METHOD FOR TREATING POLYMERIC MATERIAL TO PRODUCE HYDROCARBON PRODUCTS AND CONTINUOUS FLOW REACTOR APPARATUS

Abstract

METHOD FOR TREATING POLYMERIC MATERIAL TO PRODUCE HYDROCARBON PRODUCTS AND CONTINUOUS FLOW REACTOR APPARATUS. The present invention provides methods and apparatus for converting polymeric material into hydrocarbon products.

Description

1 / 103 METHOD FOR TREATING POLYMERIC MATERIAL TO PRODUCE HYDROCARBON PRODUCTS AND CONTINUOUS FLOW REACTOR APPARATUS INCORPORATION BY WAY OF CROSS-REFERENCE

[0001] The present invention claims priority to provisional patent application number AU 2019903756, filed on October 4, 2019, the content of which is incorporated herein in its entirety by way of cross-reference. FIELD OF TECHNIQUE

[0002] The present invention relates generally to the field of waste treatment. More specifically, the present invention relates to methods and apparatus for converting polymeric materials, such as plastics, into hydrocarbon products. BACKGROUND

[0003] The current single and widespread use of plastic products is unsustainable and is creating a plastic waste problem that is harming the environment. Plastic waste is poorly biodegradable and represents a growing environmental problem and a danger to wildlife. Most plastic waste is still disposed of in landfills, meaning that a significant amount of processed raw materials and energy is lost / not used.

[0004] Since crude oil reserves are a finite resource, it is important that plastics become more sustainable by avoiding single-use plastics and increasing recycling, preventing plastic from simply being discarded in landfills. Petition 870260053158, dated 01 / 06 / 2026, page 11 / 148 2 / 103

[0005] There are limits to the extent to which plastic can be mechanically recycled, so a significant amount of plastic remains at the end of its useful life that cannot be mechanically recycled. In fact, many types of polymer waste are not suitable for recycling.

[0006] Currently, the main disposal options for this end-of-life plastic are incineration or landfill. Many countries discourage landfill because it is unsustainable and potentially polluting. Incineration, due to the small amounts of chlorine, for example, from the polyvinyl chloride (PVC) content of polymer waste, operates under relatively inefficient conditions and requires extensive treatment of combustion gases to avoid polluting the environment. Although it allows for some energy recovery, incineration still results in the loss of valuable hydrocarbon raw materials.

[0007] Another option for this end-of-life plastic is thermochemical recycling (e.g., pyrolysis or catalytic pyrolysis or gasification) to produce fuels or chemicals by thermal or catalytic cracking of the polymers. These processes suffer from the problems of applying heat externally, to the outside of the container holding the waste plastic, and therefore may suffer from carbon formation and have hot surfaces that become blocked. Some plastics also decompose producing chemicals that sublimate, blocking downstream equipment. Heat transfer to the polymer masses is also problematic, leading to plant blockages. Catalytic processes can be sensitive to ash, metals, cellulose (paper), inorganic fillers, and additives as impurities in the polymer feed. As Petition 870260053158, dated 01 / 06 / 2026, page 12 / 148 3 / 103 As a consequence of these problems, several plastic waste pyrolysis plants that attempted to operate commercially have closed down.

[0008] There is a need for improved methods and / or devices capable of converting polymeric materials (e.g., plastics) into hydrocarbon feedstock from which new plastics can be manufactured, creating a fully circular economy for plastics. SUMMARY OF THE INVENTION

[0009] The present invention addresses one or more problems existing in the prior art by providing improved means for converting polymeric materials, such as waste plastics, into valuable hydrocarbon products and / or transportation fuels and / or other chemicals.

[0010] By practicing the methods described in this document, valuable chemical constituents of end-of-life plastic can be chemically recycled, producing hydrocarbon products that can be reused in various applications, including, for example, the production of new plastic. The present invention also offers a solution to the problem of plastic waste accumulation, reducing the consumption of finite crude oil reserves.

[0011] Methods and apparatus for treating polymeric material to produce hydrocarbon products are disclosed in this document.

[0012] In some embodiments, the polymeric material being treated may be processed by a suitable extruder which can increase the pressure and therefore the temperature of the polymeric material as it exits the extruder. The material Petition 870260053158, dated 01 / 06 / 2026, p. 13 / 148 4 / 103 polymeric material can be further heated by supercritical water as it exits the extruder to generate a reaction mixture that may comprise polymeric material, water, and optionally another component (or components). A mixer may be employed to further mix the reaction mixture and / or a heater may be used to further heat the reaction mixer. The reaction mixture comprising the polymeric material and a solvent (e.g., an aqueous solvent) may be received into a reactor apparatus that houses or includes a reaction zone providing predetermined reaction temperature(s) and / or reaction pressure(s). The reaction mixture may be treated in the reaction zone for a suitable period of time to convert all or part of the polymeric material present in the reaction mixture into a product, which may exit the reaction zone in the form of a fluid product stream.

[0013] In certain embodiments, the fluid product stream exiting the reaction zone at elevated temperature and pressure can be rapidly depressurized in a flash vaporization vessel in such a way as to vaporize a large proportion of the fluid product stream, generating a vapor comprising hydrocarbon products, water vapor, and gases, which can be collected in an accumulation apparatus. The present inventors have advantageously identified that the fractionation of the vapor into individual components, including gas, can be enhanced by the aforementioned rapid reduction in the pressure of the fluid product stream and by utilizing the energy of the vapor.

[0014] The steam gas can be used as energy in the methods of the present invention. For example, the gas can be transferred to a device such as a boiler to generate energy. Petition 870260053158, dated 01 / 06 / 2026, page 14 / 148 5 / 103 to heat supercritical water. The gas energy can be used for any process in the method.

[0015] As described in more detail below, the means by which the present invention addresses one or more of the deficiencies in the prior art mentioned above include, without limitation, any one or more of the following features.

[0016] Polymeric materials such as plastic waste can be readily prepared by means known in the art for extrusion by a suitable extruder. The extrudate of polymeric material exiting the extruder at high pressure can be combined with a heated / pressurized aqueous solvent (superheated water) to provide a mixture with a high concentration of polymeric material, when compared to an equivalent reaction mixture formed without extrusion of the polymeric material. The superheated water phase can provide efficient heat transfer to the molten polymer by virtue of its high diffusivity and / or the presence of water can suppress carbon formation. Halogens (e.g., chlorine) present in the reaction mixture can be largely transferred to the aqueous phase as inorganic halides, thus reducing problems surrounding dioxin formation.Cellulose-based impurities, such as paper, can be extensively gasified or converted into oil components. Ash-like components and inorganic fillers can be largely carried by the process and can be separated from the products by means known in the art (e.g., fractional distillation). The design of the extruder-reactor interface and / or the mixing interface for dilution with supercritical or superheated aqueous solvent (e.g., water) may, for example, be at least partly responsible. Petition 870260053158, dated 01 / 06 / 2026, page 15 / 148 6 / 103 because it provides an advantage (or advantages) over the methods of the prior art.

[0017] One or more collection devices according to the present invention may be provided in various configurations. When substantial energy has been introduced into the steps of the method, the energy of the steam can be used to fractionate the steam into constituents. For example, a vertical vessel may include several containers in a vertical arrangement that receive the constituents as their energy propels them to various heights within the vessel so that they go to a specific container. The vessel may be associated with a collecting tube to direct the constituents to their respective reservoirs for further processing. Water may be a constituent and collected for cleaning. Gas may be at least one constituent of a fractionated steam that is used as energy in the method.

[0018] Depending on the energy stored in various vapor constituents, the constituents can self-separate to be captured separately. Providing the constituents with the opportunity for self-separation avoids the need for additional separation steps that may require reheating the products, requiring additional energy and time to be spent. Self-separation of fractionated vapor constituents can be, for example, hard wax residue.

[0019] The methods and apparatus described in this document can be used to process so-called end-of-life plastics that have been manufactured with impurities to exhibit various characteristics. Impurities can, for example, make a plastic opaque and colored. These impurities can be, for example, Petition 870260053158, dated 01 / 06 / 2026, page 16 / 148 7 / 103 example, TiO2, CaCOa, ZnO and / or NaCl. The weight of the impurities may cause them to gravitate to the bottom of one or more reactor vessels, where they can be collected. Later, one of the several vessels of the collection apparatus may contain a useful product such as bitumen. The methods and apparatus may include means for adding the impurities to one or more bitumen products for safe disposal. As mentioned above, the water constituent of the fractionated steam can be cleaned, whereby the impurities can be collected and added to a useful product such as bitumen for safe disposal. Bitumen, for example, can be used in road construction.

[0020] As described in this document, treating the reaction mixture in a reactor apparatus at various reaction temperatures and reaction pressures over various time periods suitable for converting all or a portion of the polymeric material present in the reaction mixture into a fluid product stream can determine the ultimate fractionated vapor end products. Depending on the available feedstock and the desired product output, various parameters can be adjusted.

[0021] The methods of the present invention may involve substantially adverse conditions due to high pressure and high temperatures. Therefore, the appropriate selection of steel for vessels and piping is beneficial. Depending on the steel selected, the reaction mixture may interact with the steel, where the steel may act as a catalyst causing various end products to take on characteristics. Depending on the desired end products, additional surfaces may be added, for example, to the vessel (or vessels) of the apparatus. Petition 870260053158, dated 01 / 06 / 2026, page 17 / 148 8 / 103 reactor. One of these surfaces may include nickel, for example, which can lead to the occurrence of certain target reactions.

[0022] The present invention relates, at least in part, to the following embodiments:

[0023] Modality 1. A method for treating polymeric material to produce hydrocarbon products, wherein the method comprises:

[0024] - generate a reaction mixture comprising the polymeric material and an aqueous solvent,

[0025] - treat the reaction mixture in a reactor apparatus at a reaction temperature and a reaction pressure for a period of time suitable for conversion of all or a portion of the polymeric material present in the reaction mixture into a fluid product stream, and

[0026] - to depressurize the fluid product stream, where:

[0027] the fluid product stream is at a temperature of at least 350 °C and a pressure of at least 180 bar immediately before depressurization,

[0028] Depressurization comprises reducing the pressure of the fluid product stream to less than 25 bar in a flash vaporization vessel, thereby vaporizing at least a portion of the fluid product stream and generating a vapor comprising constituent parts of hydrocarbon products, water vapor and gas, and

[0029] vaporization provides energy to facilitate the fractionation of vapor into its constituent parts; and

[0030] - collect fractionated vapor. Petition 870260053158, dated 01 / 06 / 2026, p. 18 / 148 9 / 103

[0031] Modality 2. The method according to modality 1, wherein the fluid product stream is at a temperature of at least: 380 °C, 400 °C, 420 °C, 450 °C or 470 °C, immediately before depressurization.

[0032] Modality 3. The method according to modality 1 or 2, wherein the fluid product stream is at a pressure of at least: 200 bar, 220 bar, 240 bar, 260 bar, 280 bar or 300 bar, immediately before depressurization.

[0033] Modality 4. The method of any of the embodiments 1 to 3, in which the flash vaporization vessel is coupled directly to the accumulation apparatus, is an integral part of the accumulation apparatus or is coupled directly to one or more staged product condensers.

[0034] Modality 5. The method according to any of the embodiments 1 to 4, which comprises fractionating and condensing the vapor into fractions having a maximum atmospheric equivalent boiling point below: 400 °C, 450 °C, 500 °C, 550 °C or 600 °C and collecting a residual fraction having a minimum atmospheric equivalent boiling point above 400 °C, 450 °C, 500 °C, 550 °C or 600 °C.

[0035] Modality 6. The method according to any of the modalities 1 to 5, in which solid charges and / or inorganic matter and / or metallic salts from the depressurized product stream are retained in the residue matrix produced by said vaporization and fractionation.

[0036] Modality 7. The method of any of the modalities 1 to 6, in which depressurization and fractionation allow the separation of the aqueous solvent from the hydrocarbon products, Petition 870260053158, dated 01 / 06 / 2026, p. 19 / 148 10 / 103 including the separation of aqueous solvent from low-boiling-point hydrocarbons at a temperature below: 10 °C, 20 °C, 30 °C, 40 °C, 50 °C or 60 °C.

[0037] Embodiment 8. The method according to embodiment 7, in which the separation of the aqueous solvent of low-boiling-point hydrocarbons is carried out under an effective gravity of 9.8 ± 0.1 m / s².

[0038] Embodiment 9. The method according to embodiment 7 or 8, wherein the separated aqueous solvent comprises a total organic carbon (TOC) content of less than: 15,000 mg / l, 10,000 mg / l, 5,000 mg / l, 2,500 mg / l, 1,000 mg / l or 500 mg / l.

[0039] Modality 10. The method of modalities 1 to 9 further comprises injecting water vapor into the instant vaporization vessel and bringing the fluid product stream into contact with the water vapor.

[0040] Modality 11. The method of any of the modalities 1 to 10, in which the so-called generation of the reaction mixture comprises:

[0041] - provide a molten stream of the polymeric material;

[0042] - inject the aqueous solvent into the molten stream of polymeric material; and

[0043] - to mechanically mix the aqueous solvent and the molten stream of polymeric material.

[0044] Modality 12. The method of embodiment 11, in which the aqueous solvent is supercritical before said injection.

[0045] Modality 13. The method of modality 11 or modality 12, in which the aqueous solvent is water or substantially water. Petition 870260053158, dated 01 / 06 / 2026, p. 20 / 148 11 / 103

[0046] Embodiment 14. The method of any of the embodiments 11 to 13, in which the mechanical mixing comprises the use of solvent distribution grids in an assembly comprising one or more static mechanical mixing devices.

[0047] Modality 15. The method of embodiment 12, in which the fluid flow discharged by any said mechanical mixing device has a volume uniformity greater than about: 94%, 95%, 96%, 97% or 98%.

[0048] Embodiment 16. The method of any of the embodiments 11 to 15, in which the aqueous solvent is injected into the molten stream of polymeric material through a series of nozzles spanning the circumference of either of said mixing device and said solvent distribution grid.

[0049] Modality 17. The method of modalities 14 to 16, in which during the said generation of the reaction mixture there is a pressure drop along the mixing device of less than: 2 bar, 5 bar, 10 bar, 20 bar or 30 bar.

[0050] Embodiment 18. The method of any of the embodiments 12 to 17, in which the supercritical aqueous solvent is generated in a boiler apparatus comprising a burner fed by gas released from the fluid product stream.

[0051] Embodiment 19. The method of embodiment 18, in which the supercritical aqueous solvent is generated in a boiler apparatus comprising a burner fed by natural gas.

[0052] Modality 20. The method of modality 18 or modality 19, in which the supercritical aqueous solvent exits the boiler apparatus at a temperature of at least: 450 °C, 500 °C or 550 °C Petition 870260053158, dated 01 / 06 / 2026, p. 21 / 148 12 / 103 W.

[0053] Embodiment 21. The method of any of the embodiments 18 to 20, in which the boiler operates at a pressure of at least: 180 bar or at least 200 bar, or at least 220 bar, or at least 240 bar, or at least 250 bar, at least 270 bar, or 290 bar, or 310 bar or 330 bar during the generation of the supercritical aqueous solvent.

[0054] Embodiment 22. The method of any of the embodiments 18 to 21, which comprises heating the gas released from the fluid product stream in the boiler apparatus to a temperature of at least 850 °C for at least 2 seconds in order to destroy halogenated organic compounds including any one or more of: chlorinated dioxins, chlorinated furans, chlorinated biphenyls and other dioxin-like compounds of environmental concern.

[0055] Modality 23. The method of any of the embodiments 1 to 22, wherein said treatment comprises bringing the reaction mixture into contact with additional metal catalysts in addition to those present on any metal surface in contact with the reaction mixture during said generation or treatment, wherein the additional metal catalysts are:

[0056] - components of a solid material that is mixed into the reaction mixture to facilitate contact between the fluids and the supplementary metal catalyst and / or

[0057] - a component of any said mixing device.

[0058] Embodiment 24. The method according to embodiment 23, in which the supplementary metal catalysts are catalysts Petition 870260053158, dated 01 / 06 / 2026, page 22 / 148 13 / 103 of a solid transition metal.

[0059] Embodiment 25. The method according to embodiment 23 or embodiment 24, wherein the supplementary metal catalysts are solid-state transition metal catalysts and wherein the oxidation state of the transition metal is initially a formal zero-valence oxidation state.

[0060] Modality 26. The method according to modality 25, in which the zero-valence metal is selected from either of: nickel and zero-valence iron.

[0061] Embodiment 27. The method of embodiments 23 to 26, in which supplementary metal catalysts catalyze the transfer of hydrogen atoms from the aqueous solvent to the hydrocarbon products resulting from said treatment of the polymeric material.

[0062] Modality 28. The method according to any of the modalities 1 to 27, which further comprises the removal of solid materials from the reaction mixture during said treatment, wherein the solid materials:

[0063] - are inorganic materials present in the polymeric material,

[0064] - have a higher density than the fluids in the reaction mixture and separate from the reaction mixture by gravity during said treatment; and

[0065] - are removed from a reactor apparatus in which said treatment is carried out by purging into a receiving vessel during said treatment by means of remotely operated valves. Petition 870260053158, dated 01 / 06 / 2026, page 23 / 148 14 / 103

[0066] Modality 29. The method according to modality 28, in which the inorganic materials:

[0067] - are fillers or contaminants present in the polymeric material before the method is performed; and / or

[0068] - reacted with the aqueous solvent and / or with carbon-rich materials formed in small volumes by secondary reactions during said treatment.

[0069] Modality 30. The method according to embodiment 28 or 29, in which the solid materials are purged into the receiving vessel with a portion of the hydrocarbon products, waxes, polymer oligomers or partially depolymerized materials.

[0070] Modality 31. The method according to any of the embodiments 1 to 30, wherein the method is carried out in a reactor apparatus comprising any one or more of:

[0071] - systems for testing pressure levels in valves and a pressure reducing vessel within the said reactor apparatus,

[0072] - a system that allows the cooling of the purged material into a receiving vessel of the reactor apparatus,

[0073] - a final collection pot with a removable lid for purged material that is interlocked with its lid and with interconnected tubes and valves to prevent accidental removal of the pot and its contents.

