IESs WHc2F process is a result of an extensive analytical and laboratory research. The process design allows modularized skid-mounted plant that makes transportation and assembly highly efficient. The key process steps are:
The feed material (waste plastics, used tires, refinery sludge, waste heavy oils, etc.) goes through series of preparatory steps such as size reduction, blending with intermediate liquid products, and preheating as applicable.
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. IESs -proprietary catalyst allows the cracking reaction to be carried out at relatively low temperatures (approximately 350-400°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.
Monomer vapors resulting from the catalytic cracking pass through a series of specially 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.