • plastic pyrolysis oil refers to pyrolysis oil where at least 50 wt% of the pyrolysis oil is derived from a plastic source. That is, the feedstock (also referred to as plastic feedstock) that is pyrolyzed comprises at least 50 wt% plastic.
  • naphtha or “naphtha fraction’ refers to a hydrocarbon composition having an initial boiling point (ASTM D2887-19a using a using a 15-theoretical plate column and 5:1 flux ratio is a classical method to obtain the distillation curve) of about -6''C to about. 193°C.
  • distillate or “distillate fraction” refers to a hydrocarbon composition having an initial boiling point ( ASTM D2887-19a using a using a 15-theoretical plate column and 5:1 flux ratio is a classical method to obtain the distillation curve) of about 193°C to about 371 °C.
  • the term “heavy pyrolysis fuel” or “heavy pyrolysis fuel” refers to a hydrocarbon composition having an initial boiling point (ASTM D2887-19a using a using a 1.5- theoretical plate column and 5: 1 flux ratio is a classical method to obtain the distillation curve) of about 371 °C to about 56 PC.
  • the sulfur content is measured by ASTM D2622-16.
  • the metal content e.g., the amount of vanadium and other metals
  • the metal content is measured by inductively couple plasma methods.
  • cetane index is measured by ASTM 04737-10(2016) Procedure A,
  • kinematic viscosity is measured by ASTM D445-19.
  • solubility blending number (SN) and insolubility number (IN) are determined as described in US Patent No, 5,997,723, incorporated herein by reference.
  • flashpoint is measured by ASTM D6450- 16a.
  • CCAI calculated carbon aromaticity index
  • lubricity is measured by high frequency reciprocating rig (HERR) using ASTM D6079-I8.
  • NACE is a corrosion based test measured according to NACE Standard TM0 172-2001.
  • Methods of the present disclosure include mixing (or blending) a plastic pyrolysis oil (e.g., a total liquid product from a plastic pyrolysis process or a fraction of the total liquid product) with a fuel oil.
  • a plastic pyrolysis oil e.g., a total liquid product from a plastic pyrolysis process or a fraction of the total liquid product
  • a fuel oil e.g., a fuel oil.
  • plastic pyrolysis oils and blendstock fuels include, but are not limited to, a naphtha fraction of a plastic pyrolysis total liquid product and gasoline; a distillate fraction of a plastic pyrolysis total liquid product and diesel; a. distillate fraction of a plastic pyrolysis total liquid product and marine fuel; a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product and marine fuel; and a plastic pyrolysis total liquid product and marine fuel.
  • the amount of plastic pyrolysis oil (as the total liquid product or a fraction thereof) in a fuel may be about 20 vol% or less (or about 1 vol% to about 20 vol%, or about 1. vol% to about 15 vol%, or about 1 vol% to about 10 vol%, or about 1 vol% to about 5 vol%, or about 3 vol% to about 8 vol%, or about 10 vol.% to about 20 vol%).
  • a blended fuel composition of the present disclosure may comprise about 20 vol% or less, (or about 1 vol% to about 20 vol%, or about 1 vol% to about 15 vol%, or about 1 vol% to about 10 vol%, or about 1 vol% to about 5 vol%, or about 3 vol% to about 8 vol%, or about 10 vol% to about 20 vol%) of a plastic pyrolysis total liquid product and about 80 vol% or more (or about 80 vol% to about 99 vol%, or about 85 vol% to about 99 vol%, or about 90 vol% to about 99 vol%, or about 95 vol% to about 99 vol%, or about 92 vol% to about 97 vol%, or about 80 vol% to about 90 vol%) of a marine fuel.
  • a method of the present disclosure may comprise mixing (or blending) a plastic pyrolysis total liquid product with a marine fuel in the foregoing amounts to produce a blended fuel composition.
  • a blended fuel composition of the present disclosure may comprise about 20 vol% or less (or about 1 vol% to about 20 vol%, or about 1 vol.% to about 15 vol%, or about 1 vol% to about 10 vol%, or about 1 vol% to about 5 vol%, or about 3 vol% to about 8 vol%, or about 10 vol% to about 20 vol%) of a naphtha fraction of a plastic pyrolysis total liquid product and about 80 vol% or more (or about 80 vol% to about 99 vol%, or about 85 vol% to about 99 vol%, or about 90 vol% to about 99 vol%, or about 95 vol% to about 99 vol%, or about 92 vol% to about 97 vol%, or about 80 vol% to about 90 vol%) of a gasoline.