[0074] - ventilation for the release of gases formed during or after said treatment, Petition 870260053158, dated 01 / 06 / 2026, page 24 / 148 15 / 103

[0075] - to provide inert atmospheres comprising nitrogen, argon, carbon dioxide and / or other inert gases preventing the ignition and combustion of materials contained within the reduction pot and collection pot,

[0076] - sequencing systems to minimize mechanical shock to the reactor apparatus.

[0077] Modality 32. The method of any of the modalities 1 to 31, in which:

[0078] - one or more heat exchangers are used to indirectly heat the reaction mixture to the reaction temperature;

[0079] - one or more heat exchangers do not comprise an expansion below the arrangement; and

[0080] - One or more heat exchangers comprise a double heated probe type arrangement comprising a water vapor tube inside a water vapor tube and / or an electric heating element used to indirectly heat the water vapor and / or the reaction mixture.

[0081] Modality 33. The method according to embodiment 10, which comprises using a superheater to heat the water vapor before injecting the water vapor into the instant vaporization vessel.

[0082] Modality 34. The method according to any of the embodiments 1 to 33, wherein the reaction temperature is at least: 380 °C, 400 °C, 450 °C or 500 °C.

[0083] Modality 35. The method of any of the embodiments 1 to 34, in which the hydrocarbon product comprises a Petition 870260053158, dated 01 / 06 / 2026, p. 25 / 148 16 / 103 naphtha component with a boiling point between 10 °C and 210 °C AEBP, wherein the naphtha component comprises:

[0084] - more than 10%, 20%, 30%, 40% by mass of olefins; and / or

[0085] - more than 10%, 20%, 30%, 40% by mass of n-paraffins; and / or

[0086] - more than 10%, 20%, 30%, 40% by mass of cycloalkanes or cycloalkenes; and / or

[0087] - more than 10%, 20%, 30%, 40% by mass of aromatics.

[0088] Modality 36. The method of any of the embodiments in 35, wherein the hydrocarbon product comprises a diesel component with a boiling point between 210 °C and 360 °C AEBP, and wherein the diesel component comprises:

[0089] - more than 10%, 20%, 30%, 40% by mass of olefins; and / or

[0090] - more than 10%, 20%, 30%, 40% by mass of n-paraffins; and / or

[0091] - more than 10%, 20%, 30%, 40% by mass of cycloalkanes or cycloalkenes; and / or

[0092] - more than 10%, 20%, 30%, 40% by mass of aromatics.

[0093] Modality 37. The method of any of the embodiments in 36, wherein the hydrocarbon product comprises a heavy diesel component boiling between 360 °C and 550 °C AEBP, and the heavy diesel component comprises:

[0094] - more than 10%, 20%, 30%, 40% by mass of olefins; and / or

[0095] - more than 10%, 20%, 30%, 40% by mass of n-paraffins; and / or

[0096] - more than 10%, 20%, 30%, 40% by mass of cycloalkanes Petition 870260053158, dated 01 / 06 / 2026, p. 26 / 148 17 / 103 or cycloalkenes; and / or

[0097] - more than 10%, 20%, 30%, 40% by mass of aromatics.

[0098] Modality 38. The method of any of the modalities 1 to 37, where:

[0099] - the polymeric material used to generate the so-called reaction mixture is an extrudate of molten polymeric material;

[0100] - the extruded polymeric material is diverted to a collection container before generating said reaction mixture;

[0101] - the collection container is equipped with an inert atmosphere preventing combustion of the molten polymer extrudate; and

[0102] - the collection vessel is connected to a reactor apparatus by one or more lines providing double valve isolation on each line to prevent reverse flow of molten polymer extrudate from the reactor.

[0103] Modality 39. The method according to embodiment 14 or 15, in which a temperature measurement system provides warning of backflow from the mixing device (or devices) towards an extruder connected to the mixing device (or devices), allowing the operation of isolation valves thus preventing backflow from the mixing device (or devices).

[0104] Modality 40. The method according to any of the embodiments 1 to 39, wherein the reactor apparatus is a continuous flow reactor apparatus.

[0105] Modality 41. The method according to any of the modalities 1 to 40, in which the treatment is carried out under conditions Petition 870260053158, dated 01 / 06 / 2026, page 27 / 148 18 / 103 continuous flow.

[0106] Modality 42. The method according to any of the embodiments 1 to 41, wherein the polymeric material does not comprise any one or more of: lignocellulosic matter; naturally occurring carbohydrate polymers; lignin; cellulose; hemicellulose; combinations of any two of lignin, cellulose, hemicellulose; lignite (brown coal); subbituminous coal; any combination thereof.

[0107] Modality 43. A continuous flow reactor apparatus for the treatment of polymeric material comprising:

[0108] - an extruder for producing an extrudate comprising a molten stream of polymeric material;

[0109] - a boiler apparatus for preparing and adding supercritical water to the extrudate;

[0110] - a mechanical mixing device configured to mix the extrudate with supercritical water to form a reaction mixture;

[0111] - a reaction zone in communication with the mechanical mixing device and with indirect heaters, wherein the reaction zone is to treat the reaction mixture at a defined temperature and pressure during a defined residence time in order to produce a fluid product stream;

[0112] - a pressure reducing device for depressurizing the fluid product stream, wherein the pressure reducing device is in communication with the reaction zone and an instant vaporization vessel;

[0113] - a fractionating apparatus for separating vapor Petition 870260053158, dated 01 / 06 / 2026, page 28 / 148 19 / 103 generated in the instant vaporization container.

[0114] Modality 44. The continuous flow reactor apparatus of modality 43, in which the indirect heaters are not circumferential.

[0115] Modality 45. The continuous flow reactor apparatus of modality 43 or 44, in which the flash vaporization vessel:

[0116] - is coupled directly to the fractionating device; or

[0117] - is an integral part of the instant vaporization column; or

[0118] - and the fractionating apparatus are separate product condensers.

[0119] Embodiment 46. The continuous flow reactor apparatus of any of the embodiments 43 to 45, wherein the mechanical mixing device is a static mechanical mixing device.

[0120] Embodiment 47. The continuous flow reactor apparatus of any of the embodiments 43 to 46, comprising a series of nozzles spanning the circumference of the mechanical mixing device or a portion thereof, for injection and distribution of supercritical water in the molten stream of polymeric material.

[0121] Embodiment 48. Continuous flow reactor apparatus, according to any of embodiments 43 to 47, characterized in that the boiler apparatus comprises a burner in communication with the fractionation apparatus (for example, a vessel in the fractionation apparatus) to receive gas.

[0122] Modality 49. Continuous flow reactor apparatus Petition 870260053158, dated 01 / 06 / 2026, p. 29 / 148 20 / 103 of any of the modalities 43 to 48, in which the boiler apparatus comprises a burner in communication with a natural gas source.

[0123] Embodiment 50. The continuous flow reactor apparatus of any of the embodiments 43 to 49, in which one or more components of the reaction zone comprise a source of metallic catalysts for the reaction mixture.

[0124] Embodiment 51. The continuous flow reactor apparatus of embodiment 50, in which the metal catalysts are solid-state transition metal catalysts.

[0125] Modality 52. ​​The continuous flow reactor apparatus of any of the modalities 43 to 51, in which:

[0126] - a collection vessel configured to collect the molten polymer extrudate before generating said reaction mixture is connected to the reactor apparatus by one or more lines;

[0127] - one or more lines provide double valve isolation on each line and prevent reverse flow from the reactor;

[0128] - the collection container is equipped with an inert atmosphere to prevent combustion of the extrudate.

[0129] Modality 53. The continuous flow reactor apparatus of any of the embodiments 43 to 52, comprising a purge component for removing solid materials from the reaction mixture and a receiving vessel for the solid materials.

[0130] Modality 54. Continuous flow reactor apparatus Petition 870260053158, dated 01 / 06 / 2026, page 30 / 148 21 / 103 of any of the embodiments 43 to 53, which comprises means for separating solid waste and / or bottoms formed during the pre-treatment of the polymeric material and / or the treatment of the reaction mixture and means for combining the solid waste and / or bottoms with the fluid product stream in the flash vaporization vessel in order to vaporize volatile components of the solid waste and / or bottoms.

[0131] Modality 55. The continuous flow reactor apparatus of any of the modalities 43 to 54, comprising:

[0132] - a heat exchanger for indirect heating of the reaction mixture at the defined temperature at various points along a vessel in the reactor apparatus housing the reaction zone through which the reaction mixture flows;

[0133] means for supplying supercritical water vapor generated by a supercritical water vapor generator to the heat exchanger. DEFINITIONS

[0134] As used in this request, the singular forms a, an, or include plural references unless the context clearly dictates otherwise. For example, the term catalyst also includes a plurality of catalysts.

[0135] As used in this document, the term comprising means including. Variations of the word comprising, such as comprising and includes, have correspondingly varied meanings. Thus, for example, a solvent comprising water may consist exclusively of water or may include one or more additional components (e.g., alcohol). Petition 870260053158, dated 01 / 06 / 2026, page 31 / 148 22 / 103

[0136] As used in this document, the terms polymers and polymeric material will be understood to encompass prepolymers, oligomers, homopolymers (e.g., prepared from a single monomer species), copolymers (e.g., prepared from at least two monomer species), terpolymers, polymer grafts, plastics, elastomeric materials, rubber materials, and mixtures thereof. In some embodiments, the polymeric material (or materials) is produced synthetically. In some embodiments, the polymeric materials may be natural materials with carbon-carbon structures, for example, natural rubber and its derivatives.The terms polymers and polymeric material, as used in this document, shall be understood as specifically excluding: lignocellulosic matter; naturally occurring carbohydrate polymers; lignin; cellulose; hemicellulose; combinations of any two of lignin, cellulose, hemicellulose; lignite (brown coal); subbituminous coal; and any combination thereof.

[0137] As used herein, the term continuous flow refers to a process in which a mixture comprising a raw material (for example, and any one or more of: an aqueous solvent, reagent, catalyst additive and / or oil additive) is subjected to:

[0138] (a) heating and pressurizing to a target temperature and pressure,

[0139] (b) treatment at the target temperature (or temperatures) and pressure (or pressures) for a defined period of time (a retention time), and Petition 870260053158, dated 01 / 06 / 2026, page 32 / 148 23 / 103

[0140] (c) cooling and depressurization;

[0141] during which the mixture is maintained in a continuous flow stream along the length (or partial length) of a given surface of a reactor vessel. It will be understood that the continuous flow conditions contemplated herein are defined by an initial heating and pressurization point (i.e., (a) above) and by a final cooling and depressurization point (i.e., (c) above). The continuous flow conditions as contemplated herein do not imply any particular limitation with respect to the flow rate or phase behavior of the mixture, provided it is maintained in a continuous flow stream.

[0142] As used in this document, end-of-life plastic or waste plastic shall be understood as plastic material containing at least some proportion of non-plastic contaminant(s), such as, for example, at least: 0.1%, 0.5%, 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40% of non-plastic material. Non-limiting examples of such contaminants include dirt, paper, wood, food scraps, soil, agricultural waste, metals, putrescible material, mineral matter, cardboard, plant and animal matter, fabric or fabric fibers.

[0143] As used in this document, a supercritical substance (e.g., a supercritical solvent) refers to a substance existing at a temperature and pressure that is above the substance's critical point.

[0144] As used in this document, a subcritical substance (e.g., a subcritical solvent) refers to Petition 870260053158, dated 01 / 06 / 2026, page 33 / 148 24 / 103 a substance at a temperature and / or pressure below the substance's critical point. Thus, a substance can be subcritical at a temperature below its critical point and a pressure above its critical point, at a temperature above its critical point and a pressure below its critical point, or at a temperature and pressure below its critical point.

[0145] As used in this document, the term aqueous solvent refers to a solvent comprising at least one percent water based on the total weight of the solvent. An aqueous solvent may therefore comprise between one percent water and one hundred percent water based on the total weight of the solvent. An aqueous solvent will also be understood as including within its scope aqueous alcohol, aqueous ethanol, and aqueous methanol.

[0146] As used in this document, the term intrinsic catalyst will be understood as a catalyst that is inherently present in one or more other components of a reaction mixture processed according to the methods of the present invention and / or the materials used to manufacture the process (including mixer, vessel walls of a reactor apparatus in which the methods are carried out and / or a catalyst that forms in situ during the performance of the methods.

[0147] As used in this document, a supplemental catalyst is a catalyst included in a feedstock stream, solvent stream, and / or reaction mixture that is supplemental to catalytic compounds that intrinsically contain other components of the reaction mixture (i.e., supplemental to intrinsic catalysts), being added separately to or being in contact with the reaction mixture as a distinct / autonomous component. The catalyst Petition 870260053158, dated 01 / 06 / 2026, page 34 / 148 25 / 103 supplementary catalyst may be in the form of a fixed solid-state catalyst positioned within the apparatus to come into contact with the reaction mixture.

[0148] As used in this document, the terms reactor and reactor apparatus are used interchangeably and have the same meaning. Each term covers any apparatus suitable for carrying out the methods of the present invention including, for example, continuous flow reactors and batch reactors. As used in this document, the term “about” when used in reference to a recited numerical value includes the recited numerical value and numerical values ​​within plus or minus ten percent of the recited value.

[0149] As used in this document, the term between when used in reference to a range of numeric values ​​encompasses the numeric values ​​at each endpoint of the range.

[0150] Any description of prior art documents in this document, or statements in this document derived from or based on such documents, is not an admission that the documents or derived statements are part of the general common knowledge of the relevant art.

[0151] For descriptive purposes, all documents referred to in this document are incorporated herein by reference in their entirety, unless otherwise indicated. BRIEF DESCRIPTION OF THE DRAWINGS

[0152] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying Figures, where: Petition 870260053158, dated 01 / 06 / 2026, p. 35 / 148 26 / 103

[0153] Figure One is a process flow diagram of an apparatus according to embodiments of the present invention.

[0154] Figure Two shows an indirect heater design according to the embodiments of the present invention.

[0155] Figure Three is a process flow diagram showing an arrangement for removing solid materials from a pressurized reactor vessel.

[0156] Figure Four is a process flow diagram showing the stages from the condenser proceeding to the flash vaporization vessel according to embodiments of the present invention.

[0157] Figure Five is a process flow diagram showing a flash vaporization vessel coupled to a fractionation column according to embodiments of the present invention.

[0158] Figure Six provides a process flow diagram showing a flash vaporization vessel with a fractionating column and additional vacuum distillation unit according to embodiments of the present invention.

[0159] Figure Seven shows a defogging apparatus according to the embodiments of the present invention.

[0160] Figure Eight shows the configuration of the boiler and indirect heater according to the embodiments of the present invention.

[0161] Figure Nine shows a naphtha product (upper yellow layer) according to embodiments of the present invention that easily separates from the aqueous solvent (lower layer). Petition 870260053158, dated 01 / 06 / 2026, page 36 / 148 27 / 103

[0162] Figure Ten is a graph that describes the simulated boiling point distribution of the product resulting from a full-temperature flash vaporizer coupled to the fractionation column.

[0163] Figure Eleven is an additional graph depicting the simulated boiling point distribution of the product resulting from a full-temperature flash vaporizer coupled to the fractionation column.

[0164] Figure Twelve is an additional graph that describes the simulated boiling point distribution of the product resulting from a full-temperature flash vaporizer coupled to the fractionation column.

[0165] Figure Thirteen shows a pipe mixer design according to the embodiments of the present invention.

[0166] Figure Fourteen shows a design of a pipe mixer with two static mixing elements according to the embodiments of the present invention.

[0167] Figure Fifteen shows a design of a pipe mixer with four static mixer elements according to the embodiments of the present invention.

[0168] Figure Sixteen shows a design of a pipe mixer according to the embodiments of the present invention showing the position of the bars.

[0169] Figure Seventeen shows a design of a pipe mixer with two mixing elements according to the embodiments of the present invention.

[0170] Figure Eighteen shows a mixer design. Petition 870260053158, dated 01 / 06 / 2026, page 37 / 148 28 / 103 tubes with four mixing elements according to the embodiments of the present invention.

[0171] Figure Nineteen is a bar graph showing the volume uniformity of the molten plastic volume fraction according to embodiments of the present invention.

[0172] Figure Twenty depicts a configuration for combining supercritical water with polymeric material according to embodiments of the present invention in which a mixer is absent.

[0173] Figure Twenty-One depicts a configuration for combining supercritical water with polymeric material according to embodiments of the present invention including two mixing elements.

[0174] Figure Twenty-Two shows temperature profiles (downstream of the injection point) resulting from the combination of supercritical water with polymeric material according to embodiments of the present invention including two mixing elements.

[0175] Figure Twenty-Three is a process flow diagram of an apparatus according to embodiments of the present invention. [017 6] Figure Twenty-Four is a flow diagram of a pressure reduction and fractionation system according to embodiments of the present invention. Figure Twenty-Five is a graph showing the results of a thermogravimetric analysis (TGA) of a total syncrude sample in a nitrogen atmosphere.

[0177] Figure Twenty-Six shows an arrangement of parts Petition 870260053158, dated 01 / 06 / 2026, page 38 / 148 29 / 103 of the pressure reduction / fractionation system according to embodiments of the present invention. DETAILED DESCRIPTION

[0178] The present invention provides processes and apparatus for converting polymers or polymeric materials into a product or products.

