Regeneration of plastics pyrolysis catalysts
AssigneeAnellotech, Inc.
InventorsZhihua Wu, Torren Carlson, Omar Basha, Leslaw Mleczko
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Abstract
Methods and apparatus for the regeneration of catalysts used in catalytic pyrolysis of waste plastics, polymers, and other waste materials to useful chemical and fuel products such as paraffins, olefins, and aromatics such as BTX is described in which minerals are removed by washing to restore catalytic activity and selectivity. A catalytic pyrolysis process that includes the regeneration of a portion of the catalyst used for the catalytic pyrolysis with a washing process is described.
Claims32
A method of regenerating a catalyst used in the catalytic pyrolysis of plastics, comprising:
- providing a catalyst that has been used to catalyze a catalytic pyrolysis of plastics process;
- oxidatively regenerating the catalyst;
- washing at least a portion of the catalyst with a liquid wash solution;
- rinsing the washed catalyst with an aqueous liquid solution;
- separating the catalyst from the rinse solution;
- and
- returning at least a portion of the separated catalyst to the process for the catalytic pyrolysis of plastics.
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A method of converting plastics to hydrocarbon products, comprising:
- feeding plastics into a reactor fitted with a catalyst;
- pyrolyzing the plastics in the reactor in the presence of the catalyst that catalyzes the pyrolysis reaction which results in coke-contaminated catalyst;
- removing a portion of the catalyst from the reactor;
- oxidatively regenerating the catalyst;
- washing at least a portion of the catalyst with a liquid wash solution;
- rinsing the washed catalyst with an aqueous solution;
- separating the catalyst from the rinse solution;
- returning at least a portion of the washed catalyst to the process for the catalytic pyrolysis of plastics;
- and
- returning at least a portion of the unwashed regenerated catalyst to the process for the catalytic pyrolysis of plastics.
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A catalyst that has been used in the catalytic pyrolysis of plastics wherein one or more of the elements Ca, Mg, K, or Na deposited on the catalyst during the catalytic pyrolysis reaction has been at least partially removed by washing with a liquid wash solution and rinsing with an aqueous solution, wherein the deposited elements comprise at least 0.1% of the total mass of catalyst.
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Dependencies are inferred from the claim text.