Processes for viscosity breaking of plastics

Patent metadata

Field	Value
Publication number	US-12384971-B2
Application number	US-202318471545-A
Country	US
Kind code	B2
Filing date	Sep 21, 2023
Priority date	Nov 16, 2022
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

Abstract

A process for converting solid plastic waste to hydrocarbon oil includes melting a feed comprising solid plastic waste to produce a liquefied plastic stream and visbreaking the liquefied plastic stream in a visbreaker unit having a visbreaker furnace and a soaker vessel. Visbreaking includes heating the liquefied plastic stream in the visbreaker furnace to produce a heated liquefied plastic stream, maintaining the heated liquefied plastic stream at the reaction temperature in the soaker vessel for a residence time to produce a visbreaker effluent, and injecting a stripping gas into the soaker vessel. The stripping gas includes at least one of steam, nitrogen, helium, argon, or combinations of these. The process includes introducing the stripping gas to the liquefied plastic stream upstream of the visbreaker furnace, the heated liquefied plastic stream downstream of the visbreaker furnace, or both. The visbreaker effluent is separated to produce a liquid hydrocarbon oil.

First claim

What is claimed is:

1. A system for converting solid plastic waste comprises:
a melting vessel;
a visbreaker unit in fluid communication with the melting vessel and downstream of the melting vessel, wherein the visbreaker unit comprises a visbreaker furnace and a soaker vessel downstream of the visbreaker furnace, wherein the visbreaker furnace comprises a convection section and a radiation section downstream of the convection section; and
a visbreaker effluent separation unit in fluid communication with the visbreaker unit and downstream of the visbreaker unit
wherein:
the visbreaker furnace is in fluid communication with the soaker vessel via a heated liquid plastic stream,
the system further comprises a stripping gas stream in fluid communication with the heated liquid plastic stream at a point between the visbreaker furnace and a stripper vessel; and
the stripping gas stream passes through the convection section, upstream of the point of fluid communication between the stripping gas stream and the heated liquid plastic stream.

2. The system of claim 1 , further comprising a plastic grinder in fluid communication with the melting vessel and upstream of the melting vessel.

3. The system of claim 1 , further comprising a supercritical water unit in fluid communication with the visbreaker effluent separation unit and downstream of the visbreaker effluent separation unit.

4. The system of claim 3 , further comprising a supercritical water unit effluent separation system downstream of the supercritical water unit.

5. The system of claim 3 , further comprising a filter in fluid communication with and disposed between the visbreaker effluent separation unit and the supercritical water unit, wherein the filter is configured to remove solid material.

6. The system of claim 1 , further comprising a filter in fluid communication with and disposed between the melting vessel and the visbreaker unit, wherein the filter is configured to remove solid material.

7. The system of claim 1 , further comprising a metering pump in fluid communication with and disposed between the melting vessel and the visbreaker unit.

8. The system of claim 1 , wherein the melting vessel is in fluid communication with the visbreaker unit through at least one pipe, and the at least one pipe is heated externally.

9. The system of claim 1 , wherein the radiation section is a thermal radiation section.

10. The system of claim 1 , wherein the radiation section comprises an electric heater.

11. The system of claim 1 , wherein the convection section and the radiation section are separated by a partition such that the convection section is out of sight of the radiation section.

12. A system for converting solid plastic waste comprises:
a melting vessel;
a visbreaker unit in fluid communication with the melting vessel and downstream of the melting vessel, wherein the visbreaker unit comprises a visbreaker furnace and a soaker vessel downstream of the visbreaker furnace;
a visbreaker effluent separation unit in fluid communication with the visbreaker unit and downstream of the visbreaker unit; and
a supercritical water unit in fluid communication with the visbreaker effluent separation unit and downstream of the visbreaker effluent separation unit, wherein the supercritical water unit comprises:
a mixing unit;
a pressurized water preheater upstream of and in fluid communication with a tubular reactor,
the tubular reactor being downstream of the mixing unit; and
a furnace, wherein:
the furnace is the visbreaker furnace;
the at least a portion of the tubular reactor passes through a convection section of the visbreaker furnace; and
at least a portion of the pressurized water preheater passes through a radiation section of the visbreaker furnace

wherein:
the visbreaker furnace is in fluid communication with the soaker vessel via a heated liquid plastic stream,
the system further comprises a stripping gas stream in fluid communication with the heated liquid plastic stream at a point between the visbreaker furnace and a stripper vessel; and
the stripping gas stream passes through the convection section, upstream of the point of fluid communication between the stripping gas stream and the heated liquid plastic stream.

13. The system of claim 12 , further comprising a supercritical water unit effluent separation system downstream of the supercritical water unit.

14. The system of claim 12 , further comprising a metering pump disposed between the visbreaker effluent separation unit and the supercritical water unit.

15. The system of claim 12 , further comprising a filter disposed between the visbreaker effluent separation unit and the supercritical water unit, wherein the filter is configured to remove solid material.

16. The system of claim 12 , wherein the radiation section of the visbreaker furnace is a thermal radiation section.

17. The system of claim 12 , wherein the convection section and the radiation section are separated by a partition such that the convection section is out of sight of the radiation section.

Assignees

• Saudi Arabian Oil Co

Inventors

• Choi Ki-Hyouk
• Alabdulhadi Abdullah Tariq
• Lee Joo-Hyeong
• Ahn Young Kyoung
• Yami Abdullah Saleh
• Shahrani Saad Abdullah

Classifications

• B09B2101/77

  containing chlorine · CPC title

• B09B3/80

  involving an extraction step · CPC title

• B09B3/45 Primary

  Steam treatment, e.g. supercritical water gasification or oxidation · CPC title

• C10G9/007

  Visbreaking · CPC title

• C10G55/04

  including at least one thermal cracking step · CPC title