[0179] By way of non-limiting example, polymers or polymeric materials may be passed through an extrusion apparatus and extruded at elevated temperature and pressure into a mixing zone where the extrudate may be mixed with a supercritical aqueous solvent. The mixture may optionally be further heated and may be passed through one or more reactors with a reaction zone with a residence time sufficient for depolymerization and other chemical reactions to occur. The resulting product stream mixture may then be rapidly depressurized causing at least partial vaporization of the product into component parts within, for example, a fractionation unit.At least some of the thermal energy initially retained within the product stream mixture and released after vaporization can be used to fractionate the mixture into different boiling range fractions and / or to separate and recover the supercritical aqueous solvent from the product or products. Part of the fractionated material can optionally be recycled for refractionation. Catalysts or reagents can optionally be added at any stage of the process. Solid-state catalysts can optionally be contained within the apparatus, especially within the reactors. Mixing devices, especially static mixers, can optionally be used, for example, after injection. Petition 870260053158, dated 01 / 06 / 2026, page 39 / 148 30 / 103 Supercritical aqueous solvent. The solvent may also participate in chemical reactions to produce the product. Non-condensable gases and vapors formed in the chemical reactions are calorific and may be burned, for example, in a boiler purposely designed to provide thermal energy to the process and / or destroy chemicals that may be toxic and / or of environmental concern. Solid materials that are or become insoluble in the reaction mixture may be gravitationally separated from the reaction mixture during the process by means of their higher density and optionally removed from the process by means of valves at the bottom of the apparatus. POLYMERIC MATERIAL

[0180] According to the methods of the present invention, the raw material of polymeric material can be treated. The polymeric material may comprise, for example, plastics. The polymeric material may be unsuitable for physical recycling methods. The polymeric material may currently be suitable only for landfill or incineration. The polymeric material may be End-of-Life Plastics (ELP). The polymeric material (e.g., plastic) may be contaminated with non-plastic materials, including, but not limited to, one or more food wastes, soil, agricultural waste, metals, putrescible material, paper, cardboard, plant and animal matter, fabric or fabric fibers.

[0181] Non-limiting examples of polymeric materials suitable for use in the methods and apparatus of the present invention include prepolymers, oligomers, homopolymers, copolymers, terpolymers, graft polymers, plastic, end-of-life plastic, waste plastic, elastomeric material, materials of Petition 870260053158, dated 01 / 06 / 2026, page 40 / 148 31 / 103 Rubber and mixtures can be included in the raw material and subjected to cracking in the reactor. Other non-limiting examples include Polyethylene (PE), Low-Density Polyethylene (LDPE), High-Density Polyethylene (HDPE), Polypropylene (PP), Polyester, Poly(ethylene terephthalate) (PET), Poly(lactic acid) PLA, Poly(vinyl chloride) (PVC), Polystyrene (PS), Polyamide, Nylon, Nylon 6, Nylon 6,6, Acrylonitrile-butadiene-styrene (ABS), Poly(ethylene vinyl alcohol) (E / VAL), Poly(melamine formaldehyde) (MF), Poly(phenolformaldehyde) (PF), Epoxies, Polyacetal, (Acrylic), Polyacrylates (Acrylic), Polyacrylonitrile (PAN), Polyamide-imide (PAI), Polyaryletherketone (PAEK), Polybutadiene (PBD), Polybutylene (PB), Polycarbonate (PC), Polydicyclopentadiene (PDCP), Polytone (PK), polycondensate, Polyetheretherketone (PEEK), Polyetherimide (PEI), Polyethersulfone (PES), Polyethylenechlorinates, (PEC), Polyimide, (PI), Polymethylpentene (PMP), Poly(phenylene oxide) (PPO),Polyphenylene sulfide (PPS), Polyphthalamide (PTA), Polysulfone (PSU), Polyurethane (PU), Polyvinylidene chloride (PVDC), Polytetrafluoroethylene (PTFE), Polyfluoroalkane (PFA), Polysiloxanes, silicones, thermoplastics, thermosetting polymers, natural rubbers, tire rubbers, ethylene propylene diene monomer rubbers (EPDM), chloroprene rubbers, acrylonitrile butadiene (nitrile) rubbers, polyacrylate rubbers, ethylene acrylic rubbers, styrene-butadiene rubbers, polyester urethane rubbers, polyether urethane rubbers, fluorosilicon rubbers, silicone rubbers and copolymers, synthetic polymeric materials, naturally occurring polymeric materials with, Petition 870260053158, dated 01 / 06 / 2026, page 41 / 148 32 / 103 carbon-carbon main chains, plastics and mixtures thereof.

[0182] Without limitation, the polymeric material may comprise a low content of elements other than carbon, hydrogen, and oxygen. For example, the polymeric material may contain less than about 5% by weight of nitrogen, less than about 1% by weight of nitrogen, less than about 0.5% by weight of nitrogen, less than about 0.1% by weight of nitrogen, or less than about 0.01% by weight of nitrogen, as a percentage of the total weight of the polymeric material.

[0183] Alternatively or additionally, the polymeric material may comprise less than about 5% by weight of total halogens, less than about 1% by weight of total halogens, less than about 0.5% by weight of total halogens, less than about 0.1% by weight of total halogens, less than about 0.05% by weight of total halogens, or less than about 0.01% of total halogens, as a percentage of the total weight of the polymeric material.

[0184] Additionally or alternatively, the polymeric material may comprise a hydrogen-to-carbon molar ratio (H / C) that is as high as possible. For example, the H / C molar ratio may be greater than 2.15, greater than 2.0, greater than 1.8, greater than 1.6, greater than 1.4, greater than 1.2, greater than 1.0, or greater than 0.8.

[0185] In some embodiments, the polymeric material may be in the form of mixed or sorted plastic waste and, in some cases, may be contaminated with organic and inorganic impurities. The residual plastic material may require some pre-processing before being processed from Petition 870260053158, dated 01 / 06 / 2026, page 42 / 148 33 / 103 in accordance with the methods of the present invention. For example, residual plastic may require sieving or screening to remove abrasive particles.

[0186] Without limiting the mode of action, polymers treated according to the methods of the present invention can be cracked in liquids with lower boiling and melting points and / or can act directly or indirectly as sources of hydrogen that are then incorporated into the liquid products.

[0187] By way of non-limiting example, a reaction mixture treated according to the methods of the present invention may comprise at least: 1% by weight, 2% by weight, 3% by weight, 4% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, 50% by weight, 60% by weight, 70% by weight, 80% by weight, 90% by weight, 95% by weight or 98% by weight of polymeric material (as a percentage of the total weight of raw material and / or reaction mixture).

[0188] By way of non-limiting example, a reaction mixture treated according to the methods of the present invention may comprise less than: 98% by weight, 95% by weight, 90% by weight, 80% by weight, 70% by weight, 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, 30% by weight, 25% by weight, 20% by weight, 15% by weight, 10% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight or 1% by weight of polymeric material (as a proportion of the total weight of raw material and / or reaction mixture).

[0189] By way of non-limiting example, a reaction mixture treated according to the methods of the present invention may comprise between: about 2% by weight and about 70% by weight. Petition 870260053158, dated 01 / 06 / 2026, page 43 / 148 34 / 103 weight, approximately 2% by weight and approximately 60% by weight, approximately 2% by weight and approximately 50% by weight, approximately 2% by weight and approximately 40% by weight, approximately 2% by weight and approximately 30% by weight, approximately 5% by weight and approximately 70% by weight, approximately 5% by weight and approximately 60% by weight, approximately 5% by weight and approximately 50% by weight, approximately 5% by weight and approximately 40% by weight, approximately 5% by weight and approximately 30% by weight, approximately 10% by weight and approximately 70% by weight, approximately 10% by weight and approximately 60% by weight, approximately 10% by weight and approximately 50% by weight, approximately 10% by weight and approximately 40% by weight, approximately 10% by weight and approximately 30% by weight, approximately 15% by weight and approximately 70% by weight, approximately 15% by weight and approximately 60% by weight, approximately 15% by weight and approximately 50% by weight, approximately 15% by weight and approximately 40% by weight, approximately 15% by weight and approximately 30% by weight of polymeric material (as a proportion of the total weight of raw material and / or reaction mixture).

[0190] In some embodiments, the polymeric raw material supplied to the extruder and / or the reaction mixture comprises at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% polyethylene by weight on a dry basis (db).

[0191] In some embodiments, the polymeric raw material supplied to the extruder and / or the reaction mixture comprises at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% polypropylene by weight on a dry basis (db).

[0192] In some embodiments, the polymeric raw material supplied to the extruder and / or the reaction mixture comprises at least 30%, at least 40%, at least 50%, 60%, at least 70%, at least 80% or at least 90% polystyrene Petition 870260053158, dated 01 / 06 / 2026, page 44 / 148 35 / 103 by weight on a dry basis (db).

[0193] As a non-limiting example, polymeric materials suitable for the methods of the present invention may have a melt mass flow rate (MFR) between 0.05 grams and 20 grams per 10 minutes, or 0.1 grams to 10 grams per 10 minutes, or 0.01 grams to 5 grams per 10 minutes, as measured in accordance with ISO guideline 1133-1-2011 Plastics Determination of the Melt Mass-Flow Rate (MFR). SOLVENT COMPONENT

[0194] A reaction mixture for use according to the methods of the present invention may comprise a solvent such as, for example, an aqueous solvent.

[0195] In some embodiments, the aqueous solvent comprises more than 5% by weight, more than 10% by weight, more than 20% by weight, more than 30% by weight, more than 40% by weight, more than 50% by weight, more than 60% by weight, more than 70% by weight, more than 80% by weight, more than 90% by weight, or more than 95% by weight of water as a proportion of the total weight of the reaction mixture. In some embodiments, the aqueous solvent comprises less than 10% by weight, less than 20% by weight, less than 30% by weight, less than 40% by weight, less than 50% by weight, less than 60% by weight, less than 70% by weight, less than 80% by weight, less than 90% by weight, or less than 95% by weight of water (as a percentage of the total weight of the reaction mixture).

[0196] In some embodiments, the water used in aqueous solvents of the present invention can be recycled from the product of the raw material comprising polymeric material previously treated by the method. For example, a portion of the water Petition 870260053158, dated 01 / 06 / 2026, page 45 / 148 36 / 103 present after treatment of a given reaction mixture can be withdrawn as a side stream and recycled to the method (e.g., as part or all of a separate supercritical solvent stream in contact with the extruded polymeric material).

[0197] The solvent may comprise or consist of one or more aqueous alcohols. Non-limiting examples of suitable alcohols include methanol, ethanol, isopropyl alcohol, isobutyl alcohol, pentyl alcohol, hexanol, isohexanol, and any combination thereof. By way of non-limiting example only, the solvent may comprise more than 5% by weight, more than 10% by weight, more than 20% by weight, more than 30% by weight, more than 40% by weight, more than 50% by weight, more than 60% by weight, more than 70% by weight, more than 80% by weight, more than 90% by weight, or more than 95% by weight of alcohol as a proportion of the total weight of the reaction mixture. In some embodiments, the solvent may comprise less than 10% by weight, less than 20% by weight, less than 30% by weight, less than 40% by weight, less than 50% by weight, less than 60% by weight, less than 70% by weight, less than 80% by weight, less than 90% by weight, or less than 95% by weight of alcohol (as a percentage of the total weight of the reaction mixture). PRETREATMENT OF POLYMERIC MATERIAL

[0198] Although optional and not necessarily mandatory, the polymeric material may be pre-treated before its inclusion in a reaction mixture according to the present invention, including, but not limited to, before extrusion in an extruder. This pre-treatment may be carried out, for example, to prepare the material ready for extrusion, to remove contaminants and / or to control specific polymers. Petition 870260053158, dated 01 / 06 / 2026, page 46 / 148 37 / 103 to be processed.

[0199] The pretreatment of polymeric material may comprise physical methods, examples of which are not limited to grinding, chipping, pelletizing, granulation, flaking, pulverization, crushing, milling (e.g., vibratory ball milling), compression / expansion, agitation, density separation, washing, air classification, filtration, drying and / or pulsed electric field (PEF) treatment. The polymeric material may, for example, be pretreated using crushers, screens and / or sieves, magnetic and eddy current separators to remove metals, dry cleaning techniques and / or optical, infrared or ultraviolet and induction classification to remove, for example, poly(vinyl chloride) and other polymers and chlorinated or halogenated metals.

[0200] Pretreatment processes can be wet (i.e., involving washing with water or another solvent) or dry. Pretreatment may include the use of air separators to remove glass, magnetic and / or eddy current separators to remove metals, dry or wet cleaning to remove food and paper residues, drying of plastic using residual heat and / or optical, infrared, or ultraviolet sorting to remove, for example, poly(vinyl chloride) and other chlorinated or halogenated polymers. Other types of polymeric materials that are unsuitable for particular aspects of the invention may also be removed by sorting technologies known in the art. Non-limiting examples of polymers that can be removed are polyethylene terephthalate (PET) and polyamides.

[0201] Additionally or alternatively, pretreatment of Petition 870260053158, dated 01 / 06 / 2026, page 47 / 148 38 / 103 Polymeric material may comprise physicochemical methods, examples of which are not limited to pyrolysis, water vapor explosion, ammonia fiber explosion (AFEX), ammonia recycling percolation (ARP), and / or carbon dioxide explosion. For example, water vapor explosion involves exposing the polymeric material to high-pressure water vapor in a contained environment before the resulting product is explosively discharged at atmospheric pressure. Water vapor explosion pretreatment may further involve agitation of the polymeric material.

[0202] Additionally or alternatively, the pretreatment of the polymeric material may comprise chemical methods, examples of which are not limited to ozonolysis, acid hydrolysis (e.g., dilute acid hydrolysis using H2SO4 and / or HCl), alkaline hydrolysis (e.g., dilute alkaline hydrolysis using sodium, potassium, calcium and / or ammonium hydroxides) and / or oxidative treatments. EXTRUSION OF POLYMERIC MATERIAL

[0203] The polymeric material treated according to the methods of the present invention can be subjected to extrusion before forming the main reaction mixture. The extrusion of the polymeric material can be carried out in any suitable extruder, examples of which are not limiting, including single-screw extruders, multi-screw extruders (e.g., twin-screw extruders), interlocked-screw extruders, radial extruders, and roll-type extrusion presses. Multi-screw extruders can be counter-rotating or co-rotating. The extruder may comprise a kneading disc (or discs) and / or other screw element(s) for mixing or Petition 870260053158, dated 01 / 06 / 2026, pages 48 / 148 39 / 103 disperse the melt.

[0204] Suitable extruders can typically be from about 1 meter to about 50 meters in length and can be specifically designed for processing plastic waste with a plastic compaction feature, with pressure buildup occurring as a single extruder step or multiple extruder steps, with or without extruder venting.

[0205] By way of non-limiting example, the energy required by the extruder to heat the polymeric material may be supplied by friction and / or shear of the material in the extruder and / or by heating elements. The extruder may comprise one or more series of heating zones.

[0206] The polymeric material can be heated in the extruder to a temperature (or temperatures) sufficient for the material to melt and flow. For example, the polymeric material can be heated in the extruder to more than 50 °C, more than 75 °C, more than 100 °C, more than 150 °C, more than 200 °C, more than 250 °C, more than 300 °C, more than 350 °C, or more than 400 °C. Consequently, the polymeric material can be heated in the extruder, for example, between about 250 °C and about 350 °C, between about 275 °C and about 375 °C, between about 300 °C and about 400 °C, between about 50 °C and about 350 °C, between about 50 °C and about 300 °C, between about 50 °C and about 200 °C, between about 50 °C and about 150 °C, between about 80 °C and about 300 °C, between about 80 °C and about 200 °C, or between about 80 °C and about 150 °C.

[0207] The residence time of the polymeric feedstock in the extruder can be, for example, about 30 seconds to about Petition 870260053158, dated 01 / 06 / 2026, p. 49 / 148 40 / 103 minutes, about 2 minutes to about 6 minutes or about 3 minutes to about 5 minutes.

[0208] The extruder can be fitted with a suitable feeding device (e.g., a hopper, compactor, cutter compactor) for applying the polymeric material to / into the extruder.

[0209] Alternatively, the extruder can be fitted with a die to facilitate the generation of back pressure.

[0210] A molten stream of polymeric material can exit the extruder at a desired temperature and pressure. For example, the material stream exiting the extruder can be: at a temperature between about 150 °C and about 400 °C and a pressure between about 200 bar and 350 bar; at a temperature between about 250 °C and about 350 °C and a pressure between about 250 bar and 350 bar; or at a temperature between about 220 °C and about 280 °C and a pressure between about 200 bar and 350 bar. Combining polymeric material with aqueous solvent

[0211] According to the present invention, the polymeric material (e.g., extrudate comprising or consisting of polymeric material) can be mixed with a solvent (e.g., an aqueous solvent) to form a reaction mixture. The solvent, for example, may have been heated and / or pressurized before coming into contact with the polymeric material. The solvent can be heated and / or pressurized using any suitable means.

[0212] For example, an aqueous solvent used in the methods of Petition 870260053158, dated 01 / 06 / 2026, page 50 / 148 41 / 103 The present invention may be in a subcritical or supercritical state before and at the time of contact with the extruded polymeric material.

[0213] In some embodiments, the aqueous solvent is water or water vapor (for example, supercritical water, superheated water vapor or subcritical water).

[0214] Contact of a supercritical aqueous solvent with extruded polymeric material can initiate a supercritical to subcritical phase change in the aqueous solvent (i.e., bring it to a subcritical state as the temperature and / or pressure of the solvent drops below its critical point). The phase change can trigger a large release of energy which, in turn, can help to successfully combine the aqueous solvent with the extruded polymeric material.

[0215] Alternatively, contact of a supercritical aqueous solvent with the extruded polymeric material may not initiate a supercritical to subcritical phase change in the aqueous solvent.

[0216] As a non-limiting example only, the aqueous solvent may be supercritical (e.g., supercritical water) and may be at a temperature between about 375 °C and about 800 °C, between about 375 °C and about 600 °C, between about 375 °C and about 550 °C, between about 375 °C and about 500 °C, or between about 375 °C and about 450 °C at the time of contact with the extruded polymeric material.

