BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method in which waste plastic material or waste
rubber material is recycled so as to obtain hydrocarbon oil and an apparatus used
for carrying out the method.
[0002] In present motor vehicles, a vehicle body panel, various interior parts, tires, etc.
are formed by polymer such as plastic or rubber material and ratio of plastic material
or rubber material used for each motor vehicle has been raised gradually. Therefore,
even if only one motor vehicle is scrapped after its service life, a considerable
quantity of waste plastic material or waste rubber material is generated. Since a
number of motor vehicles are scrapped every day at present, a total quantity of waste
plastic material or waste rubber material is enormous.
[0003] Such waste plastic material or waste rubber material, which is produced in huge quantity
only in connection with motor vehicles, is tested for various effective recycling
purposes in various industrial fields including car industry. Furthermore, efforts
for further promoting the recycling are being exerted. Under these circumstances,
Japanese Patent Laid-Open Publication No. 63-178195 (1988) proposes, as one example
of recycling of waste plastic material or waste rubber material, that hydrocarbon
oil is produced from waste plastic material and the produced hydrocarbon oil is used
as fuel, etc.
[0004] In a known method of producing hydrocarbon oil from waste plastic material, the waste
plastic material is subjected to thermal cracking so as to obtain thermal cracking
gas and the thermal cracking gas is subjected to catalytic cracking by using proper
catalyst so as to obtain catalytic cracking gas and then, the catalytic cracking gas
is cooled so as to obtain hydrocarbon oil having relatively low boiling point. For
example, in a method disclosed in the above mentioned prior art document No. 63-178195
(1988), thermal cracking of the plastic material is performed in melt phase at a temperature
of 390 °C to 500 °C, while catalytic cracking of the thermal cracking gas is performed
at a temperature of 200 °C to 350 °C by using zeolite as the catalyst. As a result,
low-boiling hydrocarbon oil containing 22 carbon atoms or less is obtained. This known
method in which the hydrocarbon oil is obtained by thermal cracking, catalytic cracking
and cooling steps can be applied to not only waste plastic material but waste rubber
material.
[0005] When the hydrocarbon oil is produced from waste plastic material or waste rubber
material as described above, catalyst such as zeolite used for catalytic cracking
of the thermal cracking gas produced through thermal cracking of the waste plastic
material or the waste rubber material is maintained at not more than a predetermined
temperature lower than a temperature for thermal cracking of the waste plastic material
or the waste rubber material so as to prevent heat deterioration of the catalyst.
Therefore, the thermal cracking gas produced through thermal cracking of the waste
plastic material or the waste rubber material is cooled by the catalyst during catalytic
cracking. As a result, high-boiling hydrocarbon component (wax component) contained
in the thermal cracking gas adheres to the catalyst, thereby resulting in drop of
function of the catalyst.
[0006] Thus, as a measure for restraining drop of function of the catalyst for catalytic
cracking, a method is considered in which content of the high-boiling hydrocarbon
component in the thermal cracking gas is lowered by further raising temperature for
thermal cracking of the waste plastic material or the waste rubber material such that
amount of the high-boiling hydrocarbon component adhering to the catalyst for catalytic
cracking is reduced. However, in this case, content of low-boiling hydrocarbon component
in the catalytic cracking gas, which is kept in gaseous state without being converted
to hydrocarbon oil even when being cooled, increases. As a result, recovery of the
hydrocarbon oil drops undesirably.
SUMMARY OF THE INVENTION
[0007] Accordingly, in view of the above mentioned disadvantages inherent in prior art,
an essential object of the present invention is to provide a method of obtaining hydrocarbon
oil from waste plastic material or waste rubber material and an apparatus used for
carrying out the method, in which when thermal cracking gas obtained by thermal cracking
of the waste plastic material or the waste rubber material is subjected to catalytic
cracking by using proper catalyst so as to obtain catalytic cracking gas and the catalytic
cracking gas is cooled so as to obtain the hydrocarbon oil, not only heat deterioration
of the catalyst for catalytic cracking and drop of function of the catalyst for catalytic
cracking due to adherence of high-boiling hydrocarbon component thereto can be restrained
effectively but recovery of the hydrocarbon oil can be raised.