  • a method of the present disclosure may comprise mixing (or blending) a naphtha, fraction of plastic pyrolysis total liquid product with a gasoline in the foregoing amounts to produce a blended fuel composition.
  • a blended fuel composition of the present disclosure may comprise about 20 vol% or less (or about 1 vol% to about 20 vol%, or about 1 vo'1% to about 15 vol%, or about 1 vol% to about 10 vol%, or about 1 vol% to about 5 vol%, or about 3 vol% to about 8 vol%, or about 10 vol% to about 20 vol%) of a distillate fraction of a plastic pyrolysis total liquid product and about 80 vol% or more (or about 80 vol% to about 99 vol%, or about 85 vol% to about 99 vol%, or about 90 vol% to about 99 vol%, or about 95 vol% to about.99 vol%, or about 92 vol% to about 97 vol%, or about 80 vol% to about 90 vol%) of a diesel
  • a method of the present disclosure may comprise mixing (or blending) a distillate fraction of a plastic pyrolysis total liquid product with a diesel in the foregoing amounts to produce a blended fuel composition.
  • a blended fuel composition of the present disclosure may comprise about 20 vol% or less (or about 1 vol% to about 20 vol%, or about 1 vol% to about 15 vol%, or about 1 vol% to about 10 vol%, or about 1 vol% to about 5 vol%, or about 3 vol.% to about 8 vol%. or about 10 vol% to about 20 vol%) of a distillate fraction of a plastic pyrolysis total liquid product and about. SO vol% or more (or about 80 vol% to about 99 vol%, or about 85 vol% to about 99 vol%, or about 90 vol% to about 99 vol%, or about 95 vol% to about 99 vol%, or about 92 vol% to about 97 vol%, or about 80 vol% to about 90 vol.%) of a marine fuel.
  • a method of the present disclosure may comprise mixing (or blending) a distillate fraction of a plastic pyrolysis total liquid product with a marine fuel in the foregoing amounts to produce a blended fuel composition.
  • a blended fuel composition of the present disclosure may comprise about 20 vol% or less (or about 1 vo1% to about 20 vol%, or about 1 vol% to about 15 vol%, or about 1 vol% to about 10 vol%, or about 1 vol% to about 5 vol%, or about 3 vol% to about 8 vol%, or about 10 vol% to about 20 vol%) of a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product and about 80 vol% or more (or about 80 vol% to about 99 vol%, or about 85 vol% to about 99 vol%, or about 90 vol% to about 99 vol%, or about 95 vol% to about 99 vol%.
  • a method of the present disclosure may comprise mixing (or blending) a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product with a marine fuel in the foregoing amounts to produce a blended fuel composition.
  • the plastic pyrolysis oil may be produced on-site where the blending occurs or produced off-site and transported to the blending site.
  • Pyrolysis of the plastic feedstock may be performed by known methods and in known systems (e.g, at temperatures of 400°C to 850°C, or 400°C to 600°C, or 500°C to 850°C).
  • the pyrolysis process produces a gas product stream and a liquid product stream (also referred to herein as the total liquid product).
  • the total liquid product is then distilled (or separated) into one or more fractions including, but not limited to, a naphtha fraction, a distillate fraction, and a heavy pyrolysis fuel fraction (e.g., comprising wax and non-distilled residue).
  • plastic sources include, but are not limited to, plastic waste (e.g., plastic straws, plastic utensils, plastic bags, food containers, plastic textiles, and the like), composite materials (e.g., composite packaging), waste streams, industrial scrap, municipal waste, and the like, and any combination thereof.
  • plastic waste e.g., plastic straws, plastic utensils, plastic bags, food containers, plastic textiles, and the like
  • composite materials e.g., composite packaging
  • waste streams industrial scrap, municipal waste, and the like, and any combination thereof.