[0217] The combination of independently heated / pressurized solvent (e.g., aqueous solvent such as water) with extruded polymeric material according to the methods of Petition 870260053158, dated 01 / 06 / 2026, p. 51 / 148 42 / 103 The present invention may provide a means of generating a reaction mixture comprising a higher concentration of the extruded polymeric material than could be achieved, for example, by (i) mixing an equivalent amount of the polymeric material that has not been subjected to the aforementioned extrusion process with an equivalent amount of the aqueous solvent heated and / or pressurized independently; and / or (ii) mixing an equivalent amount of the polymeric material that has not been subjected to the aforementioned extrusion process with an equivalent amount of the aqueous solvent and heating / pressurizing the mixture to the same levels.

[0218] In some embodiments, the supercritical solvent, including for example an aqueous supercritical solvent such as water, may be applied to the polymeric material extrudate at the extruder exit point and / or at multiple injection points along the length of a vessel connecting the extruder to another apparatus or component thereof, including for example a static mixing tank or the reaction zone of a reactor (for example, a hydrothermal reactor, a continuous flow hydrothermal reactor). Such an arrangement may be used to promote further mixing of the polymeric material extrudate and / or to maintain the extrudate at an elevated temperature. MIXTURE

[0219] After the initial contact of the extrudate with the aqueous solvent, the mixing of the extrudate and the aqueous solvent can optionally be improved using static mixing devices.

[0220] Consequently, the methods described in this document Petition 870260053158, dated 01 / 06 / 2026, page 52 / 148 43 / 103 can: encourage rapid heating of the polymeric material by close contact with hot solvent and / or reduce overall system pressure losses through improved fluid flow properties, and / or include wide channels that are not blocked by material that has passed through the extruder, and / or avoid high stresses on the tube walls by nozzle design and solvent distribution system, and / or by selecting catalytic material that favors the initiation of depolymerization reactions. Additionally or alternatively, the installation may include trace heating to prevent solidification of the polymeric material. PRESSURIZATION AND HEATING

[0221] A reaction mixture comprising polymeric material (for example, an extrudate of polymeric material) and a solvent (for example, an aqueous solvent such as water) according to the present invention can be heated and pressurized using means known in the art.

[0222] For example, pressurization within an apparatus according to the present invention can be generated by means of an extruder and / or pump (or pumps) used to pressurize the aqueous solvent before it comes into contact with the extruded polymeric material. In continuous flow systems, the pressure generally changes from atmospheric pressure to the target pressure during the time it takes to pass through the extruder and / or pump (i.e., almost instantaneously).

[0223] In some embodiments, the reaction mixture can be brought to a target temperature and / or pressure in a time period between about 30 seconds and about 30 minutes. Petition 870260053158, dated 01 / 06 / 2026, page 53 / 148 44 / 103

[0224] In some embodiments, the reaction mixture can be brought to a target temperature and / or pressure in a time period less than about 15 minutes, less than about 10 minutes, less than about 5 minutes, or less than about 2 minutes.

[0225] In certain embodiments, the reaction mixture can be brought to a target pressure substantially instantaneously or during a period of time between about 30 seconds and about 30 minutes, and brought to a target temperature in less than about 20 minutes, less than about 10 minutes, or less than about 5 minutes, less than 2 minutes.

[0226] In other embodiments, the reaction mixture can be brought to a target pressure substantially instantaneously and brought to a target temperature in less than about two minutes. In other embodiments, the reaction mixture can be brought to a target pressure substantially instantaneously and brought to a target temperature in between about 1 and about 2 minutes, or less than 20 seconds.

[0227] In some embodiments of the invention, the reaction mixture may optionally be further heated by means of one or more indirect heaters after mixing with the solvent (for example, a supercritical aqueous solvent). The indirect heater (or heaters) may, for example, increase the temperature of the reaction mixture by more than 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 120 °C or less than about an additional 150, 130, 110, 90, 70, 50 °C. Indirect heating may increase the average temperature of the reaction mixture from about 380 °C to about 450 °C or from about 400 °C to about 460 °C.

[0228] In some applications, indirect heaters do not Petition 870260053158, dated 01 / 06 / 2026, p. 54 / 148 45 / 103 are circumferential.

[0229] In some embodiments, the indirect heater supplies thermal energy to the reaction mixture by means of superheated steam or supercritical water from a process boiler. Figure 2 shows an example of such a heater design. Without limitation, the advantages of this design include that steam can be readily produced from the combustion of the process gas and the temperature of the incoming steam can be readily controlled, thus avoiding excessive metal temperatures that would cause excessive charring of the plastic mixture. By using steam that is ultimately supplied to the process, the pressure drop in the elements of each heater is minimal and any leakage in the inner tube would be a small flow of steam into the process.

[0230] In some embodiments, additional indirect heating of the reaction mixture may be by means of electric heating elements and / or by a fluid heat exchanger and / or by a fluidized bed of, for example, ilmenite heated by calorific gas combustion. In some embodiments, the heating elements are not circumferential. In some embodiments, this calorific gas may comprise process gases and vapors formed by the depolymerization of polymeric material.

[0231] In some forms, the electric heating elements are not circumferential. REACTION PARAMETERS

[0232] After mixing the heated / pressurized aqueous solvent independently with the material Petition 870260053158, dated 01 / 06 / 2026, page 55 / 148 46 / 103 extruded polymeric, the reaction mixture thus formed may optionally be heated and / or pressurized to achieve and / or maintain the desired reaction temperature and / or pressure levels.

[0233] For example, the reaction mixture can be fed to a reactor (e.g., a hydrothermal reactor, a continuous flow hydrothermal reactor) in which the polymeric material is subjected to predetermined levels of temperature and pressure for a predetermined period of time to facilitate its conversion into hydrocarbon product(s) of lower average molecular weight than that of the polymeric material before conversion.

[0234] Thus, according to the methods of the present invention, a reaction mixture comprising extruded polymeric material and an aqueous solvent can be treated at a target temperature (or within a range of target temperatures) and a target pressure (or within a range of target pressures) for a defined period of time (“retention time” or residence time”) to provide product (or products).

[0235] The average residence or retention time can be determined or measured or limited by the flow rate of the extrudate and / or aqueous solvent.

[0236] The ideal reaction temperature (or temperatures) and / or pressure (or pressures) for a given reaction mixture can be readily determined by the skilled recipient by preparing and carrying out a series of reactions that differ only in the temperature and / or pressure used and analyzing the yield and / or quality of the product (or products).

[0237] It will be understood that in certain modalities a solvent Petition 870260053158, dated 01 / 06 / 2026, page 56 / 148 47 / 103 aqueous solvent used in the methods of the present invention can be heated and pressurized beyond its critical temperature and / or beyond its critical pressure (i.e., beyond the “critical point” of the solvent) during treatment in the reactor. Consequently, the solvent can be a “supercritical” aqueous solvent if heated and pressurized beyond the “critical point” of the aqueous solvent.

[0238] In some embodiments, the aqueous solvent (e.g., water) in a reaction mixture with extruded polymeric material treated by the methods of the present invention may be heated and pressurized to levels above its critical temperature and pressure (i.e., above the “critical point” of the aqueous solvent). Consequently, the mixture may comprise a “supercritical” aqueous solvent when performing the methods.

[0239] In other embodiments, an aqueous solvent (e.g., water or superheated steam) in a reaction mixture with extruded polymeric material treated by the methods of the present invention may be heated and pressurized to a level (or levels) below its critical temperature and pressure (i.e., below the “critical point” of the aqueous solvent). Consequently, the mixture may comprise a “subcritical” aqueous solvent when carrying out the methods. For example, the “subcritical” solvent may be heated and / or pressurized to a level (or levels) close to the “critical point” of the solvent (e.g., between about 10 °C and about 50 °C below the critical temperature and / or between about 10 bar and about 50 bar below its critical pressure).

[0240] In other embodiments, an aqueous solvent (e.g., water) in a reaction mixture with extruded polymeric material treated by the methods of the present invention may be Petition 870260053158, dated 01 / 06 / 2026, page 57 / 148 48 / 103 heated and pressurized to levels both above and below its critical temperature and pressure (i.e., heated and / or pressurized both above and below the solvent's "critical point" at different times). Consequently, the aqueous solvent of the mixture may oscillate between "subcritical" and "supercritical" states when performing the methods.

[0241] In certain embodiments, the treatment of a reaction mixture comprising extruded polymeric material, an aqueous solvent (e.g., water) and, optionally, any one or more of: (i) supplementary catalysts and / or (ii) oil, none of which is derived from the polymeric feedstock, the aqueous solvent or the walls of a reactor apparatus in which the treatment is carried out, and none of which are products generated in situ during the preparation and / or treatment of the reaction mixture, may be conducted at: temperature (or temperatures) above 370 °C and pressure (or pressures) above 20 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 40 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 60 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 80 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 100 bar;temperature (or temperatures) above 370 °C and pressure (or pressures) above 120 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 140 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 160 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 180 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 200 bar; temperature (or temperatures); Petition 870260053158, dated 01 / 06 / 2026, page 58 / 148 49 / 103 above 370 °C and pressure (or pressures) above 220 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 240 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 260 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 280 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 300 bar; temperature (or temperatures) above 370 °C and pressure (or pressures) above 350 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 20 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 40 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 60 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 80 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 100 bar;temperature (or temperatures) above 400 °C and pressure (or pressures) above 120 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 140 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 160 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 180 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 200 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 220 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 240 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 260 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 280 bar; temperature (or temperatures) above 400 °C and pressure; Petition 870260053158, dated 01 / 06 / 2026, page 59 / 148 50 / 103 (or pressures) above 300 bar; temperature (or temperatures) above 400 °C and pressure (or pressures) above 350 bar(s); temperature (or temperatures) above 374 °C and pressure (or pressures) above 221 bar; temperature (or temperatures) above 375 °C and pressure (or pressures) above 225 bar; temperature (or temperatures) between 370 °C and 550 °C and pressure (or pressures) between 20 bar and 400 bar; temperature (or temperatures) between 374 °C and 500 °C and pressure (or pressures) between 221 bar and 400 bar; temperature (or temperatures) between 374 °C and 550 °C and pressure (or pressures) between 221 bar and 400 bar; temperature (or temperatures) between 375 °C and 550 °C and pressure (or pressures) between 221 bar and 400 bar; temperature (or temperatures) between 375 °C and 550 °C and pressure (or pressures) between 221 bar and 400 bar.

[0242] In certain embodiments, the treatment of a mixture comprising extruded polymeric material and an aqueous solvent (e.g., water) using the methods of the invention can be carried out at: temperatures between 400 °C and 550 °C and pressures between 100 bar and 300 bar.

[0243] In certain embodiments, the reaction mixture may be treated at a temperature between 370 °C and 500 °C, between 370 °C and 480 °C, between 374 °C and 500 °C, between 380 °C and 500 °C, between 380 °C and 450 °C, between 400 °C and 480 °C, or between 440 °C and 480 °C; and the pressure may be greater than 100 bar.

[0244] In some embodiments, the reaction mixture may be treated at a temperature exceeding approximately: 350 °C, 360 °C, 370 °C, 380 °C, 390 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, 460 °C, 470 °C, or 480 °C. In some embodiments, the reaction mixture is treated at any of the temperatures mentioned in this paragraph and at a pressure exceeding approximately: Petition 870260053158, dated 01 / 06 / 2026, page 60 / 148 51 / 103 180 bar, 200 bar, 220 bar, 240 bar, 260 bar, 280 bar, 300 bar or 320 bar.

[0245] In certain embodiments, the pH of the molten polymeric material stream / extrudate, supercritical aqueous solvent and / or reaction mixture can be maintained at a pH higher than: 6, 7, 8, 9, 10 or 11, for example, by adding base. This can serve to minimize acid-catalyzed isomerization and / or hydration reactions of alkenes, especially 1-alkenes, during the process. The pH can be measured after depressurizing the product stream. The pH can be measured after cooling the product stream to a temperature below 100 °C. RETENTION TIME

[0246] The specific time period during which a reaction mixture of the present invention comprising polymeric material (e.g., an extrudate of polymeric material) and a solvent (e.g., an aqueous solvent) can be treated at a target temperature and pressure (i.e., the holding time) to yield products may depend on several different factors, including, for example, the type of polymeric material under treatment and the relative proportions or types of components in the reaction mixture (e.g., the proportion of aqueous solvent, additive catalyst (or catalysts) and / or any other additional component (or components)) and / or the type of apparatus in which the methods are carried out. These and other factors may be varied to optimize a particular method in order to maximize the yield of certain products and / or reduce processing time.Ideally, the retention time is sufficient to convert substantially all of the polymeric material used as raw material into product (or. Petition 870260053158, dated 01 / 06 / 2026, page 61 / 148 52 / 103 hydrocarbon products.

[0247] In certain modalities, the retention time is less than about 60 minutes, 45 minutes, 30 minutes, 25 minutes, 20 minutes, 15 minutes, 10 minutes, or less than about 5 minutes. In certain modalities, the retention time is greater than about 60 minutes, 45 minutes, 30 minutes, 25 minutes, 20 minutes, 15 minutes, 10 minutes, or more than about 5 minutes. In other modalities, the retention time is between about 1 minute and about 60 minutes. In additional modalities, the retention time is between about 5 minutes and about 45 minutes, between about 5 minutes and about 35 minutes, between about 10 minutes and about 35 minutes, or between about 15 minutes and about 30 minutes. In other modalities, the retention time is between about 20 minutes and about 30 minutes.

[0248] The ideal retention time for a given set of reaction conditions, as described in this document, can be readily determined by the skilled recipient by preparing and executing a series of reactions that differ only in retention time and analyzing the yield and / or quality of the updated product generated.

[0249] The average residence or retention time can be determined or measured or limited by the flow rate of the extrudate and / or aqueous solvent.

[0250] In some embodiments, the retention time in the reactor, calculated assuming plug flow of a fluid with the density of an idealized mixture of water plus oil derived from polymeric material, at the reaction temperature, is about 30 seconds, about 1 minute, about 2 minutes, about 5 minutes, between Petition 870260053158, dated 01 / 06 / 2026, page 62 / 148 53 / 103 minutes and 10 minutes, between 10 minutes and 20 minutes, between 20 minutes and 30 minutes, between 30 minutes and 40 minutes, more than 40 minutes or less than about 60 minutes. REMOVAL OF SOLIDS

[0251] A non-limiting advantage of the present invention is that it can provide a means for removing from the process stream materials that are solid at the reaction temperature and pressure. Without limitation, the solids may be mineral matter contained in the polymer feedstocks, such as fillers, opacifiers, pigments, rheology modifiers and the like. The solids may be ash. The solids may be contaminants in the feedstock such as, for example, glass, small stones, metallic particles or pieces of metal foil. The solids may be carbon-containing materials formed during the chemical reactions in the process. The solids generally have a higher density than the process fluids at the reaction temperature and pressure and (in vertical reactors) the solid particles settle under gravity under conditions where the sedimentation velocity of the particles is greater than the fluid flow velocity.

[0252] By way of non-limiting example, calculations made by the present inventors have shown that particles with a material density of 2700 kg / m3 (e.g., calcium carbonate) and with a diameter greater than about 20 microns, have a sedimentation velocity of about 2.5 mm / s when subjected to the methods described in this document at about 450 °C and about 200 bar, and using about 60% polyolefin plastic feed with 40% water by mass.

[0253] The upward flow rate of the reaction fluid Petition 870260053158, dated 01 / 06 / 2026, page 63 / 148 54 / 103, for example, can be in the range of 1 to 1000 mm / s in a bottom-fed vertical reactor tube. Particles with a diameter greater than about 10, 20, or 50 microns and a density greater than about 1000 kg / m3 can be expected to settle in the vertical reactor under the method conditions, depending on the upward flow velocity of the fluid and the nature of the flow regime (e.g., turbulent or laminar flow conditions). Solid particles that settle in the lower parts of the (vertical) reactors can optionally be periodically or intermittently, on demand, in a controlled manner, ejected from the bottom of the reactor by the brief operation of purge valves at the base of the vessels.

[0254] A simplified diagram showing a non-limiting operation of a solids removal system is shown in Figure 3. In the scheme shown in Figure 3, the system design is to drain a defined quantity into a sealed pressurized capture vessel, so as to avoid depressurizing the reactor and to provide a means of quantifying the quantity to be removed. The sealed pot would then be depressurized in the venting system and then emptied into an inert final pot with an inert gas system for further processing. The aim is to prevent hydrocarbon oils associated with the removed solids from catching fire, for example, if they are above their auto-ignition temperature in air. For example, the final pot could be a metal bucket with a lid. Interlocks in the collection pot could be designed to test the integrity of the valves as part of the sequence. Only when depressurized would the capture pot empty into the final pot.In some versions of such a project, each drain would have double insulation. Petition 870260053158, dated 01 / 06 / 2026, page 64 / 148 55 / 103 This will be achieved by means of an isolation valve in the pipe at the base of each reactor and then a common isolation valve before the capture pot and the end pot. In normal operation, the reactor contents will be above the auto-ignition temperature of the product oil. In addition, significant amounts of steam will potentially be released – downstream systems are designed to mitigate the applicable risks. Without this method for solids removal, the downstream apparatus comprising the depressurization valve(s) can lead to rapid fouling, requiring frequent cleaning operations, making plant operation uneconomical. Optionally, the solids removed in this way can be combined with residues from product fractionation and used as mixtures or additives for bitumen and asphalt. Optionally, the solids removed in this way can be further refined to recover metals by means known in the art. Depressurization and Fractionation

[0255] According to embodiments of the present invention, a reaction mixture can be converted into a product stream that can be depressurized by means of flash vapor depressurization at the reaction temperature. Flash vapor depressurization can constitute a form of heat recovery, wherein the thermal energy released during depressurization can be used to fractionate the product into at least two different boiling ranges using, for example, a distillation column directly connected to the flash vapor depressurization unit. Otherwise, the fractionation process would require the product stream Petition 870260053158, dated 01 / 06 / 2026, page 65 / 148 56 / 103 would subsequently be heated under vacuum in, for example, a vacuum distillation unit, requiring energy input.

[0256] In certain embodiments, the reaction mixture can be depressurized by flash vaporization from a temperature of at least 350 °C, 375 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C or at least 460 °C and a pressure of at least 200 bar, 220 bar, 240 bar, 260 bar, 280 bar, 300 bar down to a pressure lower than 25 bar, 20 bar, 15 bar, 10 bar, 8 bar, 6 bar, 4 bar, 2 bar, 1.5 bar, 1.2 bar absolute.