[0008] In order to accomplish this object of the present invention, a method of obtaining
hydrocarbon oil from waste plastic material or waste rubber material, according to
the present invention comprises the steps of: subjecting the waste plastic material
or the waste rubber material to thermal cracking at a temperature exceeding 450 °C
so as to obtain a thermal cracking product; subjecting the thermal cracking product
to catalytic cracking by using solid acid catalyst so as to obtain a catalytic cracking
product; cooling the catalytic cracking product so as to obtain first hydrocarbon
oil and cracking gas component; and subjecting the cracking gas component to oligomerization
by using polymerization catalyst so as to obtain second hydrocarbon oil.
[0009] In this method, it is preferable that the catalytic cracking product is obtained
at a temperature of 120 °C to 250 °C.
[0010] Meanwhile, an apparatus for producing hydrocarbon oil, according to the present invention
comprises: a thermal cracking portion in which waste plastic material or waste rubber
material is subjected to thermal cracking at a temperature exceeding 450 °C so as
to obtain a thermal cracking product; a catalytic cracking portion in which the thermal
cracking product is subjected to catalytic cracking by using solid acid catalyst so
as to obtain a catalytic cracking product; a cooling portion in which the catalytic
cracking product is cooled so as to obtain first hydrocarbon oil and cracking gas
component; an oligomerization portion in which the cracking gas component is subjected
to oligomerization by using polymerization catalyst so as to obtain second hydrocarbon
oil; and a recovery portion for recovering the first and second hydrocarbon oils from
the cooling portion and the oligomerization portion, respectively.
[0011] Meanwhile, in this apparatus, it is preferable that the catalytic cracking product
is obtained in the catalytic cracking portion at a temperature of 120 °C to 250 °C.
[0012] As described above, in the method of obtaining the hydrocarbon oil from the waste
plastic material or the waste rubber material, according to the present invention
and the hydrocarbon oil producing apparatus of the present invention, the waste plastic
material or the waste rubber material is subjected to thermal cracking at a relatively
high temperature exceeding 450 °C so as to obtain the thermal cracking product and
the thermal cracking product is subjected to catalytic cracking at a relatively low
temperature of, for example, 120 °C to 250 °C by using the solid acid catalyst so
as to obtain the catalytic cracking product. Therefore, content of the high-boiling
hydrocarbon component in the thermal cracking product is lowered. Thus, even during
catalytic cracking at a relatively low temperature, drop of function of the solid
acid catalyst for catalytic cracking due to adherence of the high-boiling hydrocarbon
component thereto can be restrained effectively. Meanwhile, since the solid acid catalyst
for catalytic cracking is maintained at a relatively low temperature, heat deterioration
of the solid acid catalyst is restrained effectively. Furthermore, the cracking gas
component which is obtained together with the first hydrocarbon oil by cooling the
catalytic cracking product is oligomerized by using the polymerization catalyst so
as to produce the second hydrocarbon oil. Accordingly, in addition to the first hydrocarbon
oil obtained by cooling the catalytic cracking product, the second hydrocarbon oil
is obtained by oligomerization of the cracking gas component, so that recovery of
the hydrocarbon oil is raised greatly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] This object and features of the present invention will become apparent from the following
description taken in conjunction with the preferred embodiment thereof with reference
to the accompanying drawings, in which:
Fig. 1 is a schematic view of a hydrocarbon oil producing apparatus of the present
invention, which is used for carrying out a method of obtaining hydrocarbon oil from
waste plastic material or waste rubber material, according to the present invention;
and
Fig. 2 is a schematic view of an experimental apparatus employed for comparison between
the method of the present invention and another method.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to the drawings, there is shown in Fig. 1, a hydrocarbon oil producing
apparatus K of the present invention, which is used for carrying out a method of obtaining
hydrocarbon oil from waste plastic material or waste rubber material, according to
the present invention. In Fig. 1, the apparatus K includes a hopper 12 in which recycling
material 11 such as waste plastic material including polypropylene or waste rubber
material is stored. A screw conveyor 14 is provided in operative association with
the hopper 12 so as to, by using a rotating screw 13, grind and deliver to a thermal
cracking tank 15 the recycling material 11 supplied from the hopper 12.
