US20250001474
2025-01-02
Performing operations; transporting
B09B3/40
The patent application describes systems and methods for converting waste plastic into hydrocarbon fuels, providing a solution to the challenge of managing plastic waste. The process employs a Non-Catalytic Reformation System (NCR) to transform un-recycled plastic waste into sustainable fuels like diesel and gasoline, along with other products such as paraffin and LPG. This eco-friendly approach supports a circular economy by reducing reliance on fossil fuels and mitigating the environmental impact of plastic waste.
Plastic is extensively used in various applications, resulting in significant waste generation. In the United States alone, over 30 million tons of plastic waste are produced annually, with less than 10% being recycled. This contributes to severe environmental issues, including pollution of land and oceans. Traditional recycling methods fail to address the majority of non-recyclable plastics, necessitating innovative solutions for responsible waste management.
The proposed method involves a single, concurrent thermal physical process to generate hydrocarbon fuels from plastic waste. Initially, shredded plastic is super-heated in an oxygen-free environment, volatilizing it into gas. This gas is then transferred to condensing units where it is liquefied into various fuel types. The process is non-catalytic, utilizing an NCR system to efficiently convert plastic into valuable resources without additional catalyst materials.
The system includes reformers that heat preprocessed plastic in an oxygen-free environment to produce gas. A series of condensing units then concurrently condense this gas into different fuel types. The NCR system features enhanced insulation and automated thermodynamic control for improved efficiency and reduced labor requirements. It also includes emergency gas evacuation systems and residue removal equipment to ensure safe and efficient operation.
Once volatized, the gas from the plastic waste is cooled and condensed into various products such as paraffin, diesel, heavy diesel, gasoline fuels, and LPG. The LPG is reused within the system to fuel heaters for the reformation process. The generated fuels are collected, tested, and stored with systems in place to detect emissions from potential leaks or spills. Special additives may be introduced as needed to meet market specifications.