[0257] In certain forms, depressurization by instant vaporization can be regulated by means of one or more valves.

[0258] In the present invention, the depressurized stream is directed to a depressurization and fractionation vessel or vessels where the stream is fractionated into at least three boiling range fractions plus a gas and / or vapor stream. A portion of the energy in the process stream fluids is thus used to fractionate the product stream into product fractions, for example, gas / vapor, naphtha, middle distillate or gas oil, heavy gas oil, heavy wax residue.

[0259] In certain embodiments, the depressurization-fractionation apparatus may comprise an instant vaporization vessel and two or more condensers in series, as exemplified in Figure 4. If two condensers are used, the first condenser may be employed to condense distillates with boiling points in the range of approximately 200 °C to 400 °C AEBP, or 450 °C or 500 °C AEBP, the second condenser may be employed to condense distillates with Petition 870260053158, dated 01 / 06 / 2026, page 66 / 148 57 / 103 Boiling points in the range of approximately 20 °C to 200 °C AEBP, and fractions with boiling points above approximately 400 °C or 450 °C or 500 °C AEBP may be retained at the bottom of the instantaneous and periodic vaporization vessel or continuously drained into storage tanks. Water may be separated from the outlet of the second condenser by decantation, as water is denser and immiscible with the liquid products.

[0260] In certain embodiments, the depressurization-fractionation apparatus comprises a flash vaporization vessel and a fractionation column in series, as exemplified in Figure 5. In certain embodiments, the vessel comprising a fractionation column may also act as the flash vaporization vessel (i.e., the fractionation column itself is a flash vaporization vessel). The fractionation column may be used to separate product fractions in at least three boiling ranges. The boiling ranges may be, for example, about 20 °C to about 200 °C AEBP, about 200 °C to about 360 °C AEBP, about 360 °C to about 400 °C AEBP, about 360 °C to about 450 °C AEBP, or 360 °C to about 500 °C AEBP. Gases and vapors not condensed by the primary condenser can be directed to a boiler and / or a burner for combustion.Water can be separated from the liquid fraction with a lower boiling point (e.g., the fraction with a boiling point of about 20 °C to about 200 °C AEBP) or from other liquid fractions by means of a separator. The separator can, for example, be a gravity plate separator, an API separator, or an electrostatic separator. Alternatively or additionally, the separator can be an enhanced gravity separator, for example, a... Petition 870260053158, dated 01 / 06 / 2026, p. 67 / 148 58 / 103 centrifuge, a decanter centrifuge or a hydrocyclone. Fractions with a boiling point above approximately 500 °C AEBP can be retained at the bottom of the container for instant and periodic vaporization or continuously drained into storage containers.

[0261] In certain embodiments, water vapor or superheated water vapor or supercritical water may be additionally introduced into the depressurization vessel to facilitate the fractionation of liquid products.

[0262] Heating / pressurization and cooling / depressurization and fractionation processes can be carried out in a continuous flow system (see the section below entitled “Continuous flow”).

[0263] The fractionation column may contain distillation trays for separating the condensed liquid product.

[0264] The fractionation column can fractionate the product stream into different boiling ranges. As noted in this document, boiling points will be considered as atmospheric equivalent boiling points (AEBP) unless otherwise indicated. For example, the fractionation column can separate the product stream by boiling range into a naphtha fraction with a boiling point between about 70 °C and about 210 °C AEBP and a distillate gas oil fraction with a boiling point between about 210 °C and about 360 °C AEBP and a heavy gas oil fraction with a boiling point between about 360 °C and about 400 °C AEBP, about 360 °C and about 450 °C AEBP, or 360 °C and about 500 °C AEBP. Diesel and heavy diesel fractions may be wholly or partially waxy solids at 25 °C. Gases and vapors that are not Petition 870260053158, dated 01 / 06 / 2026, p. 68 / 148 59 / 103 of the condensate in the column can pass to a condenser that can condense a low-boiling-point oil (naphtha fraction). The naphtha fraction and any other condensed fractions can be wholly or partially recirculated in the fractionation column. The gases and vapors passing through the condenser can be directed to the boiler, after which the gases can be burned, producing the supercritical aqueous solvent, optionally with the addition of an additional fuel gas, such as natural gas. Combustion can recover energy from the gas and can destroy any compounds of environmental concern in the combustion process. Optionally, some or all of the gases and vapors can be directed to a flare. The flare can be a closed flare.

[0265] In some embodiments, a non-distillable portion of the product stream (heavy wax residue), with a boiling point of, for example, >500 °C, can be removed continuously or intermittently from the bottom of the depressurization vessel (located at the bottom of the fractionation column).

[0266] It will be evident to those skilled in the art that the fractionation column can be operated in a manner known in the field to provide the desired boiling ranges for the product fractions.

[0267] In some embodiments, the undistilled residue from the flash vaporization vessel and / or fractionation column may optionally be distilled in a vacuum distillation unit to provide a vacuum gas oil fraction and a heavy residue as shown in Figure 6. The boiling range of the VGO fraction may be, for example, 360 °C to 650 °C. Petition 870260053158, dated 01 / 06 / 2026, page 69 / 148 60 / 103 AEBP.

[0268] In some embodiments of the present invention, the lower part of the flash vaporization column may be a demister. Without any particular limitation, the mixture entering the flash vaporization column after being reduced from a very high pressure to a pressure close to atmospheric may be predominantly in the gas phase with liquid droplets of high-boiling-point hydrocarbons comprising an aerosol. The design of the lower section of the flash vaporization column is therefore to act as a demister separating the high-boiling-point hydrocarbon droplets from the gas mixture.

[0269] Upon entering the column, the product gas stream can be forced by a baffle plate to make a sharp turn; as the gas rotates, the momentum of the droplets means that they impact the baffle plate where they coalesce and flow down as a liquid to the bottom of the flash vaporization column. A non-limiting example of a suitable apparatus for the method is shown in Figure 7.

[0270] The base of the flash vaporization column may have a sufficiently large diameter to ensure a very low upward velocity within that section of the column. The diameter at the base of the column may be selected so that the largest droplets that are carried by the gas phase have about 50 microns, or about 40 microns, or about 30 microns, or about 20 microns, or about 10 microns, or about 5 microns in diameter. Droplets larger than this diameter cannot be carried upwards and fall into the liquid residue at the base of the column. Petition 870260053158, dated 01 / 06 / 2026, page 70 / 148 61 / 103 PROCESS GAS COMBUSTION

[0271] In some aspects of the present invention, the gaseous products of the methods described in this document (including non-condensable vapors) can be burned to provide energy for the generation of the supercritical aqueous solvent, for example, in a supercritical fluid boiler. The supercritical fluid boiler can be specifically designed for the purpose of burning the process gas at temperatures that destroy quantities of pollutants of environmental concern. Such pollutants may include, for example, sulfides, haloalkanes, haloarenes, haloalkenes and / or polychlorinated dibenzo-p-dioxins.

[0272] It is known in the art and prescribed in environmental regulations in certain jurisdictions (e.g., United Kingdom, EU, European Industrial Emissions Directive) that, in order to ensure the destruction of the species mentioned above, combustion gases must be held for a residence time greater than 2 seconds at a temperature equal to or greater than 850 °C in the presence of excess oxygen.

[0273] In some embodiments of the present invention, the process gas together with air and recycled combustion gas from the boiler exhaust can be burned within a secondary chamber, for example, an uncooled refractory-lined chamber, which is large enough to provide 2 seconds of residence time with the combustion gases above 850 °C. The refractory can separate the boiler metal from the potentially corrosive environment of the cyclic oxidizing-reducing atmosphere near the burner flame. The cycle between oxidizing and reducing conditions is known in the art to increase the chloride corrosion rate of steel. The recirculated combustion gas Petition 870260053158, dated 01 / 06 / 2026, p. 71 / 148 62 / 103 can be employed to prevent overheating of the chamber and minimize the production of nitrogen oxides (NOx emissions). It can also lead to lower metal temperatures (therefore lower corrosion rates) when combustion gases are introduced to the boiler tube rows. To provide the necessary volume, the custom boiler design comprises a horizontal, uncooled refractory-clad section that is long enough to allow the burner flame to terminate without impacting the boiler walls. This is then followed by a larger, vertically arranged boiler section. Optionally or additionally, this system can be combined with a selective catalytic reduction system for NOx control, meaning the plant is capable of meeting stringent emission limits applicable to gas boilers.

[0274] A non-limiting example of an indirect boiler heater configuration suitable for combustion media of process gases and vapors and / or natural gas or other calorific gas and supplying thermal energy to the reaction mixture according to the method of the present invention is shown in Figure 8. Here, process gases and vapors from the depolymerization of the polymeric material and optionally other calorific gases are burned by means of the burner. The hot combustion products are held in the refractory-lined chamber for a minimum residence time of 2 seconds at a minimum temperature of 850 °C. The hot gases heat the pressurized aqueous solvent in the tubes in a refractory-lined furnace box with water walls that slowly cools the process gas. The aqueous solvent is thus heated to a temperature above 374 °C and below about 600 °C. Petition 870260053158, dated 01 / 06 / 2026, page 72 / 148 63 / 103 thus generating a supercritical aqueous solvent stream. The supercritical aqueous solvent is supplied to the mixer to be mixed with the polymer feedstock and optionally or additionally to one or more indirect heaters to further heat the reaction mixture. Once the water vapor has passed through the indirect heaters, the cold water vapor is returned to the boiler to be reheated. The water vapor is passed through convection heat transfer tubes located within the second boiler pass, where the hot boiler gases heat the water vapor. Once reheated, the water vapor is again used in the next pair of indirect heaters before being reheated again. Multiple reheating phases can be used to obtain the necessary heat transfer to the polymer material plus the aqueous solvent mixture, for example, four phases.

[0275] In some embodiments, the supply of water vapor to the indirect heaters may be in a separate circuit from the supply of supercritical aqueous solvent to the mixer, at a lower pressure, for example, 2 bar, 5 bar, 10 bar or 20 bar, or 50 bar or 100 bar, less than 221 bar. The temperature of the water vapor exiting the boiler may be at least 450 °C, at least 470 °C, at least 500 °C, less than 520 °C, less than 550 °C.

[0276] In some applications, indirect heaters are not circumferential. Separation of aqueous solvent

[0277] The fractionation columns described here can provide a means of separating the aqueous solvent from the products. Without Petition 870260053158, dated 01 / 06 / 2026, p. 73 / 148 64 / 103 This fractionation, the separation of the aqueous solvent from the product, can be difficult or impossible.

[0278] Without limitation, the depolymerization products of a plastic feedstock material may contain significant wax fractions and / or may have a high viscosity at room temperature (e.g., 25 °C). The aqueous solvent may be physically carried into the waxy products and, consequently, emulsion-breaking chemicals may be required in combination with centrifugation or gravity-assisted decantation to separate the aqueous solvent. An advantage of the present invention may be that the aqueous solvent is readily separated from the low-boiling-point product fraction (naphtha) after fractionation as illustrated in Figure 9. The aqueous solvent is denser and insoluble in the product fraction and can be readily separated under normal gravity by means known in the art, such as decantation.An additional advantage of the present invention is that the aqueous solvent separated in this manner may contain low concentrations of suspended solids and soluble metals and organic compounds. The total organic carbon (TOC) content measured according to the European standard method EN 1484 may be less than 10000 mg / l, less than 5000 mg / l, less than 2500 mg / l, less than 1000 mg / l, or less than 500 mg / l. The low organic content of the separated aqueous solvent means that the aqueous solvent can be easily treated for discharge into the environment. Without limitation, the aqueous solvent can be discharged into the environment or recycled as solvent. CONTINUOUS FLOW

[0279] The methods according to the present invention are carried out under continuous flow conditions. Petition 870260053158, dated 01 / 06 / 2026, page 74 / 148 65 / 103

[0280] Implementing the invention process under continuous flow conditions can provide several advantageous effects. For example, continuous flow can facilitate the accelerated implementation and / or removal of heat and / or pressure applied to a reaction mixture. This can help achieve desired rates of mass and heat transfer, heating / cooling, and / or pressurization / depressurization. Continuous flow can also allow the retention time to be rigidly controlled. Without limiting to a particular mode of action, it is postulated that the increased heating / cooling and / or pressurization / depressurization rate facilitated by continuous flow conditions, along with the ability to tightly regulate the retention time, assists in preventing the occurrence of undesirable side reactions (e.g., repolymerization, carbon formation) as the reaction mixture heats / pressurizes and / or cools / depressurizes.It is also believed that continuous flow enhances the reactions responsible for converting polymeric materials into hydrocarbon products due to the generation of mixing and shear forces that are believed to aid in emulsification.

[0281] Thus, the methods of the present invention are carried out under continuous flow conditions. As used in this document, the term continuous flow refers to a process in which:

[0282] (i) reaction mixture precursors (e.g., extruded polymeric material, aqueous solvent and, optionally, catalyst and / or oil streams) are maintained in a continuous flow in the reactor apparatus;

[0283] (ii) the reaction mixtures are maintained in a continuous flow of movement through the reactor apparatus; and Petition 870260053158, dated 01 / 06 / 2026, page 75 / 148 66 / 103

[0284] (iii) product stream (or streams) is maintained in a continuous flow out of the reactor apparatus

[0285] Consequently, in a continuous flow system, the reaction mixture is maintained in a continuous moving stream along the length (or partial length) of a given surface of the reactor apparatus, from the reactor inlet point to the reactor outlet point.

[0286] The continuous flow conditions as contemplated herein do not imply any particular limitation with respect to the flow rate of a reaction mixture, provided that it is maintained in a continuous flow stream.

[0287] Continuous flow conditions can be facilitated, for example, by carrying out the methods of the invention in a suitable reactor apparatus. A suitable reactor apparatus will generally comprise heating / cooling, pressurization / depressurization and reaction components in which a continuous stream of reaction mixture is maintained.

[0288] The use of an appropriate flow rate (under continuous flow conditions) can be advantageous in preventing fouling formation along the length of a particular surface that the reaction mixture moves along (e.g., walls of a reactor apparatus vessel) and / or generating a mixing regime for efficient heat transfer into and within the reaction mixture. ADDITIONAL REAGENTS AND CATALYSTS

[0289] Optionally, additional (i.e., supplementary) reagents and / or catalysts may be added to the process. Petition 870260053158, dated 01 / 06 / 2026, p. 76 / 148 67 / 103

[0290] In some embodiments, the supplementary reagent (or reagents) and / or catalyst (or catalysts) may be solid at room temperature and may be mixed with the polymer feedstock before the polymer feedstock enters an extruder. In some embodiments, the additive may be solid at room temperature and may be mixed with the polymer feedstock inside an extruder by means of a suitable port.

[0291] In some embodiments, the supplementary catalysts may be a solid calcium salt chosen from calcium oxide, calcium hydroxide, calcium carbonate, calcium bicarbonate. In some embodiments, the supplementary catalysts may be a solid base chosen from sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, lithium hydroxide, lithium carbonate, magnesium oxide, magnesium hydroxide, barium oxide and barium hydroxide.

[0292] Without limitation to one mode of action, the additive can react with organic halides or with halogen-containing species, for example, hydrogen chloride, to form inorganic halides. The inorganic halides can be removed as solids by purging in hydrothermal reactors.

[0293] Without limitation to a mode of action, the additive may accelerate the decomposition of compounds such as terephthalic acid (TPA) and / or benzoic acid (BA), formed from the decomposition or depolymerization of poly(ethylene terephthalate) present in the polymer feedstock. TPA and BPA may be decomposed into other aromatic compounds including, but not limited to, benzene, toluene, benzophenone and benzaldehyde. The additive may be Petition 870260053158, dated 01 / 06 / 2026, page 77 / 148 68 / 103 removed as a solid by purging, the form of the additive may have changed by chemical reaction prior to said removal.

[0294] In some embodiments, the supplementary reagent(s) and / or catalyst(s) may be added in liquid form (e.g., as aqueous solutions). The liquids may be added under pressure using a high-pressure dosing pump or similar means. The liquid may be added at any stage of the process before the depressurization stage. The liquid may be added to the extruder, between the extruder and the point(s) of supercritical aqueous fluid addition, after the point(s) of supercritical aqueous fluid addition but before any additional heating stages, if present, or before any of the reactor vessels, or before the depressurization stage.

[0295] In some embodiments of the present invention, the base may be included in the molten polymeric material stream / extrudate, aqueous solvent stream and / or reaction mixture. There is no specific restriction on the type or form of base that may be used or the point (or points) in the process where it may be introduced. By way of non-limiting example, the base may be introduced, for example, as a solid feed to the extruder with the polymeric material and / or as a liquid form at any point after the extrusion step (e.g., to the extrudate / melt stream, to the aqueous solvent stream and / or directly to the reaction mixture). In a continuous or semi-continuous version of the process of the invention, at least some base may be added before the final leg of the reactor.

[0296] Non-limiting examples of suitable bases for this purpose are carbonates, hydroxides, hydrogen carbonates, oxides of Petition 870260053158, dated 01 / 06 / 2026, page 78 / 148 69 / 103 Group I and Group II metals and materials containing significant quantities thereof (e.g., black liquor, white liquor, green liquor, red mud, limestone, calcite).

[0297] A reaction mixture for use according to the methods of the present invention may comprise catalysts that can enhance the formation of the desired products.

[0298] Catalysts may be intrinsic catalysts that are derived from other components of the reaction mixture itself (e.g., from the polymeric material, aqueous solvent, any other component of the reaction mixture), understood as generated in situ during the treatment of the reaction mixture according to the methods of the present invention, and / or are derived from the materials of the mixer and walls of a reactor apparatus within which the reaction mixture is treated. For example, catalysts may be hydronium / hydroxide ions in the reaction mixture, compound(s) in the polymeric material, and / or transition / noble metals from the walls of the reactor vessel. Plastic polymer waste treated according to the methods of the present invention may have contaminants with catalytic activity.