[0015] The thermal cracking tank 15 is constituted by a tank body 15B having an inlet port
15A and a heater 16. A discharge portion of the screw conveyor 14 is coupled with
the inlet port 15A such that the recycling material 11 supplied from the inlet port
15A into the tank body 15B is heated for thermal cracking by the heater 16. A temperature
sensor 17 for detecting temperature of interior of the tank body 15B is provided on
the tank body 15B. Temperature control of the heater 16 is performed on the basis
of detection output of the temperature sensor 17 such that thermal cracking temperature
in the tank body 15B is maintained at a predetermined temperature exceeding 450 °C.
[0016] An upper portion of the tank body 15B of the thermal cracking tank 15 is coupled
with a gas inlet port 18A of a catalytic cracking tank 18 in which thermal cracking
gas obtained, as thermal cracking product, in the tank body 15B is subjected to catalytic
cracking. The catalytic cracking tank 18 contains aluminum chloride (AlCl₃.6H₂O) 19
acting as solid acid catalyst and the thermal cracking gas supplied through the gas
inlet port 18A from the tank body 15B is brought into contact with the aluminum chloride
19 so as to be subjected to catalytic cracking. A temperature sensor 20 for detecting
temperature of interior of the catalytic cracking tank 18 is provided on the catalytic
cracking tank 18. The catalytic cracking tank 18 is heated by a heater (not shown)
undergoing temperature control on the basis of detection output of the temperature
sensor 20 such that catalytic cracking temperature in the catalytic cracking tank
18 is maintained at a temperature of 120 °C to 250 °C.
[0017] One end of a duct 21 is connected with a gas outlet port 18B of the catalytic cracking
tank 18. The duct 21 is provided with a pressure compensated flow control valve 22
and the other end of the duct 21 is connected with an inlet of a cooler 23 in which
catalytic cracking gas obtained, as catalytic cracking product, in the catalytic cracking
tank 18 is cooled. An outlet of the cooler 23 is led to a neutralization tank 25 via
a duct 24. The neutralization tank 25 stores 20 % sodium hydroxide (NaOH) aqueous
solution 26 acting as neutralization liquid and includes a rotary stirrer 27 for stirring
the 20 % sodium hydroxide aqueous solution 26. The duct 24 extending from the outlet
of the cooler 23 has a distal end dipped into the 20 % sodium hydroxide aqueous solution
26 in the neutralization tank 25.
[0018] An intermediate portion in the neutralization tank 25 is led, through a duct 28,
to a recovery tank 29 for recovering hydrocarbon oil, while an upper portion in the
neutralization tank 25 is led to an oligomerization tank 31 by way of a duct 30. The
oligomerization tank 31 stores 100 % phosphoric acid (H₃PO₄) 32 acting as polymerization
catalyst and includes a rotary stirrer 33 for stirring the 100 % phosphoric acid 32.
The oligomerization tank 31 is heated by a heater (not shown) such that temperature
of interior of the oligomerization tank 31 reaches about 130 °C. An intermediate portion
in the oligomerization tank 32 is led, via a duct 34, to the recovery tank 29, while
an upper portion in the oligomerization tank 31 is led to a blower 36 through a duct
35. The blower 36 is, in turn, led to an accumulator 38 by way of a duct 37 and the
accumulator 38 is further led to the heater 16 of the thermal cracking tank 15 via
a duct 39.
[0019] Hereinbelow, one example of the method of obtaining hydrocarbon oil from waste plastic
material or waste rubber material by using the hydrocarbon oil producing apparatus
K of the above described arrangement, according to the present invention is described.
