Technology Process Feedstock Products Automation Pilot Plant
IES-Thermopac Green Technology

IESs WHc2F process is a result of an extensive analytical and experimental research and development. The process design allows modularized skid-mounted plant that makes transportation and assembly highly efficient. The key process steps are:

Feedstock Pre-processing
The feed materials (waste plastics, used tires, refinery sludge, waste heavy oils, etc.) go through series of preparatory steps such as size reduction, blending with intermediate liquid products, and preheating as applicable.

Thermo-Catalytic Cracking
The pre-processed feed is subjected to cracking by heating the feed mass in the presence of catalyst and absence of oxygen to the desired temperature. The heating is accomplished to help maintain a control on the cracking reaction. Cracking takes place in liquid-phase feed and resulting monomers vaporize to enter the catalytic reforming step. IES-designed proprietary catalyst allows the cracking reaction to be carried out at relatively low temperatures (under 450 °C) Vs traditional Thermal Pyrolysis which is carried out at substantially higher temperatures (over 800 °C). The heat needed for the process is supplied by the gaseous hydrocarbon by-products formed during the cracking thereby making the process self-sustained in its process heating requirements.

Catalytic Reforming
Monomer vapors resulting from the catalytic cracking pass through a series of specially IES-designed proprietary reforming catalysts, where the monomers are bonded together to hydrocarbons of desired carbon chain lengths - C7 to C30, which contain gasoline, kerosene and diesel.

Distillation Liquid Hydrocarbon Products
Vapors exiting the catalytic reformer are then subjected to industry-standard distillation process to separate the desired liquid hydrocarbon product cuts, such as gasoline, kerosene and diesel.

Gaseous Pollution Control
Depending upon the feed materials, non-condensable gases and light vapor hydrocarbons pass through a series of pollution control steps to ensure removal of pollutants like sulfur and chlorine compounds, nitrogen oxides and carbon monoxide and hydrocarbons from the gaseous exhaust.

Solid Residue Handling
Inorganic solid impurities in the feed and coke formed during cracking is periodically removed from the Cracking reactor. Depending on the purity of the feed materials, this solid residue can range from pure carbon to a mixture of carbon and inorganic materials from fillers, pigments, UV stabilizers, etc.

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