[0299] Additionally or alternatively, the catalysts may be supplementary catalysts that are not derived from other components of the reaction mixture itself, are not generated in situ during the treatment of the reaction mixture according to the methods of the present invention, and are not derived from the construction materials or walls of a reactor apparatus within which the reaction mixture is treated. Instead, the supplementary catalysts are added separately to the Petition 870260053158, dated 01 / 06 / 2026, page 79 / 148 70 / 103 reaction mixture as a discrete / autonomous component and are therefore additional to the intrinsic catalysts present in the reaction mixture.

[0300] Although the addition of supplementary catalysts may be advantageous in certain circumstances, the skill recipient will recognize that the methods of the invention can be carried out without using them.

[0301] A supplementary catalyst as contemplated in this document may be any catalyst that enhances the formation of desired hydrocarbon products, such as fuels and chemicals from polymeric feedstock using the methods of the invention, non-limiting examples of which include basic catalysts, acid catalysts, alkali metal hydroxide catalysts, transition metal hydroxide catalysts, alkali metal formate catalysts, transition metal formate catalysts, reactive carboxylic acid catalysts, transition metal catalysts, sulfide catalysts, noble metal catalysts, water-gas shift catalysts, metals supported on nitrogen-doped carbon materials and combinations thereof.

[0302] Beyond theory, supplementary basic catalysts can play a multiple role, as they can enhance product formation and also control pH, which can be advantageous for reducing corrosion rates in the reactor's metallic components, and can promote the precipitation of halogens contained in the feedstock as metal halides that are insoluble or poorly soluble in supercritical water. After cooling and depressurization, the metal halides can be Petition 870260053158, dated 01 / 06 / 2026, page 80 / 148 71 / 103 dissolve again in the aqueous phase. This action is advantageous because halogens, particularly chlorine, can be effectively removed from the gaseous and / or oily phases. Chlorine is undesirable in the gaseous and oily phases because it can form dioxins and other environmental pollutants if not burned off in a subsequent process.

[0303] In some embodiments, supplementary catalysts known in the art to promote water-gas shift (WGS) reactions may be included in the reaction mixture to promote hydrogen transfer from water to oil products. Any WGS catalysts or hydrogen transfer catalysts known in the art may be used. Without limitation, the catalysts may be in the form of a finely dispersed solid added to the extruder feed. Alternatively, they may be in the form of a fixed bed. Alternatively, they may be homogeneous when present in a reaction stream (e.g., aqueous solvent, polymeric material extrudate and / or reaction mixture) under subcritical and / or supercritical conditions.

[0304] Without being limited by theory, the addition of WGS and / or hydrogen transfer catalysts can increase the degree of hydrocarbon saturation in the product. This can be desirable as the cetane number of the middle distillates in the product can increase and the proportion of n-paraffins in the wax fractions in the product can also increase, making the waxes valuable by virtue of their high purity and sharp and distinct melting point ranges. SOLID METAL CATALYSTS Petition 870260053158, dated 01 / 06 / 2026, page 81 / 148 72 / 103

[0305] In some embodiments of the invention, the solid metal catalysts are placed in contact with the reaction stream.

[0306] In some embodiments, the solid metal catalysts are fixed metallic surfaces within the reactor vessels. The solid metal catalysts may be, for example, wires, meshes, sheets and shapes known in the art, such as Raschig rings.

[0307] In some embodiments, the solid metal catalysts comprise nickel. In some embodiments, the nickel is in a formal zero oxidation state. Nickel may be present as an alloy with other metals, for example, 310 or 316 stainless steel.

[0308] Without being limited by theory, nickel can facilitate the transfer of hydrogen from the aqueous solvent to the depolymerization products of the polymer feed.

[0309] It will be appreciated by persons skilled in the art that numerous variations and / or modifications can be made to the present invention, as disclosed in the specific embodiments, without departing from the spirit or scope of the present invention as fully described. The present embodiments should therefore be regarded in all respects as illustrative and not restrictive. EXAMPLES

[0310] The present invention will now be described with reference to a specific Example (or Examples), which should not be construed as limiting in any way. Petition 870260053158, dated 01 / 06 / 2026, p. 82 / 148 73 / 103 EXAMPLE ONE

[0311] The behavior of a flash vapor depressurization coupled to a fractionation column was demonstrated below. Post-consumer plastics of two broad types were prepared for extrusion. Hard plastics from the post-consumer collection known as PTT (Pots, Tubs and Trays, e.g., food containers, personal hygiene product containers, toys, laundry baskets, milk cartons) were chipped or shredded to sizes of approximately 1-20 mm. Metals were removed by magnetic separation and eddy currents. Plastics denser than water (e.g., PVC, PET) were removed primarily by flotation on water. The chipped PTT plastics were dewatered by centrifugation and bagged in preparation for extrusion. Soft plastics known as Films (e.g., single-use LDPE plastic bags, plastic bags, food packaging, etc.) were shredded.Metals were removed by magnetic separation and eddy currents. Plastics denser than water (e.g., PVC, PET) were removed primarily by flotation on water. Shredded film plastics were dehydrated by centrifugation and densified by agglomeration / pelletizing. Optionally, the agglomerates were extruded and passed through a screen filter to remove, for example, small pieces of aluminum foil, and then the extrudate was cut into pellets. The film pellets / agglomerates were bagged in preparation for processing.

[0312] The PTT and Film materials were mixed in various proportions as described in Table 1 and depolymerized in Petition 870260053158, dated 01 / 06 / 2026, page 83 / 148 74 / 103 a continuous flow reactor consisting of, in series, an extruder (110-EX-001), a supercritical water injection zone, a series of heaters, three or four reactors, a cooler, a depressurization stage, and one or more product tanks. The experimental conditions are given in Table 1. The depolymerization products were synthetic crude oils. Samples of the synthetic crude oils were dried in the laboratory to remove water, and their boiling ranges were characterized by simulated distillation according to ASTM D7169 and by vacuum distillation approximating ASTM D1160. The results of the simulated distillation are presented in Tables 2 to 4.Simulated distillation curves were used to construct a model of the flash vaporization distillation and fractionation behavior of synthetic crude oils in a flash vaporization depressurization from the total reaction temperature and pressure in a fractionation column. The simulation was performed using AspenTech's HYSYS software. The resulting boiling point distributions of four fractions are shown in the three modeled cases in Figures 10, 11, and 12. The modeling assumed a mass flow rate out of the reactor of 3893 kg / h and a 1.2 m diameter fractionation column. TABLE 1. EXPERIMENTAL PARAMETERS FOR THE PRODUCTION OF SYNTHETIC CRUDE OILS BY DEPOLYMERIZATION OF POST-CONSUMER PLASTICS Petition 870260053158, dated 01 / 06 / 2026, page 84 / 148 75 / 103 Test No. PTT Proportion in Polymer Feed Film Proportion in Polymer Feed Polymer / Water Mass Ratio Reaction Temperature °C Reaction Pressure Bar Extruder Outlet Temperature °C Supercritical Water Temperature in Mixing Zone °C 1 1 1 48 / 51 440 220 350 510 2 2 1 68 / 32 440 220 350 510 3 3 1 65 / 35 435 220 350 500 TABLE 2 SIMDIS BOILING POINT DATA FOR CRUDE OIL Synthetic version of test 2 % by weight outside BP °C % by weight outside BP °C % by weight outside BP °C 0.5 44.2 34 223.0 68 394.2 1 62.4 35 228.6 69 399.4 2 19.4 36 234.0 70 405.2 3 95.6 37 237.2 71 411.6 4 104.4 38 238.8 72 416.0 5 110.8 39 242.4 73 422.8 6 117.6 40 248.0 74 428.4 7 124.4 41 254.4 75 434.6 8 128.0 42 257.4 76 440.8 9 133.2 43 263.6 77 447.0 10 133.2 44 270.0 78 453.6 11 135.6 45 274.0 79 460.4 12 135.6 46 277.4 80 468.0 13 138.2 47 283.0 81 474.6 14 140.8 48 289.0 82 482.2 15 143.4 49 291.8 83 489.4 16 146.0 50 299.2 84 497, 6 17 150, 8 51 304,8 85 505, 2 18 153, 0 52 307,8 86 513, 8 Petition 870260053158, dated 01 / 06 / 2026, page 85 / 148 76 / 103 19 155, 0 53 313, 0 87 522.4 20 162, 6 54 318.2 88 531.4 21 167.0 55 321.6 89 241.4 22 174.2 56 329.6 90 558.1 23 176.6 57 334.0 91 563.0 24 178.8 58 340.0 92 575.0 25 183.8 59 345.6 93 589.9 26 189.8 60 348.8 94 ​​604.8 27 193.8 61 356, 4 95 624,2 28 198,0 62 360, 6 96 648, 8 29 199, 6 63 367,2 97 686, 0 ​​30 203,4 64 371, 6 97,6 719, 6 31 209, 2 65 376, 8 32 215, 8 66 383,2 33 219, 2 67 388,8 TABLE 3 SIMDIS BOILING POINT DATA FOR CRUDE OIL Synthetic version of test 2 % by weight outside BP °C % by weight outside BP °C % by weight outside BP °C 0.5 79.4 34 310.4 68 506.6 1 95.6 35 315.2 69 513.8 2 128.0 36 319.6 70 520.2 3 135.6 37 325.2 71 527.6 4 138.2 38 332.2 72 534.4 5 146.0 39 336.0 73 541.6 6 154.0 40 342.2 74 549.0 7 164.8 41 346.8 75 556.4 8 174.6 42 351.8 76 564.0 9 178.8 43 359.0 77 572.0 10 186.8 44 363.2 78 580.2 Petition 870260053158, dated 01 / 06 / 2026, page 86 / 148 77 / 103 11 192.8 45 369.2 79 588.6 12 198.6 46 373.0 80 597.4 13 202.4 47 380.0 81 606.8 14 209.2 48 384.8 82 616.6 15 217.0 49 391.6 83 627.0 16 220.4 50 395.6 84 638.6 17 226.8 51 402.6 85 650.8 18 233.2 52 407.6 86 664.4 19 236.8 53 414.2 87 681.2 20 239.2 54 418.8 88 699.6 21 243.6 55 425.0 89 719.6 22 249.4 56 431.6 23 255.4 57 436.4 24 258.8 58 443.2 25 266.0 59 450.0 26 272.0 60 455.2 27 275.0 61 461.6 28 279.6 62 468.8 29 285.2 63 474.6 30 290.2 64 481, 0 31 295, 0 65 487,4 32 301,8 66 493, 6 33 305, 8 67 500,4 TABLE 4 SIMDIS BOILING POINT DATA FOR CRUDE OIL Synthetic Test 3 % by weight outside BP °C % by weight outside BP °C % by weight outside BP °C 0.5 103.2 34 351.4 68 548.6 1 120.2 35 356.4 69 554.0 2 128.2 36 363.0 70 559.4 Petition 870260053158, dated 01 / 06 / 2026, page 87 / 148 78 / 103 3 132.4 37 367.2 71 564.8 4 138.6 38 374.6 72 570.0 5 149.2 39 380.0 73 575.8 6 160.8 40 387.0 74 581.0 7 172.4 41 391.4 75 586.8 8 183.2 42 398.8 76 592.4 9 192.8 43 404.8 77 597.8 10 201.8 44 410.0 78 603.8 11 213.0 45 416.4 79 609, 6 12 221, 6 46 422.2 80 615, 4 13 228, 6 47 428.8 81 621.4 14 233, 0 48 434.2 82 627.4 15 238.0 49 440.2 83 633, 6 16 245, 0 50 446.8 84 639, 8 17 251.4 51 452.4 85 646.0 18 258, 6 52 458, 6 86 652.6 19 265, 6 53 464.6 87 659, 4 20 269, 6 54 470, 6 88 666, 4 21 275, 0 55 476, 6 89 674, 0 22 281, 6 56 482,0 90 682,0 23 286, 0 ​​57 487,4 91 690,2 24 293, 8 58 493, 8 92 698,0 25 299, 8 59 499, 4 93 705, 6 26 304,4 60 505, 2 94 713, 8 27 309, 6 61 510, 6 94,7 719, 6 28 314,0 62 515, 8 29 320, 6 63 521, 6 30 327, 6 64 526, 8 31 333, 0 65 532,2 32 339, 2 66 537, 6 33 343,4 67 543,2 Petition 870260053158, dated 01 / 06 / 2026, page 88 / 148 79 / 103 EXAMPLE TWO

[0313] The results presented in this Example demonstrate the importance of using static mixers to provide good mixing between the molten polymer extrudate and the supercritical aqueous solvent. This is important to obtain good heat transfer from the supercritical aqueous solvent, which is at a higher temperature than the molten polymer, and also to intimately mix the solvent and the polymeric material, thus allowing the solvent to influence the reaction pathways of the polymeric material during polymerization, including the transfer of hydrogen from the solvent to the depolymerization products. Mixing profiles for two different scenarios (Iteration 1: Figures 13-15; Iteration 2: Figures 16-17) were examined by computational fluid dynamics (CFD) modeling. The supercritical aqueous solvent was modeled as supercritical water (SCW) at 500 °C. Other modeling parameters were as follows:

[0314] - Molten plastic inlet:

[0315] Mass flow rate: 2782 kg / h, Temperature: 350 °C

[0316] - SCW Entrance:

[0317] Mass flow rate at four inlets: 1762 kg / h, Temperature: 500 °C

[0318] - Pipe walls:

[0319] Adiabatic. TABLES 5, 6 AND 7: FLUID PROPERTIES USED IN MODELING Table 5 Petition 870260053158, dated 01 / 06 / 2026, page 89 / 148 80 / 103 Properties of plastics 16 Temperature °C 325 350 375 400 425 450 17 Shear rate l / s 10 10 10 10 10 10 18 Viscosity Pa.s 331 270 224 189 161 139 19 Density kg / m³ 685 670 655 640 625 610 20 Enthalpy kJ / kg 1019 1109 1201 1295 1391 1488 Supercritical properties of water vapor / water at 300 bar 21 Temperature °C 350 375 400 425 450 500 22 Viscosity Pa.s 7.55E05 6.45E05 4.5OEOS 3.19E05 3.09E05 0.0000 32 23 Density kg / m3 644 558 357 189 148 115 24 Enthalpy kJ / kg 1609 1792 2153 2612 2821 3085 TABLE 6 Plastic Properties Temperature (degrees C) 350 375 400 425 450 Thermal Conductivity (W / mK) 0.138 0.1355 0.133 0.1305 0.128 TABLE 7 SCW at 300 bar Temperature (degrees C) 350 375 400 425 450 Thermal conductivity (W / mK) 0.49597 0.43807 0.33204 0.17582 0.13616

[0320] Iteration 1 (Figures 13-15) modeled a 15.24 tube Petition 870260053158, dated 01 / 06 / 2026, pp. 90 / 148 81 / 103 cm (6 inches) in diameter with four radial 10 mm diameter SCW inlets in a single plane, the iteration was modeled with 0, 2, and 4 static mixer elements.

[0321] Iteration 2 (Figures 16-18) modeled a 15.24 cm (6 inch) tube with four 10 mm diameter SCW inlets in two planes 50 mm apart and triangular bars just upstream of the SCW inlets, the iteration was modeled with 0, 2 and 4 static mixing elements.

[0322] The geometry of the static mixer elements modeled as part of the assembly was a design provided by NOV, Process and Flow Technologies, Mixing Technologies, 5870 Poe Ave, Dayton, Ohio 45414.

[0323] The modeling findings showed that static mixers improve the mixing of SCW and molten polymer. The uniformity of the mixture at a distance of approximately 9 pipe diameters from the SCW injection point is shown in Figure 19. The uniformity of the mixture also represents better heat transfer from the SCW to the polymeric material.

[0324] The pressure drop introduced by the static elements of the mixer is approximately 2.5 bar per element, as per the model. This pressure drop is operationally manageable for up to about four mixers (10 bar).

[0325] The mixer configuration performance is illustrated in the attached graphs. The first, Figure 20, shows that, without a mixer, there is weak mixing of the supercritical water with the polymeric material, with two-phase flow occurring along the length of the tube. Petition 870260053158, dated 01 / 06 / 2026, page 91 / 148 82 / 103

[0326] Performing computational fluid dynamics modeling (CFD modeling) for the various mixer designs showed the benefit of including a supercritical fluid distributor with a standard industrial mixer design to achieve good mixing, as illustrated in the results shown in Figure 21.

[0327] Good mixing is reflected in the temperature profiles of the polymeric material, showing how the cold fluid (blue) is heated and how the temperature of the supercritical fluid (red) is cooled, rapidly reaching a uniform mixing temperature (Figure 22). EXAMPLE THREE

[0328] The results presented in this example demonstrate that the methods of the present invention allow easy separation of the supercritical aqueous solvent from the depolymerization product without the need, for example, for demulsifying chemicals or increased gravity methods such as centrifuges / decanters.

[0329] The behavior of a flash vapor depressurization coupled to a fractionation column was demonstrated below. Post-consumer plastics of two broad types were prepared for extrusion. Hard plastics from the post-consumer collection known as PTT (Pots, Tubs and Trays, for example, food containers, personal hygiene product containers, toys, laundry baskets, milk cartons) were chipped or shredded to sizes of approximately 1-20 mm. Metals were removed by magnetic separation and eddy currents. Denser plastics than Petition 870260053158, dated 01 / 06 / 2026, page 92 / 148 83 / 103 Water-density plastics (e.g., PVC, PET) were removed by flotation on water. Chipped PTT plastics were dewatered by centrifugation and bagged in preparation for extrusion. Soft plastics known as Films (e.g., single-use LDPE plastic bags, plastic bags, food packaging, etc.) were shredded. Metals were removed by magnetic separation and eddy currents. Plastics denser than water (e.g., PVC, PET) were removed by flotation on water. Shredded film plastics were dewatered by centrifugation and densified by agglomeration / pelletizing. Optionally, the agglomerates were extruded and passed through a screen filter to remove, for example, small pieces of aluminum foil, and then the extrudate was cut into pellets. The film pellets / agglomerates were bagged in preparation for processing.