Initially, the recycling material 11 stored in the hopper 12 is supplied into the
tank body 15B of the thermal cracking tank 15 from the inlet port 15A of the tank
body 15B by the screw conveyor 14. Then, in the thermal cracking tank 15, the tank
body 15B is heated by the heater 16 such that thermal cracking of the recycling material
11 takes place in the tank body 15B. At this time, temperature control of the heater
16 is performed on the basis of detection output of the temperature sensor 17 such
that thermal cracking temperature in the tank body 15B is maintained at a predetermined
temperature exceeding 450 °C. Thus, thermal cracking gas which is a thermal cracking
product of the recycling material 11 is obtained in the tank body 15B.
[0020] Subsequently, the thermal cracking gas obtained in the tank body 15B is introduced
into the catalytic cracking tank 18 from gas inlet port 18A of the catalytic cracking
tank 18 and is brought into contact with the aluminum chloride 19 stored, as solid
acid catalyst, in the catalytic cracking tank 18. As a result, the thermal cracking
gas from the thermal cracking tank 15 is subjected to catalytic cracking in the catalytic
cracking tank 18. At this time, temperature control of the heater of the catalytic
cracking tank 18 is performed on the basis of detection output of the temperature
sensor 20 such that catalytic cracking temperature in the catalytic cracking tank
18 is maintained at a temperature of 120 °C to 250 °C. Thus, the catalytic cracking
gas which is a catalytic cracking product of the thermal cracking gas from the thermal
cracking tank 15 is obtained in the catalytic cracking tank 18.
[0021] Thereafter, the catalytic cracking gas obtained in the catalytic cracking tank 18
is supplied to the cooler 23 through the duct 21 provided with the pressure compensated
flow control valve 22 so as to be cooled by the cooler 23. Thus, in the cooler 23,
low-boiling hydrocarbon oil 50 based on the catalytic cracking gas and cracking gas
component 51 mainly consisting of polymer having, for example, three to four carbon
atoms are obtained. Then, the low-boiling hydrocarbon oil 50 and the cracking gas
component 51 which are obtained in the cooler 23 are supplied, through the duct 24,
to the 20 % sodium hydroxide aqueous solution 26 stored, as neutralization liquid,
in the neutralization tank 25. In the neutralization tank 25, a layer of the 20 %
sodium hydroxide aqueous solution 26, a layer of the low-boiling hydrocarbon oil 50
from the cooler 23 and a layer of the cracking gas component 51 from the cooler 23
are formed sequentially upwardly in this order from a bottom of the neutralization
tank 25.
[0022] Thus, the low-boiling hydrocarbon oil 50 which forms the intermediate layer in the
neutralization tank 25 as described above is supplied to the recovery tank 29 through
the duct 28, while the cracking gas component 51 which forms the uppermost layer in
the neutralization tank 25 is supplied, via the duct 30, to the 100 % phosphoric acid
32 stored, as polymerization catalyst, in the oligomerization tank 31. Therefore,
in the oligomerization tank 31, oligomerization of the cracking gas component 51 takes
place in the 100 % phosphoric acid 32 and thus, low-boiling hydrocarbon oil 52 based
on the cracking gas component 51 is obtained. However, since all of the cracking gas
component 51 from the neutralization tank 25 is not oligomerized, a portion of the
cracking gas component 51 remains as unreactive cracking gas component 53. Accordingly,
in the oligomerization tank 31, a layer of the 100 % phosphoric acid 32, a layer of
the low-boiling hydrocarbon oil 52 produced by oligomerization of the cracking gas
component 51 and a layer of the unreactive cracking gas component 53 are formed sequentially
upwardly in this order from a bottom of the oligomerization tank 31.
[0023] Thus, the low-boiling hydrocarbon oil 52 which forms the intermediate layer in the
oligomerization tank 31 is supplied to the recovery tank 29 through the duct 34. Therefore,
the low-boiling hydrocarbon oil 50 supplied from the neutralization tank 25 through
the duct 28 and the low-boiling hydrocarbon oil 52 supplied from the oligomerization
tank 31 through the duct 34 are recovered, as low-boiling hydrocarbon oil 55, by the
recovery tank 29. Meanwhile, the unreactive cracking gas component 53 which forms
the uppermost layer in the oligomerization tank 31 is supplied to the blower 36 via
the duct 35 and then, is fed to the accumulator 38 through the duct 37 by the blower
36. The unreactive cracking gas component 53 is further supplied from the accumulator
38 to the heater 16 of the thermal cracking tank 15 through the duct 39 so as to be
recycled in the heater 16.