  • Said plastic sources may comprise one or more polymers that include, but are not limited to, polyolefins (e.g., homopolymer or copolymers of ethylene, propylene, butene, hexene, butadiene, isoprene, isobutylene, and other olefins), polystyrene, polyvinylchloride, polyamide (e.g., nylon), polyethylene terephthalate, polyurethane, ethylene vinyl acetate, and the like. While halogenated polymers, nitrogen-containing polymers, and oxygen-containing polymers may be used, the inclusion of said polymers is preferably minimized so that the hydrocarbon content in the plastic pyrolysis oil is maximized. Other materials may be used in combination with the plastic source to produce the plastic pyrolysis oil, for example, paper, cardboard, textiles, tissues, and the like, and any combination thereof.
  • polyolefins e.g., homopolymer or copolymers of
  • the plastic portion of the plastic feedstock for pyrolysis may comprise poiyolefm at 50 wt% or greater (or 65 wt% to 100 wt%, or 65 wt% to 80 wt%, or 75 wt% to 90 wt%, or 80 wt% to 100 wt%) with a balance of one or more other polymers.
  • a plastic pyrolysis total liquid product may have a density of about 0.75 g/mL to about 0.90 g/mL (or about 0.75 g/mL to about 0.85 g/mL, or about 0.80 g/mL to about 0.90 g/mL).
  • a plastic pyrolysis total liquid product may have a sulfur content of 100 ppm or less (or about 0.5 ppm to about 100 ppm, or about 0.5 ppm to about 50 ppm, or about 25 ppm to about 100 ppm).
  • a plastic pyrolysis total liquid product may have a kinematic viscosity at 50°C of about 1.0 mm 2 /s to about 3.0 rnniVs (or about 1.0 mm 2 /s to about 2.5 mm 2 /s, or about 2.0 mm 2 /s to about 3.0 mm 2 /s).
  • a plastic pyrolysis total liquid product may have a kinematic viscosity at 100°C of about 0.5 mm 2 /s to about 2.5 mnr/s (or about 0.5 mm 2 /s to about 1.5 mm 2 /s, or about 1.0 mm 2 /s to about 2.5 mm 2 /s).
  • a naph tha fracti on of a plastic pyrolysis total liquid product may have a den si ty of about
  • 0.65 g/mL to about 0.80 g/mL (or about 0.65 g/mL to about 0.75 g/mL, or about 0.70 g/mL to about 0.80 g/mL).
  • a naphtha fraction of a plastic pyrolysis total liquid product may have a sulfur content of 100 ppm or less (or about 0.5 ppm to about 100 ppm, or about 0.5 ppm to about. 50 ppm, or about 25 ppm to about 100 ppm).
  • a distillate fraction of a plastic pyrolysis total liquid product may have a density of about 0.70 g/mL to about 0.85 g/mL (or about 0.70 g/mL to about 0.80 g/mL, or about 0.75 g/mL to about 0.85 g/mL).
  • a distillate fraction of a plastic pyrolysis total liquid product may have a sulfur content of 100 ppm or less (or about 0.5 ppm to about 100 ppm, or about 0.5 ppm to about 50 ppm, or about 25 ppm to about 100 ppm).
  • a distillate fraction of a plastic pyrolysis total liquid product may have a cetane index of about 40 to about 80 (or about 40 to about 60, or abo ut 60 to about 80).
  • a distillate fraction of a plastic pyrolysis total liquid product may have a kinematic viscosity at 40°C of about 0.75 mm 2 /s to about 4.5 mm 2 /s (or about 0.75 mm 2 /s to about 3.5 mm 2 /s, or about 2.5 mm 2 /s to about 4.5 mm 2 /s).
  • a distillate fraction of a plastic pyrolysis total liquid product may have a kinematic viscosity at 100°C of about 0.25 mm 2 /s to about 2.25 .mm 2 /s (or about 0.25 mm 2 /s to about 1.5 mm 2 /s, or about 1.25 mm 2 /s to about 2.25 mm 2 /s).
  • a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product may have a density of about 0.70 g/mL to about 0.90 g/mL (or about 0.70 g/mL to about 0.85 g/mL, or about 0.75 g/mL to about 0.90 g/mL).