[0330] PTT and Film materials were mixed in a 3:1 mass ratio and depolymerized in a continuous flow reactor consisting of, in series, an extruder (110-EX-001), a supercritical water injection zone, a series of heaters, three or four reactors, a cooler, a depressurization stage, and one or more product tanks. The depolymerization product was a synthetic crude oil, waxy in nature and containing approximately 30% of its mass as entrained water. The entrained water could not be physically separated at temperatures below 95 °C from the waxy synthetic crude oil by simple means such as decantation, since no visible separation of oil and water was observed.

[0331] The fractionation method of the product of the present invention was simulated by atmospheric distillation of the fractions of Petition 870260053158, dated 01 / 06 / 2026, page 93 / 148 84 / 103 low boiling point of synthetic crude oil. The low boiling point fractions, or naphtha (boiling point of approximately 40-210 °C) of the crude product and the water from the aqueous solvent were co-distilled and condensed together. The water and naphtha spontaneously separated into phases (Figure 9), having low mutual solubility, and can be easily separated at room temperature by means known in the art such as decantation or by means of a simple outlet with a valve.

[0332] Analysis of the aqueous phase showed that it had low organic content and low metal content and, as such, could be readily recycled or treated for disposal or reuse. TABLE 8. COMPOSITION OF THE AQUEOUS PHASE IN CONTACT WITH NAPHTHA. SAMPLE DILUTED 3 TIMES WITH PURE WATER BEFORE ANALYSIS. VOCS Method in Water: AN433 Tested: 08 / 03 / 2019 Fumigants 2,2-dichloropropane pg / l 0.5 1,2-dichloropropane pg / l 0.5 cis 1,3-dichloropropene pg / l 0.5 trans 1,3-dichloropropene pg / l 0.5 1,2-dibromoethane (EDB) pg / l 0.5 Halogenated Aliphatics Dichlorodifluoromethane (CFC-12) pg / l 5 Chloromethane pg / l 5 Vinyl chloride (chloroethane) pg / l 0.3 Bromomethane pg / l 10 Chloroethane pg / l 5 Trichlorofluoromethane pg / l 1 Iodomethane pg / l 5 Petition 870260053158, dated 01 / 06 / 2026, p. 94 / 148 85 / 103 1,1-dichloroethene pg / l 0.5 Dichloromethane (methylene chloride) pg / l 5 Allyl chloride pg / l 2 trans-1,2-dichloroethene pg / l 0.5 1,1-dichloroethane pg / l 0.5 cis-1,2-dichloroethene pg / l 0.5 Bromochloromethane pg / l 0.5 1,2-dichloroethane pg / l 0.5 1,1,1-trichloroethane pg / l 0.5 1,1-dichloropropene pg / l 0.5 Carbon tetrachloride pg / l 0.5 Dibromoethane pg / l 0.5 Trichloroethane (trichloroethylene, TCE) pg / l 0.5 1,1,2-trichloroethane pg / l 0.5 1,3-dichloropropane pg / l 0.5 Tetrachloroethene (Perchlorethylene, PCE) pg / l 0.5 1,1,1,2-tetrachloroethane pg / l 0.5 sis-1,4-dichloro-2-butene pg / l 1 1,1,2,2-tetrachloroethane pg / l 0.5 1,2,3-trichloropropane pg / l 0.5 trans-1,4-dichloro-2-butene pg / l 1 1,2-dibromo-3-chloropropane pg / l 0.5 Hexachlorobutadiene pg / l 0.5 Halogenated Aromatics Chlorobenzene pg / l 0.5 Bromobenzene pg / l 0.5 2-chlorotoluene pg / l 0.5 4-chlorotoluene pg / l 0.5 1,3-dichlorobenzene pg / l 0.5 1,4-dichlorobenzene pg / l 0.3 1,2-dichlorobenzene pg / l 0.5 Petition 870260053158, dated 06 / 01 / 2026, p. 95 / 148 86 / 103 1,2,4-trichlorobenzene pg / l 0.5 1,2,3-trichlorobenzene pg / l 0.5 Monocyclic Aromatic Hydrocarbons Benzene pg / l 0.5 Toluene pg / l 0.5 Ethylbenzene pg / l 0.5 m / p-xylene pg / l 1 o-xylene pg / l 0.5 Styrene (Vinyl benzene) pg / l 0.5 Isopropylbenzene (Cumene) pg / l 0.5 n-propylbenzene pg / l 0.5 1,3,5-trimethylbenzene pg / l 0.5 tert-butylbenzene pg / l 0.5 1,2,4-trimethylbenzene pg / l 0.5 sec-butylbenzene pg / l 0.5 p-isopropyltoluene pg / l 0.5 n-butylbenzene pg / l 0.5 Nitrogen Compounds Acrylonitrile pg / l 0.5 2-nitropropane pg / l 100 <1000 + Oxygen Compounds Acetone (2-propanone) pg / l 10 150000 MtBE (methyl tert-butyl ether) pg / l 2 Vinyl acetate pg / l 10 MEK (2-butanone) pg / l 10 MIBK (4-methyl-2-pentanone) pg / l 5 2-hexanone (MBK) pg / l 5 Polycyclic VOCs Petition 870260053158, dated 01 / 06 / 2026, page 96 / 148 87 / 103 Naphthalene pg / i 0.5 Sulfonated Compounds Carbon Disulfide pg / i 2 Substitutes Dibromofluoromethane (substitute) % d4-1,2-dichloroethane (substitute) % d8-toluene (substitute) % Bromofluorobenzene (substitute) % Totals Total Xylenes gg / l 1.5 1900 Total BTEX gg / l 3 5600 Total VOC gg / l 10 160000 Trihalomethanes Chloroform (THM) gg / l 0.5 Bromodichloromethane (THM) gg / l 0.5 Dibromochloromethane (THM) gg / l 0.5 Bromoform (THM) gg / l 0.5 Volatile Hydrocarbons in Oil in Water Method: AN433 Tested on 08 / 03 / 2019 TRH C6-C10 gg / 1 50 NVL Substitutes Dibromofluoromethane (substitute) % d4-1,2-dichloroethane (substitute) % d8-toluene (substitute) % Bromofluorobenzene (substitute) % Petition 870260053158, dated 01 / 06 / 2026, page 97 / 148 88 / 103 VPH F Bands Benzene (F0) gg / 1 0.5 TRH C6-C10 less BTEX (Fl) gg / 1 50 NVL TRH (Total Renewable Hydrocarbons) Method in Water: AN403 Tested: 3 / 11 / 2019 TRH C10-C14 gg / 1 50 57000 TRH C15-C28 gg / 1 200 7200 TRH C29-C36 gg / 1 200 2600 TRH C37-C40 gg / 1 200 830 TRH C10-C36 gg / 1 450 66000 TRH C10-C40 gg / 1 650 67000 TRH F Bands TRH > C10-C16 gg / 1 60 46000 TRH > C10-C16 - Naphthalene (F2) gg / l 60 46000 TRH > C16-C34 (F3) gg / l 500 0.900 TRH > C34-C40 (F4) gg / l 500 1800 Total Phenolics in Water Method: AN289 Tested on 08 / 03 / 2019 Total phenols mg / l 0.01 40 COD in Water Method: AN179 / AN181 Tested: 11 / 03 / 2019 Chemical oxygen demand mg / l 10 6400 pH in water method: AN101 Tested: 12 / 03 / 2019 pH** No units 3.5 Oil and grease in water method: AN185 Tested on 12 / 03 / 2019 Oil and grease mg / 1 5 <5 Petition 870260053158, dated 01 / 06 / 2026, pages 98 / 148 89 / 103 Total and Volatile Suspended Solids (TSS / VSS) Method AN114 Tested on 12 / 03 / 2019 Total suspended solids dried at 103-105 °C mg / l 5 <5 BOD5 Method: AN183 Tested: 08 / 03 / 2019 Biochemical Oxygen Demand (BOD5) mg / l 5 NVL Carbon Forms Method: AN190 Tested: 11 / 03 / 2019 Total Organic Carbon as NPOC mg / l 0.2 2000 Ammonia Nitrogen Method by Distinct Analyzer (Aquakem): AN291 Tested: 08 / 03 / 2019 Ammonia Nitrogen, NHa as N mg / l 0.01 1.4 Free Cyanide in Water Method: AN076 / AN287 Tested: - Free Cyanide mg / l 0.004 NVL Anion Method by Ion Chromatography in Water: AN245 Tested: 08 / 03 / 2019 Nitrogen Nitrate NO3-N mg / l 0.005 <0.005 Nitrite Method in Water: AN277 Tested: 08 / 03 / 2019 Nitrogen Nitrite, NO2 as N mg / l 0.005 <0.005 Total Oxidized Nitrogen, NOx-N mg / l 0.005 <0.005 Kjeldahl TKN Digestion Method by Distinct Analyzer: AN281 / AN292 (Sydney only) Tested: 13 / 03 / 2019 Total Kjeldahl Nitrogen mg / l 0.0.05 NVL Total Nitrogen (calculated) mg / L 0.05 NVL Kjeldahl Digestion Method for Total Phosphorus in Water: AN279 / 293 (Sydney only) Tested: 03 / 13 / 2019 Petition 870260053158, dated 01 / 06 / 2026, page 99 / 148 90 / 103 Total Phosphorus (Kjeldahl Digestion) as P mg / l 0.02 NVL Metals in Water (Dissolved) Method by ICPOES: AN230 Tested: 11 / 03 / 2019 Tin, Sn mg / l 0.05 <0.05 Trace Metals (Dissolved) in Water Method by ICPMS: AN318 Tested: 08 / 03 / 2019 Aluminum, Al pg / l 5 7 Antimony, Sb pg / l 1 <1 Arsenic, As pg / l 1 3 Cadmium, Cd pg / l 0.1 0.2 Chromium, Cr pg / l 1 22 Cobalt, Co pg / l 1 <1 Copper, Cu pg / l 1 3 Iron, Fe pg / l 5 160 Lead, Pb pg / l 1 <1 Manganese, Mn pg / l 1 6 Molybdenum, Mo pg / l 1 <1 Nickel, Ni pg / l 1 20 Selenium, Se pg / l 1 29 Silver, Ag pg / l 1 <1 Tin, Sn* pg / l 1 <1 Tungsten, W* pg / l 1 <1 Vanadium, V pg / l 1 <1 Zinc, Zn pg / l 5 10 Mercury (dissolved) in Water Method: AN311(Perth) / AN312 tested: 13 / 03 / 2019 Mercury mg / l 0.0001 <0.0001 Alcohols in Water Method: AN478 tested: 12 / 03 / 2019 Petition 870260053158, dated 01 / 06 / 2026, pages 100 / 148 91 / 103 1-butanol* mg / 1 1 1800 1-hexanol* mg / 1 1 <1 1-butoxy-2-propanol* mg / 1 1 <1 1-propanol* mg / 1 1 30 2-butoxyethanol* mg / 1 0.02 <0.02 2-ethyl hexanol* mg / 1 1 <1 ethanol* mg / 1 1 130 isobutanol* mg / 1 1 <1 isopropanol* mg / 1 1 95 methanol* mg / 1 1 400

[0333] Comparatively, to remove the aqueous solvent (water) from the waxy synthetic crude oil, it was necessary to add a chemical demulsifier (SUEZ PROSOLV AI8565) at levels around 1000 ppm and centrifuge at high temperature (approximately 90 °C). EXAMPLE FOUR

[0334] The chemical composition of the depolymerization products of post-consumer polymeric material processed according to the methods of the invention is detailed in Table 9 below. TABLE 9: CHEMICAL COMPOSITION OF DEPOLYMERIZATION PRODUCTS OF Post-consumer polymeric material. Compositions in % by mass. Raw Material Composition of Naphtha IBP-210 °C AEBP Composition of Diesel 210 °C-360 °C AEBP Composition of VGO 360 °C-550 °C AEBP Composition of residue Vac >550 °C AEBP Petition 870260053158, dated 01 / 06 / 2026, pp. 101 / 148 92 / 103 Post-consumer rigid plastics containing PE, PP (main components), PET, polyamide, ABS, polycarbonate, PS, EPDM, PVC, polyurethane, PMMA (minor components) and post-consumer film plastics containing the same components, in a 2:1 ratio: rigid:film by mass. n-Paraffins at 16%, Isoparaffins at 26.7%, Olefins at 11.9%, naphthenes at 16.8%, aromatics at 17.3%, unknown / polar at 11.1%, % H 13.6% by mass, % C 84.95% by mass. n-Paraffins at 21%, Isoparaffins at 18%, Olefins and naphthenes at 39%, aromatics and polar at 22%, % H 13.4%, % C 86.66%, Saturated, 79% of which n-paraffins at 24.5%, Aromatics at 21%, % of H 13.56% of C 86.54% of H 13.03% of C 85.80 EXAMPLE FIVE

[0335] The results presented in this example demonstrate the principle of solid material discharge from reactors.

[0336] Post-consumer plastics of two broad types were prepared for extrusion. Hard plastics from the post-consumer collection known as PTT (Pots, Tubs and Trays, e.g., food containers, personal hygiene containers, toys, laundry baskets, milk cartons) were chipped or shredded into sizes of approximately 1-20 mm. Metals were removed by magnetic separation and eddy currents. Plastics denser than water (e.g., PVC, PET) were removed by flotation on water. The chipped PTT plastics were dewatered by centrifugation and bagged in preparation for extrusion. Soft plastics known as Films (e.g., single-use LDPE plastic bags, plastic shopping bags, food packaging, etc.) were shredded. Metals were removed by separation. Petition 870260053158, dated 01 / 06 / 2026, pages 102 / 148 93 / 103 magnetic and eddy current methods. Plastics denser than water (e.g., PVC, PET) were removed by flotation on water. The shredded film plastics were dehydrated by centrifugation and densified by agglomeration / pelletization. Optionally, the agglomerates were extruded and passed through a screen filter to remove, for example, small pieces of aluminum foil, and then the extrudate was cut into pellets. The film pellets / agglomerates were bagged in preparation for processing.

[0337] PTT and Film materials were mixed in various proportions and depolymerized in a continuous flow reactor consisting of, in series, an extruder (110-EX-001), a supercritical water injection zone, a series of heaters, three horizontally oriented reactor tubes arranged in series, a cooler, a depressurization stage, and one or more product tanks. Examples of typical experimental conditions are given in Table 10. The depolymerization products were synthetic crude oils. TABLE 10: TYPICAL EXPERIMENTAL CONDITIONS Example # PTT ratio in polymer feed Film ratio in polymer feed Polymer / water mass ratio Reaction temperature °C Reaction pressure Bar Extruder outlet temperature °C Supercritical water temperature in mixing zone °C 1 1 1 48 / 51 440 220 350 510 2 2 1 68 / 32 440 220 350 510 3 3 1 65 / 35 435 220 350 500 Petition 870260053158, dated 01 / 06 / 2026, pages 103 / 148 94 / 103

[0338] After the experiment (or experiments), the horizontal tubular reactors were opened and inspected and found to contain residual solid material that had precipitated from the fluid phases during the course of the experiment and accumulated by gravitational sedimentation at the bottom of the reactor tubes. The solids were analyzed and found to have the following compositions shown in Table 11. TABLE 11. SOLIDS COMPOSITION DATA Solids mass HRA collected (kg) % by weight of moisture content % by weight of ash content (db) % by weight extractable with toluene (db) Reactor 1 of 3 10.2 (p) 47.5 70.1 24.0 Reactor 2 of 3 8.64 (p) 45.9 74.0 17.6

[0339] The analysis showed that the solids were largely inorganic ash with a small component of toluene-soluble heavy wax also present (Table 12). The reactor samples 1 and 2 in Table 11 correspond to Analyses No. 1 and 2 in Table 12. TABLE 12: MAIN RESULTS OF THE COMPOSITION ANALYSIS OF ASHES Analysis No. % of oxide in ash (db) SiO2 Al2O3 Fe2Oa TiO2 K2O MgO Na2O CaO SO3 1 8.1 3.6 21.9 9.7 0.09 1.0 0.1 31.9 3.9 2 4.2 2.1 31.6 15.3 0.03 0.7 0.1 22.4 6.4 3 21.9 18.8 4.4 13.1 0.25 5.2 0.5 19.0 0.6 Petition 870260053158, dated 01 / 06 / 2026, pages 104 / 148 95 / 103 4 14.7 4.2 4.4 47.3 0.24 3.3 0.9 17.6 0.8 5 21.0 17.9 4.2 11.9 0.23 4.9 0.5 17.5 0.3 6 16.4 11.2 4.1 16.2 0.11 4.4 0.2 24.0 0.9 7 17.2 9.2 3.7 19.3 0.15 5.4 0.2 23.3 0.9 % of oxide in ash (db) P2O5 BaO SrO CuO MnO Cr2O3 ZnO V2O5 CO3O4 NiO 1 0.45 0.33 1.0 0.06 0.06 0.7 2.4 <0.01 0.02 0.01 2 0.48 0.26 1.7 0.06 0.06 1.0 3.5 <0.01 0.02 0.01 5 0.67 0.6 0.04 0.33 0.11 0.30 0.34 0.01 0.02 0.06 6 0.48 0.41 0.03 0.10 0.09 0.21 0.48 <0.01 0.02 0.08 7 0.55 0.63 0.03 0.09 0.08 0.38 0.58 <0.01 0.03 0.04 TABLE 13. RESULTS OF THE ANALYSIS OF METAL TRACES IN THE MATERIAL ASHES HRA Element in sample ppm (db) Ag As Ba Be Bi Cd Co Cr Cu Mn 3 7 10 2,600 <1 <1 270 13 900 800 400 4 <1 3 14200 1 210 40 20 885 350 265 Element in sample ppm (dB) Mo Ni P Pb Sn Ti V Zn Zr Hg 3 28 250 1500 1850 95 37 18 1120 570 0.35 4 25 285 2620 140 1060 230 30 10500 1080

[0340] Elemental analysis showed that the ashes (Table 13) were largely composed of metals such as Si, Ti, Fe, Ca, Al, which are normally found as, for example, fillers, additives, opacifiers, modifiers, etc. in plastic formulations. Petition 870260053158, dated 01 / 06 / 2026, pages 105 / 148 96 / 103 demonstrating that these were deposited from the plastic during polymerization, being insoluble in the supercritical phase (or phases). EXAMPLE SIX

[0341] The results presented in this example demonstrate the addition of an instantaneous depressurization from the total reaction temperature or within 50 degrees of the total reaction temperature, and the total reaction pressure, up to slightly above atmospheric pressure.

