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 substitutents 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.

What is claimed is: 
     
         1 . A process for processing plastics into one or more petroleum products, the process comprising:
 providing plastics to a pyro lysis 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.   
     
     
         2 . The process of  claim 1 , further comprising melting the plastics in a premelting reactor prior to pyrolysis. 
     
     
         3 . The process of  claim 2 , further comprising refluxing the plastics liquids and plastics solids in the pyrolysis reactor for further pyrolysis and cracking. 
     
     
         4 . The process of  claim 1 , further comprising refluxing the plastics liquids and plastics solids in the pyrolysis reactor for further pyrolysis and cracking. 
     
     
         5 . The process of  claim 1 , wherein the pyrolysis of the plastics is at a temperature of 340 to 445° C., 350 to 425° C., or 400° C. 
     
     
         6 . The process of  claim 2 , wherein the pyrolysis of the plastics is at a temperature of 340 to 445° C., 350 to 425° C., or 400° C. 
     
     
         7 . The process of  claim 3 , wherein the pyrolysis of the plastics is at a temperature of 340 to 445° C., 350 to 425° C., or 400° C. 
     
     
         8 . The process of  claim 4 , wherein the pyrolysis of the plastics is at a temperature of 340 to 445° C., 350 to 425° C., or 400° C. 
     
     
         9 . The process of  claim 2 , wherein the melting of the plastics is at a temperature of 250° C., 
     
     
         10 . The process of  claim 1 , wherein the petroleum products are diesel, gasoline, furnace fuel, kerosene, propane, butane, ethane or methane. 
     
     
         11 . The process of  claim 1 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         12 . The process of  claim 2 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         13 . The process of  claim 3 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         14 . The process of  claim 4 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         15 . The process of  claim 5 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         16 . The process of  claim 6 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         17 . The process of  claim 7 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         18 . The process of  claim 8 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         19 . The process of  claim 9 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C. 
     
     
         20 . The process of  claim 10 , wherein the separation of the plastics vapour in the separation vessel is at about 240° C. to about 300° C.