  • a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product may have a sulfur content of 150 ppm or less (or about 0.5 ppm to about 150 ppm, or about 0.5 ppm to about 75 ppm, or about 50 ppm to about 150 ppm).
  • a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product may have a CCAI of about 750 to about 870 (or about 750 to about 825. or about 800 to about 870).
  • a heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product may have a kinematic viscosity at 50°C of about 3 mm 2 /s to about 20 mm 2 /s (or about 3 mm 2 /s to about 15 mm 2 /s, or about 10 mm 2 /s to about 20 mm 2 /s).
  • Tables 1 and 2 below disclose properties for light cycle oils (LCO) and straight run diesels (SRD) for comparison to the plastic pyrolysis oils described herein.
  • the blended fuel composition produced by mixing the plastic pyrolysis total liquid product and the marine fuel may have properties desirable for a marine fuel.
  • Said blended marine fuel properties may include one or more of the following: (a) a density of about 0.88 g/mL to about 1.1 g/mL; (b) a sulfur content of 3 wt% or less (or about 0.05 wt% to about 3 wt%); (c) a CCA I of about 750 to about 870; and (d) a kinematic viscosity at 50°C of about 5 mm 2 /s to about 700 mm 2 /s (or about 5 mm 2 /s to about 100 mm 2 /s, or about 50 mm 2 /s to about 250 mm 2 /s, or about 200 mm 2 /s to about 500 mm 2 /s, or about 400 mm 2 /s to about 700 mm 2 /s).
  • the blended fuel composition produced by mixing the naphtha fraction of a plastic pyrolysis total liquid product and the gasoline may have properties desirable for a gasoline.
  • Said blended gasoline properties may include one or more of the following: (a) a. density of about 0.7 g/mL to about 0.75 g/mL; and (b) a sulfur content of 100 ppm or less (or about 0.5 ppm to about 100 ppm, or about 0.5 ppm to about 50 ppm, or about 25 ppm to about 100 ppm ).
  • the blended fuel composition produced by mixing the distillate fraction of a plastic pyrolysis total liquid product and the diesel may have properties desirable for a diesel .
  • Said blended diesel properties may include one or more of the following: (a) a density of about 0.8 g/mL to about 0.87 g/mL; (b) a sulfur content of 0.002 wt% or less (or about 0.0002 wt% to about 0.002 wt%); (c) a cetane index of about 40 to about 60; and (d) a kinematic viscosity at 50°C of about 1.5 mm 2 /s to about 4.0 mm 2 /s (or about 1.5 rnm 2 /s to about 3.0 mm 2 /s, or about 2.5 rmn 2 /s to about 4.0 mm 2 /s).
  • the blended fuel composition produced by mixing the distillate fraction of a plastic pyrolysis total liquid product and the marine fuel may have properties desirable for a marine fuel.
  • Said blended marine fuel properties may include one or more of the following: (a) a density of about 0.88 g/mL to about 1.1.
  • the blended fuel composition produced by mixing the heavy pyrolysis fuel fraction of a plastic pyrolysis total liquid product and the marine fuel may have properties desirable for a marine fuel.
  • Said blended marine fuel properties may include one or more of the following: (a) a density of about 0.88 g/mL to about 1.1 g/mL; (b) a sulfur content of 3 wt% or less (or about 0.05 wt% to about 3 wt%); (c) a CCA1 of about 750 to about 870; and (d) a kinematic viscosity at 50°C of about 5 mm 2 /s to about 700 mm 2 /s (or about 5 mm 2 /s to about 100 mm 2 /s, or about 50 mnr/s to about 250 mm 2 /s, or about 200 mm 2 /s to about 500 mm 2 /s, or about 400 mm 2 /s to about 700 mm 2 /s).
  • a first nonlimiting example embodiment of the present disclosure is a method comprising: blending a plastic pyrolysis oil with a blendstock fuel to produce a blended fuel composition, wherein the blended fuel composition comprises about 1 vol% to about 20 vol% of the plastic pyrolysis oil and about 80 vol% to about 99 vol% of the blendstock fuel, and wherein a combination of the plastic pyrolysis oil and the blendstock fuel is selected from the group consisting of: a naphtha fraction of the plastic pyrolysis total liquid product and gasoline; a distillate fraction of the plastic pyrolysis total liquid product and diesel; the distillate fraction of the plastic pyrolysis total liquid product and a marine fuel; a heavy pyrolysis fuel fraction of the plastic pyrolysis total liquid product and the marine fuel; and the plastic pyrolysis total liquid product and the marine fuel.