[0024] The low-boiling hydrocarbon oil 55 which is produced from the recycling material
11 so as to be recovered by the recovery tank 29 as described above is discharged
from the recovery tank 29 via a duct 56 and is used as, for example, fuel.
[0025] In the method of obtaining the hydrocarbon oil from waste plastic material or waste
rubber material, according to the present invention, thermal cracking temperature
for thermal cracking of the recycling material 11 is set at a predetermined temperature
exceeding 450 °C and catalytic cracking temperature for catalytic cracking of the
thermal cracking gas obtained by thermal cracking of the recycling material 11 is
set at a temperature of 120 °C to 250 °C on the following grounds. Initially, when
thermal cracking temperature for thermal cracking of the recycling material 11 is
not more than 450 °C, content of high-boiling hydrocarbon component in the thermal
cracking gas obtained by thermal cracking of the recycling material 11 becomes high.
Thus, experiments have revealed that during catalytic cracking of such thermal cracking
gas, the high-boiling hydrocarbon component adheres to the aluminum chloride acting
as solid acid catalyst for catalytic cracking, thereby resulting in extreme deterioration
of catalytic function of the aluminum chloride. Meanwhile, when catalytic cracking
temperature for catalytic cracking of the thermal cracking gas obtained by thermal
cracking of the recycling material 11 is lower than 120 °C, activation of the aluminum
chloride acting as solid acid catalyst for catalytic cracking cannot be achieved sufficiently.
On the other hand, experiments have shown that when catalytic cracking temperature
for catalytic cracking of the thermal cracking gas obtained by thermal cracking of
the recycling material 11 exceeds 250 °C, the aluminum chloride acting as solid acid
catalyst for catalytic cracking deteriorates excessively.
[0026] By using an experimental apparatus shown in Fig. 2, experiments were conducted by
the present inventors for comparison between recovery of hydrocarbon oil obtained
from waste plastic material in the method of the present invention and that obtained
from waste plastic material in another method other than the method of the present
invention. In Fig. 2, the experimental apparatus includes annular ovens 60 and 61
through which a tubular member 62 extends. One end of a duct 65 is coupled with one
end portion of the tubular member 62 through a plug 63, while one end of a duct 66
is coupled with the other end portion of the tubular member 62 through a plug 64.
A mouth of a container 68 is closed by a plug 67 such that the other end of the duct
66 pierces through the plug 67 into the container 68. The plug 67 is also pierced
through by one end of a duct 69 and the other end of the duct 69 is inserted into
a flask 71 through a plug 70. The flask 71 is disposed in an oil tank 73 placed on
a magnetic stirring machine 72. A heater 74 is provided in the oil tank 73. A stirrer
75 which is remotely driven by the magnetic stirring machine 72 is provided in the
flask 72. Meanwhile, one end of a duct 76 pierces through a plug 77 into the flask
71 and the other end of the duct 76 is open.
[0027] In a first experimental stage employing such experimental apparatus, hydrocarbon
oil is produced from waste plastic material in the method of the present invention.
At a location in the tubular member 62, which confronts inside of the annular oven
60, 50 g of polypropylene 80 is provided as waste plastic material. Furthermore, at
a location in the tubular member 62, which confronts inside of the annular oven 61,
a predetermined amount of aluminum chloride 81 is provided as solid acid catalyst.
