System and process for converting plastics to petroleum products

Abstract

A system and process for converting plastics and other heavy hydrocarbon solids into retail petroleum products are provided. The plastics are processed by melting, pyrolysis, vapourization, and selective condensation, whereby final in-spec petroleum products are produced. The system provides a reactor for subjecting the plastics to pyrolysis and cracking hydrocarbons in the plastics to produce a plastics vapour comprising hydrocarbon substituents; one or more separation vessels for separating the plastics vapour into hydrocarbon substituents based on boiling points of the hydrocarbon substituents; one or more condensers for condensing the hydrocarbon substituents into one or more petroleum products; and means for collecting the one or more petroleum products. Fuels generated during the process can be recycled for use upstream in the process.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A system for processing plastics into one or more petroleum products, the system comprising:
 a) a reactor for subjecting the plastics to pyrolysis and cracking hydrocarbons in the plastics to produce a plastics vapour comprising hydrocarbon substituents;   b) one or more separation vessels for separating the plastics vapour into hydrocarbon substituents based on boiling points of the hydrocarbon substituents;   c) one or more condensers for condensing the hydrocarbon substituents into one or more petroleum products; and   d) means for collecting the one or more petroleum products.   
     
     
         2 . The system of  claim 1 , further comprising a premelt reactor for melting the plastics prior to pyrolysis in the reactor. 
     
     
         3 . The system of  claim 1  or  2 , wherein the pyrolysis of the plastics is at a temperature of 340 to 445° C., 350 to 425° C., or 400° C. 
     
     
         4 . The system of  claim 2 , wherein the melting of the plastics is at a temperature of 250° C. to 340 C. 
     
     
         5 . The system of any one of  claims 1  to  4 , wherein the petroleum products are diesel, gasoline, furnace fuel, kerosene, propane, butane, ethane or methane. 
     
     
         6 . The system of any one of  claims 1  to  5 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         7 . The system of any one of  claims 1  to  6 , wherein the separation vessel comprises a catalyst. 
     
     
         8 . A system for processing plastics into one or more petroleum products, the system comprising:
 a) conveyor means for receiving the plastics;   b) a premelt reactor for melting the plastics to produce a liquid plastic material;   c) a reactor for subjecting the liquid plastic material to pyrolysis and cracking hydrocarbons in the plastics to produce a plastics vapour comprising hydrocarbon substituents;   d) a cyclone for removing solid and liquid residue from the reactor;   e) one or more separation vessels for separating the plastics vapour into liquid petroleum products and gaseous petroleum products based on boiling points thereof;   f) one or more receptacles in communication with the one or more separation vessels for collecting the liquid petroleum products separated from the gaseous petroleum products;   g) one or more condensers for condensing at least a portion of the gaseous petroleum products;   h) one or more receptacles for collecting the condensed portion of the gaseous petroleum products; and   i) a water seal for collecting a remaining portion of the gaseous petroleum products use as a fuel in heating the reactor or the premelt reactor.   
     
     
         9 . A process for processing plastics into one or more petroleum products, the process comprising:
 providing plastics to a pyrolysis reactor;   subjecting the plastics to pyrolysis and cracking to produce a plastics vapour, plastics liquids and plastics solids comprising hydrocarbon substituents;   separating the plastics vapour in a separation vessel to form a first liquid petroleum product from a gaseous petroleum product; and   condensing the gaseous petroleum product into a second liquid petroleum product.   
     
     
         10 . The process of  claim 9 , further comprising melting the plastics in a premelting reactor prior to pyrolysis. 
     
     
         11 . The process of  claim 9  or  10 , further comprising refluxing the plastics liquids and plastics solids in the pyrolysis reactor for further pyrolysis and cracking. 
     
     
         12 . The process of any one of  claims 9  to  11 , wherein the pyrolysis of the plastics is at a temperature of 340 to 445° C., 350 to 425° C., or 400° C. 
     
     
         13 . The process of  claim 10 , wherein the melting of the plastics is at a temperature of 250° C. 
     
     
         14 . The process of any one of  claims 9  to  13 , wherein the petroleum products are diesel, gasoline, furnace fuel, kerosene, propane, butane, ethane or methane. 
     
     
         15 . The process of any one of  claims 9  to  14 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C.