  • a second nonlimiting example embodiment of the present disclosure is a blended fuel composition
  • a blended fuel composition comprising: about 1 vol% to about 20 vol% of a plastic pyrolysis oil and about 80 vol% to about 99 vol% of the blendstock fuel, and wherein a combination of the plastic pyrolysis oil and the blendstock fuel is selected from the group consisting of: a naphtha fraction of the plastic pyrolysis total liquid product and gasoline; a distillate fraction of the plastic pyrolysis total liquid product and diesel; the distillate fraction of the plastic pyrolysis total Liquid product and a marine iuel; a heavy pyrolysis fuel fraction of the plastic pyrolysis total liquid product and the marine fuel; and the plastic pyrolysis total liquid product and the marine fuel
  • the first and second nonlimiting example embodiment may further include one or more of: Element 1 : wherein the blended fuel composition comprises about 5 vol% to about 10 vol% of the plastic pyrolysis oil and about 90 vol% to about 95 vol% of the blendstock fuel; Element 2: wherein the plastic pyrolysis oil is the plastic pyrolysis total liquid product, and wherein the plastic pyrolysis total liquid product has one or more of the following properties: (a) a density of about 0.75 g/mL to about 0.90 g/mL; (b) a sulfur content of 100 ppm or less; (c) a kinematic viscosity at 50°C of about L0 mm 2 /s to about 3.0 mm 2 /s; and (d) a kinematic viscosity at 100°C of about 0.5 mm 2 /s to about.
  • Element 1 wherein the blended fuel composition comprises about 5 vol% to about 10 vol% of the plastic pyrolysis oil and about 90 vol% to about 95 vol%
  • Element 3 Element 2 and wherein the combination is the plastic pyrolysis total liquid product and the marine fuel and wherein the blended fuel composition has one or more of the following properties: (a) a density of about 0,88 g/mL to about 1.1 g/mL; (b) a sulfur content of 3 wt% or less; (c) a CC Al of about 750 to about 870; and (d) a kinematic viscosity at 50°C of about 5 mm 2 /s to about 700 mm 2 /s; Element 4: wherein the naphtha fraction of the plastic pyrolysis oil is the plastic pyrolysis total liquid product, and wherein the naphtha fraction has one or more of the following properties: (a) a density of about 0.65 g/mL to about 0,80 g/mL; (b) a sulfur content of 100 ppm or less; (c) a cetane index of about 40 to about 80; (d) a
  • Element I in combination with Element 2 and optionally Element 3; Element 1 in combination with Element 4 and optionally Element 5; Element 1 in combination with Element 6 and optionally Element 7; Element 1 in combination with Element 6 and optionally Element 8; and Element 1 in combination with Element 9 and optionally Element 10.
  • compositions and methods are descri bed herein in terms of “comprising” various components or steps, the compositions and methods can also “consist essentially of’ or “consist of” the various components and steps.
  • Tables 3-13 provide the properties an Initial fuel oil (blendstock) and a pyrolyzed plastic oil used to produce a variety of blended fuel compositions, whose properties are also provided in Tables 3-13. More specifically, Tables 3-5 are blends of marine fuel having different sulfur contents with plastic pyrolysis total liquid product; Tables 6-8 are blends of marine fuel having different sulfur contents with the heavy fraction of plastic pyrolysis total liquid product; Tables 9- 11 are blends of marine fuel having different sulfur contents with the distillate fraction of plastic pyrolysis total liquid product; Table 12 is a blend of diesel with the distillate fraction of plastic pyrolysis total liquid product; and Table .13 is a blend of gasoline with the naphtha, fraction of plastic pyrolysis total liquid product.