On the other hand, a predetermined amount of 20 % sodium hydroxide aqueous solution
82 acting as neutralization liquid is put into the container 68, while a predetermined
amount of 100 % phosphoric acid 83 acting as polymerization catalyst is put into the
flask 71. The flask 71 is heated by the heater 74 provided in the oil tank 73 such
that interior of the flask 71 is maintained at about 130 °C. Meanwhile, the stirrer
75 in the 100 % phosphoric acid 83 in the flask 71 is remotely driven by the magnetic
stirring machine 72. In addition, while nitrogen (N₂) gas is being blown into the
tubular member 62 through the duct 65, not only temperature in the annular oven 60
is set at 500 °C but temperature in the annular oven 61 is set at 250 °C.
[0028] As a result, low-boiling hydrocarbon oils are obtained in the container 68 and the
flask 71, respectively. Meanwhile, unreactive cracking gas is recovered through the
duct 76 provided on the flask 71. A total of weights of the low-boiling hydrocarbon
oils recovered from the container 68 and the flask 71 measures about 43.5 g. Therefore,
a ratio of weight of the recovered low-boiling hydrocarbon oil to 50 g of polypropylene,
i.e., recovery is about 87 % (= 43.5 x 100/50).
[0029] On the other hand, in a second experimental stage employing the above experimental
apparatus, hydrocarbon oil is produced from waste plastic material in another method
other than the method of the present invention. In the same manner as the first experimental
stage, at a location in the tubular member 62, which confronts inside of the annular
oven 60, 50 g of polypropylene 80 is provided as waste plastic material and at a location
in the tubular member 62, which confronts inside of the annular oven 61, a predetermined
amount of aluminum chloride 81 is provided as solid acid catalyst. Likewise, a predetermined
amount of 20 % sodium hydroxide aqueous solution 82 acting as neutralization liquid
is put into the container 68. However, in the second experimental stage, the flask
71, the oil tank 73 and the magnetic stirring machine 72 are eliminated from the experimental
apparatus. While nitrogen gas is being blown into the tubular member 62 through the
duct 65, not only temperature in the annular oven 60 is set at 500 °C but temperature
in the annular over 61 is set at 250 °C.
[0030] As a result, low-boiling hydrocarbon oil is obtained in the container 68 and unreactive
cracking gas is recovered through the duct 69 provided on the container 68. Weight
of the hydrocarbon oil recovered from the container 68 measures about 30.0 g. Therefore,
ratio of weight of the recovered hydrocarbon oil to 50 g of polypropylene, i.e., recovery
is about 60 % (= 30.0 x 100/50).
[0031] It is understood from such results of the comparative experiments that recovery of
the hydrocarbon oil in production of the hydrocarbon oil from waste plastic material
in the method of the present invention is far superior to that in another method other
than the method of the present invention.
[0032] As is clear from the foregoing description of the method of obtaining the hydrocarbon
oil from the waste plastic material or the waste rubber material, according to the
present invention and the hydrocarbon oil producing apparatus of the present invention,
the waste plastic material or the waste rubber material is subjected to thermal cracking
at a relatively high temperature exceeding 450 °C and the thermal cracking product
obtained by this thermal cracking is subjected to catalytic cracking at a relatively
low temperature of, for example, 120 °C to 250 °C by using the solid acid catalyst.
Therefore, content of the high-boiling hydrocarbon component in the thermal cracking
product is lowered. Thus, even during catalytic cracking at a relatively low temperature,
drop of function of the solid acid catalyst for catalytic cracking due to adherence
of the high-boiling hydrocarbon component thereto can be restrained effectively. Furthermore,
since the solid acid catalyst for catalytic cracking is maintained at a relatively
low temperature, heat deterioration of the solid acid catalyst is restrained effectively.
Moreover, since the catalytic cracking product which is obtained by catalytic cracking
of the thermal cracking product by using the solid acid catalyst undergoes a cooling
process, the first hydrocarbon oil and the cracking gas component are obtained. At
this time, since the obtained cracking gas component is oligomerized by using the
polymerization catalyst so as to produce the second hydrocarbon oil. Accordingly,
in addition to the first hydrocarbon oil obtained by cooling the catalytic cracking
product, the second hydrocarbon oil is obtained by oligomerization of the cracking
gas component, so that recovery of the hydrocarbon oil is improved remarkably.