  • Tables 3-5 illustrate that viscosity of the marine fuel blendstock can be greatly reduced with as little as 1 vol% of plastic pyrolysis total liquid product. Further, high concentrations of plastic pyrolysis total liquid (e.g., 10 vol% to .15 vol%) reduces the sulfur content of the marine fuel. Further, these examples illustrate that the plastic pyrolysis total liquid product without further processing, which would typically be required of fossil fuel-derived blending hydrocarbons, can be included at concentrations of 15 vol% into marine fuels.
  • Tables 6-8 illustrate that viscosity of the marine fuel blendstock can be greatly reduced with as little as 1 voI% of the heavy fraction of plastic pyrolysis total liquid product. Further, high concentrations of the heavy fraction of plastic pyrolysis total liquid (e.g., 10 vol% to 15 vol%) reduces the sulfur content of the marine fuel. Additionally, these examples illustrate that the heavy fraction of a plastic pyrolysis total liquid product can be included at concentrations of 15 vol% into marine fuels.
  • Tables 9-1 1 illustrate that viscosity of the marine fuel blendstock can be greatly reduced with as little as 1 vol% of the distillate fraction of plastic pyrolysis total liquid product. Further, high concentrations of the distillate fraction of plastic pyrolysis total liquid (e.g., 10 vol% to 15 vol%) reduces the sulfur content of the marine fuel. Additionally, these examples illustrate that the distillate fraction of a plastic pyrolysis total liquid product can be included at concentrations of 15 vol% into marine fuels.
  • Table 12 illustrates that a distillate fraction of plastic pyrolysis total liquid product can be blended with an ultra-low sulfur diesel to increase the cetane index and decrease the density while minimally increasing the sulfur content.
  • fossil fuel-derived blending hydrocarbons would likely need io undergo significant and cosily desulfurization to be used with ultra-low sulfur diesel. Further, said fossil fuel-derived blending, hydrocarbons would likely have a higher density (e.g,, Table 1 and Table 2) and the reduction in density benefits of Table 3 would not be realized.
  • Table 13 illustrates that a distillate fraction of plastic pyrolysis total liquid product can be blended with an ultra-low sulfur diesel to increase the cetane index and decrease the density while minimally increasing the sulfur content.
  • fossil fuel-derived blending hydrocarbons would likely need io undergo significant and cosily desulfurization to be used with ultra-low sulfur diesel. Further, said fossil fuel-derived blending, hydrocarbons would likely have a higher density (e.g, Table 1 and Table 2) and the reduction in density benefits of
  • Fable 13 illustrates that the naphtha traction of plastic pyrolysis total, liquid product can be blended with gasoline fuel to reduce the density.
  • Tables 3-13 illustrate that plastic pyrolysis (total liquid product or a .fraction thereof) can be blended with a variety of blendstock fuels (e.g., marine fuel, naphtha fuel, and diesel) in varying concentrations, including at 15 vol%, to tune the density, viscosity, and other properties while producing a blended fuel with an acceptable low sulfur content (which in many cases is a reduced sulfur content).
  • blendstock fuels e.g., marine fuel, naphtha fuel, and diesel
  • compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of’ or “consist, of’ the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values.
  • a method of making a blended fuel composition comprising: blending a plastic pyrolysis oil with a blendstock fuel to produce a blended fuel composition, wherein the blended fuel composition comprises 1 vol% to 20 vol% of the plastic pyrolysis oil and 80 vol% to 99 vol% of the blendstock fuel, and wherein a combination of the plastic pyrolysis oil and the blendstock fuel is selec ted from the group consisting of: a naphtha fraction of the plastic pyrolysis total liquid product and gasoline; a distillate fraction of the plastic pyrolysis total liquid product and diesel; the distillate fraction of the plastic pyrolysis total liquid product and a marine fuel; a heavy pyrolysis fuel fraction of the plastic pyrolysis total liquid product and the marine fuel; and, the plastic pyrolysis total liquid product and the marine fuel.
  • the plastic pyrolysis oil is the plastic pyrolysis total liquid product
  • the plastic pyrolysis total liquid product has one or more of the following properties: (a) a density' of 0.75 g/mL to 0.90 g/mL; (b) a sulfur content of 100 ppm or less; (c) a kinematic viscosity at 50°C of 1 .0 mm 2 /s to 3.0 mm 2 /s; and (d) a kinematic viscosity at 100°C of 0.5 mm 2 /s to 2.5 mm 2 /s.
  • the naphtha fraction of the plastic pyrolysis oil is the plastic pyrolysis total liquid product, and wherein the naphtha fraction has one or more of the following properties: (a) a density of 0.65 g/mL to 0.80 g/mL; Cb) a sulfur content of 100 ppm or less; (c) a cetane index of 40 to 80; (d) a kinematic viscosity at 50°C of 0.5 mm 2 /s to 2.5 mm 2 /s; and (e) a kinematic viscosity at 100°C of 0. 1 mm 2 /s to 2.0 mm 2 /s. [0082] 5. The method of clause 4.
  • the combination is the naphtha fraction of the plastic pyrolysis total liquid product and the gasoline, and wherein the blended fuel composition has one or more of the following properties: (a) a density of 0.7 g/mL to 0.75 g/mL; and (b) a sulfur content of 100 ppm or less.
  • the distillate fraction of the plastic pyrolysis oil is the plastic pyrolysis total liquid, product, and wherein the distillate fraction has one or more of the following properties: (a) a density of 0.70 g/mL to 0.85 g/mL; (b) a sulfur content of 100 ppm or less; (c) a cetane index of 40 to 80; (d) a kinematic viscosity at 40°C of 0.75 mm 2 /s to 4.5 mm 2 /s; and (e) a kinematic viscosity at 100°C of 0.25 mm 2 /s to 2.25 mm 2 /s,
  • the combination is the distillate fraction of the plastic pyrolysis total liquid product and the marine fuel, and wherein the blended fuel composition has one or more of the following properties: (a) a density of 0.88 g/mL to 1 .1 g/mL; (b) a sulfur content of 3 wt.% or less; (c) a CCAI of 750 to 870: and (d) a kinematic viscosity at 50°C of 5 mm 2 /s to 700 mm 2 /s.
  • a blended fuel composition comprising: 1 vol% to 20 vol% of a plastic pyrolysis oil and 80 vol% to 99 vol% of the blendstock fuel, and wherein a combination of the plastic pyrolysis oil and the blendstock fuel is selected from the group consisting of: a naphtha- fraction of the plastic pyrolysis total liquid product and gasoline; a distillate fraction of the plastic pyrolysis total liquid product and diesel; the distillate fraction of the plastic pyrolysis total liquid product and a marine fuel; a heavy pyrolysis fuel fraction of the plastic pyrolysis total liquid product and the marine fuel; and the plastic pyrolysis total liquid product and the marine fuel.

Abstract

L'invention concerne une composition mélangée de carburant comprenant le produit liquide total d'une huile de pyrolyse de plastique ou une fraction correspondante et un procédé de fabrication d'une telle composition mélangée de carburant. La composition mélangée de carburant peut comprendre environ 1 % en volume à environ 20 % en volume d'une huile de pyrolyse de plastique et environ 80 % en volume à environ 99 % en volume du carburant de composé de base. La combinaison de l'huile de pyrolyse de plastique et du carburant de composé de base est choisie dans le groupe constitué par : une fraction de naphta du produit liquide total de pyrolyse de plastique et de l'essence ; une fraction de distillat du produit liquide total de pyrolyse de plastique et du diesel ; la fraction de distillat du produit liquide total de pyrolyse de plastique et un comburant marin ; une fraction lourde de comburant de pyrolyse du produit liquide total de pyrolyse de plastique et le comburant marin ; et le produit liquide total de pyrolyse de plastique et le comburant marin.
PCT/US2022/071191 2021-04-01 2022-03-17 Compositions mélangées de carburant comprenant de l'huile de pyrolyse de plastique et procédés pour leur fabrication WO2022213021A1 (fr)

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US11964315B1 (en) * 2023-06-01 2024-04-23 Nexus Circular LLC Hydrocarbon compositions derived from pyrolysis of post-consumer and/or post-industrial plastics and methods of making and use thereof

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US11964315B1 (en) * 2023-06-01 2024-04-23 Nexus Circular LLC Hydrocarbon compositions derived from pyrolysis of post-consumer and/or post-industrial plastics and methods of making and use thereof

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