[0342] The experimental setup used is shown in Figure 23. Post-industrial and post-consumer plastics comprising polyethylene from out-of-specification condiment bottles (about 68%), paper pellets (about 20%), recycled PET (about 10%), and discarded neoprene diving suits (about 2%) were prepared for extrusion. The mixed feedstock was depolymerized in a continuous flow reactor consisting of, in series, an extruder (110-EX-001), a supercritical water injection zone, a series of heaters, three or four reactors, a depressurization stage, and one or more product tanks. A product tank equipped with a reflux condenser was used as a flash vaporization vessel. The product stream was depressurized through a capillary tube in said flash vaporization vessel at a temperature of about 420 °C and a pressure of about 240 bar.The capillary end was optionally submerged under the water initially present in the flash vaporization vessel and optionally cooled by means of an external water jacket surrounding the flash vaporization vessel. Optionally and alternatively, the capillary outlet was not. Petition 870260053158, dated 01 / 06 / 2026, pages 106 / 148 97 / 103 submerged in water. The outlet of the flash vaporization vessel was at a pressure close to atmospheric (e.g., 1 bar absolute, 1.1 bar, or 1.2 bar absolute), volatile products passing through a reflux condenser and then to a burner where they were burned.

[0343] The product hydrocarbons were collected in the flash vaporization container as a waxy synthetic crude oil product mixed with water. No deposits of terephthalic acid or other insoluble materials from PET hydrolysis were found in the condenser or anywhere else in the product depressurization / collection system. EXAMPLE SEVEN

[0344] As in Example 6, but with a raw material composition of out-of-specification condiment bottles (approximately 80%) and recycled PET (approximately 20%), and the end of the pressure-reducing capillary was directed vertically downwards a few centimeters above the surface of a small amount of water in the instant vaporization container. In this case, white deposits of terephthalic acid and other PET hydrolysis products were detected on the upper surfaces of the instant vaporization container. EXAMPLE EIGHT

[0345] PET (20% by weight) in pellet form was mixed with PE pellet waste (80% by weight). The mixture was fed into a single-screw extruder fitted with electric heating elements where the polymer mixture was pressurized to approximately 240 bar and heated to approximately 330-340 °C by the extruder outlet (110 Petition 870260053158, dated 01 / 06 / 2026, pages 107 / 148 98 / 103 (EX-001). The extrudate was fed under pressure to a mixing zone where it was mixed (brought into contact) with supercritical water at approximately 490 °C and 240 bar. The fluid mixture was then raised to the reaction temperature of 440-450 °C by three trimmer heaters in series. The fluid then passed into three 30-liter 310 stainless steel tubular reactors arranged horizontally in series; the reactor zone was maintained at the reaction temperature by means of a blown gas box enclosure. During its stay in the reactor zone, the polymer mixture was depolymerized to form an oily product. The polymer flow rate was 33 kg / h, the supercritical water flow rate was 27 kg / h, the total flow rate was 60 kg / h, and the mass ratio of plastic to water was approximately 55:45.

[0346] The hot fluid was then depressurized at a temperature of 400-440 °C and 240 bar to a first flash vaporization vessel at a pressure slightly above atmospheric. The flash vaporization vessel was connected to a second vessel for condensate collection. It was observed that the temperature of the flash vaporization vessel increased to about 70 °C initially and then decreased to 21 °C during the duration of the experiment, approximately 165 minutes. The gas and vapor passing through the condensate vessel were cooled and measured using a rotary volumetric flow meter. In this way, the product fluids exiting the reactor were fractionated into a waxy, viscous, heavy hydrocarbon oil fraction, retained in the flash vaporization vessel; a light, low-viscosity hydrocarbon oil fraction, less dense than water, plus water, Petition 870260053158, dated 01 / 06 / 2026, pages 108 / 148 99 / 103 retained in the condensate vessel, and a gas-vapor fraction. The gas-vapor fraction was further passed to a second condenser / fractionation vessel stage where a small amount (1.1 kg) of naphtha and water was condensed and separated. The composition of the gas / vapor passing through the second condenser stage was analyzed offline by GC from a random sample. The flash vaporization vessel contained approximately 20 kg of water and 53.5 kg of heavy oil, and the condensate tank approximately 54 kg of water and 12.5 kg of light oil after the run. The light oil in the condensate tank easily separates from the water by gravity. It is estimated that approximately 11.1 kg of gas and condensate were produced in the corresponding period, based on an estimated density for the mixed gases and vapors based on composition.

[0347] The pressure reduction and fractionation system used is illustrated schematically in Figure 24.

[0348] Vacuum distillation of the heavy waxy oil retained in the flash vaporization vessel showed an initial boiling point of 115 °C at 10 torr pressure or approximately 240 °C AEBP, indicating that part of the boiling range of the product naphtha had been effectively fractionated into the condensate vessel. Thermogravimetric analysis (TGA) of the total syncrude (proportional recombined samples of heavy waxy oil condensate and flash vaporization vessel) is shown in Figure 25 and is consistent with the distillation analysis of the heavy waxy oil.

[0349] A gas-vapor phase composition analysis is shown in Table 14. Petition 870260053158, dated 01 / 06 / 2026, pages 109 / 148 100 / 103 TABLE 14: GAS-VAPOR PRODUCT COMPOSITION Component Unit Value Hydrogen % by vol 5.4 Carbon dioxide % by vol 17.4 Carbon monoxide % by vol 7.8 Methane % by vol 19.5 Ethene % by vol 1.4 Ethane % by vol 15.4 Propene % by vol 3.8 Propane % by vol 13.3 Butenes % by vol 3.1 Isobutane % by vol 0.4 n-butane % by vol 6.7 Pentanes % by vol 3.8 Hexanes % by vol 1.5 Heptanes % by vol 0.3 Benzene Ppm v / v 1740 Toluene Ppm v / v 410 Ethylbenzene Ppm v / v 8.4 Xylene m-, p- Ppm v / v 9.2 o-Xylene Ppm v / v 4.7 Trimethylbenzene Ppm Naphthalene ppm (v / v) 4.8 ppm 0.4 EXAMPLE NINE

[0350] Radiata pine wood was mixed with polypropylene (PP) pellets and the mixture was pelletized to form mixed wood-PP pellets. The composition of the feed mixture was: 29% by weight of dry base wood flour, 2% by weight of water associated with the wood flour and 69% by weight Petition 870260053158, dated 01 / 06 / 2026, pages 110 / 148 101 / 103 dry base polypropylene. The mixture was fed into a single-screw extruder (110-EX-001) equipped with electric heating elements where the mixture was pressurized to approximately 230-240 bar and heated to approximately 315 °C by the extruder's outlet (110-EX-001). The extrudate was fed under pressure to a mixing zone where it was mixed (brought into contact) with supercritical water at approximately 440 °C and 240 bar. The fluid mixture thus reached the target reaction temperature of approximately 390-400 °C. The fluid then passed into two 30-liter 310 stainless steel tubular reactors arranged horizontally in series; the reactor zone was maintained at the reaction temperature by means of a blown gas box enclosure. During its stay in the reactor zone, the raw material mixture was depolymerized to form an oil product.The flow rate of the raw material extrudate was 29-32 kg / h, the flow rate of supercritical water was 34 kg / h, and the total flow rate was 63-66 kg / h.

[0351] The hot fluid was then depressurized at a temperature of 380-400 °C and 240 bar to a first flash vaporization vessel at a pressure slightly above atmospheric. The flash vaporization vessel was connected to a second vessel for condensate collection. The arrangement is partially shown in Figure 26. The first flash vaporization vessel is labeled MBT. The gas and vapor passing through the condensate vessel were cooled and measured using a rotary volumetric flow meter. In this way, the product fluids exiting the reactor were fractionated into a viscous, heavy, waxy hydrocarbon oil fraction, retained in the vaporization vessel. Petition 870260053158, dated 01 / 06 / 2026, pages 111 / 148 Instantaneous 102 / 103; a light, low-viscosity hydrocarbon oil, less dense than water, plus water, retained in the condensate vessel, and a gas-vapor fraction (labeled NCG in Figure 26). The gas-vapor fraction was further passed to a second condenser stage where a small amount of naphtha and water was condensed. The composition of the gas / vapor passing through the second condenser stage was analyzed by GC from a random sample. EXAMPLE TEN

[0352] Recycled polyethylene (PE) pellets were extruded at 15 kg / h at 275 °C, 240-260 bar at the extruder outlet (110-EX-001) into a continuous flow hydrothermal reactor where the extrudate was contacted with supercritical water at a flow rate of 22.5 kg / h at 420 °C, 240-260 bar in a mixing zone containing a helical static mixing element that provided good mixing of the SCW and molten PE, thus allowing the cracking reactions to occur efficiently in the subsequent stages of the process. The fluid temperature in the mixing zone was approximately 400 °C. After passing through the mixing zone, the fluid passed through two heaters where the temperature was increased to 420-450 °C before passing into three 30-liter reactor tubes arranged in series. The reactors were maintained at 405-415 °C. During its stay in the reactors, the PE was depolymerized into a synthetic crude oil.The product fluid was cooled to approximately 150 °C and then depressurized to atmospheric pressure in a product tank. The product tank was equipped with a reflux condenser; the non-condensable gas and vapor passing through the condenser were analyzed by offline GC analysis. Petition 870260053158, dated 01 / 06 / 2026, pages 112 / 148 103 / 103 from a random sample. EXAMPLE ELEVEN

[0353] The end-of-life plastic feedstock was processed according to the method described in Example 1. The composition of the feedstock and the boiling range fractions of the resulting syncrude product are summarized in Table 15 below. TABLE 15: COMPOSITION OF THE BOILING RANGE OF SYNCRUDE NAPHTHA FOR VARIOUS RAW MATERIALS. Raw Material Composition of Naphtha IBP-210 °C AEPB Post-consumer rigid plastics containing PE, PP (main components) PET, polyamide, ABS, polycarbonate, PS, EPDM, PVC, polyurethane, PMMA (minor components) and post-consumer film plastics containing the same components, in a 2:1 ratio rigid:film by mass n-paraffins at 14%, isoparaffins at 9.3%, olefins including cycloolefins at 25%, naphthenes at 25.5%, aromatics at 26.5%, by mass Post-consumer rigid plastics containing PE, PP (main components) PET, polyamide, ABS, polycarbonate, PS, EPDM, PVC, polyurethane, PMMA (secondary components) n-paraffins at 17.4%, olefins including cycloolefins at 12.3% naphthenes at 15.7%, aromatics at 26.3%, polar and others at 28.3%, by volume. Industrial plastic waste PE (80%) and PET (20%), pellets. n-Paraffins at 34.7%, Isoparaffins at 11.6%, Olefins at 4.9%, Naphthenes at 13.2%, Aromatics at 15.8%, polar and others at 19.9%,By mass, industrial plastic waste, nominally PE, consists of n-paraffins at 33.27%, isoparaffins at 11.5%, olefins at 2.8%, naphthenes at 10.5%, aromatics at 14.4%, polar and other materials at 27.5%, by mass. Petition 870260053158, dated 01 / 06 / 2026, pp. 113 / 148

Claims

1 / 10 CLAIMS 1. Method for treating polymeric material to produce hydrocarbon products CHARACTERIZED in that it comprises: - generating a reaction mixture comprising a synthetic polymeric material and an aqueous solvent, - treating the reaction mixture in a reactor apparatus at a reaction temperature and a reaction pressure for a suitable period of time to convert all or a portion of the polymeric material present in the reaction mixture into a fluid product stream, wherein the fluid product stream is at a temperature of at least 350°C and a pressure of at least 180 bar, and - depressurizing the fluid product stream in a flash vessel, thereby vaporizing at least a portion of the fluid product stream to generate a vapor comprising constituent parts of hydrocarbon products, vapor and gas, and - injecting vapor,Superheated steam or supercritical water in the flash vessel to vaporize any remaining portion of the liquid product stream in the flash vessel to generate a vapor comprising constituent parts of hydrocarbon products, vapor and gas, wherein the depressurization comprises reducing the pressure of the fluid product stream to less than 25 bar in the flash vessel, and wherein the vaporization provides energy to facilitate the fractionation of the vapor into its constituent parts; and - to collect the fractionated vapor.

2. Method according to claim 1, CHARACTERIZED in that the fluid product stream is at: (i) a temperature of at least: 380°C, 400°C, 420°C, 450°C or 470°C, immediately before depressurization; and / or (ii) a pressure of at least: 200 bar, 220 bar, 240 bar, 260 bar, 280 bar or 300 bar, immediately before depressurization.

3. A method according to any one of claims 1 to 2, characterized in that the flash container is directly coupled to an accumulation apparatus, is an integral part of the accumulation apparatus, or is directly coupled to one or more staged product condensers.

4. A method according to any one of claims 1 to 3, CHARACTERIZED in that it comprises fractionating and condensing the vapor into fractions having a maximum atmospheric equivalent boiling point below: 400°C, 450°C, 500°C, 550°C or 600°C, and collecting a residual fraction with a minimum atmospheric equivalent boiling point above 400°C, 450°C, 500°C, 550°C or 600°C.

5. Method, according to any one of claims 1 to 4, CHARACTERIZED in that solid charges and / or inorganic matter and / or metallic salts from the depressurized product stream are retained within a residue matrix produced by said vaporization and fractionation.

6. Method according to any one of claims 1 to 5, Petition 870260053158, dated 01 / 06 / 2026, p. 115 / 148 3 / 10 CHARACTERIZED in that depressurization and fractionation allow the separation of the aqueous solvent from the hydrocarbon products, including the separation of the aqueous solvent of: (i) low boiling point hydrocarbons at a temperature below: 10°C, 20°C, 30°C, 40°C, 50°C or 60°C; or (ii) low boiling point hydrocarbons at a temperature below: 10°C, 20°C, 30°C, 40°C, 50°C or 60°C conducted under an effective gravity of 9.8 + / - 0.1 m / s2.

7. A method according to any one of claims 1 to 6, characterized in that said generation of the reaction mixture comprises: - providing a molten stream of the synthetic polymeric material; - injecting aqueous solvent into the molten stream of synthetic polymeric material, wherein the aqueous solvent is supercritical prior to said injection; and - mechanically mixing the aqueous solvent and the molten stream of synthetic polymeric material, wherein the mechanical mixing comprises the use of solvent distribution grids in an assembly comprising one or more static mechanical mixing devices.

8. Method according to claim 7, CHARACTERIZED in that the aqueous solvent is water or substantially water.

9. Method according to claim 8, CHARACTERIZED in that the supercritical aqueous solvent is generated in a boiler apparatus comprising a burner fed by Petition 870260053158, dated 01 / 06 / 2026, page 116 / 148 4 / 10 gas released from the fluid product stream, wherein the supercritical aqueous solvent exits the boiler apparatus at: (a) a temperature of at least: 450°C, 500°C or 550°C; and / or (b) a pressure of at least: 180 bar, or at least 200 bar, or at least 220 bar, or at least 240 bar, or at least 250 bar, at least 270 bar, or 290 bar, or 310 bar, or 330 bar during the generation of the supercritical aqueous solvent.

10. Method, according to any one of claims 1 to 9, CHARACTERIZED in that said treatment comprises contacting the reaction mixture with supplementary metallic catalysts in addition to those present on any metallic surface in contact with the reaction mixture during said generation or treatment, wherein the supplementary metallic catalysts are: - components of a solid material that is mixed into the reaction mixture to facilitate contact between the fluids and the supplementary metallic catalyst and / or - a component of any mixing device for the mechanical mixing of the aqueous solvent with the molten stream of synthetic polymeric material.

11. Method according to claim 10, CHARACTERIZED in that the supplementary metal catalysts are solid-state transition metal catalysts.

12. Method, according to claim 10 or claim 11, CHARACTERIZED in that the supplementary metal catalysts are transition metal catalysts in the solid state, and in which the oxidation state of the transition metal is initially a formal oxidation state of zero valence.

13. Method according to claim 12, CHARACTERIZED in that the zero-valence metal is selected from: zero-valence iron and nickel.

14. Method, according to any one of claims 1 to 13, CHARACTERIZED in that it further comprises the removal of solid materials from the reaction mixture during said treatment, wherein the solid materials: - are inorganic materials present within the polymeric material, wherein the inorganic materials: - are fillers or contaminants present in the synthetic polymeric material prior to conducting the method; and / or - have reacted with the aqueous solvent and / or with carbon-rich materials formed in small volumes by secondary reactions during said treatment, - have a higher density than the fluids within the reaction mixture and separate from the reaction mixture by gravity during said treatment; and - are removed from a reactor apparatus in which said treatment is carried out by blowing into a receiving vessel during said treatment by means of remotely operated valves.

15. Method, according to any of claims 1 to 14, CHARACTERIZED by the fact that the method is conducted in a Petition 870260053158, dated 01 / 06 / 2026, page.118 / 148 6 / 10 reactor apparatus comprising any one or more of the following: - systems for testing pressure levels in valves and a pressure reducing vessel within said reactor apparatus, - a system allowing the cooling of the blown material into a receiving vessel of the reactor apparatus, - a final collection vessel with a removable lid for blown material that is interlocked with its lid and with interconnected tubes and valves to prevent accidental removal of the final collection vessel and its contents, - ventilation for releasing gases formed during or after said treatment, - providing inert atmospheres comprising nitrogen, argon, carbon dioxide and / or other inert gases preventing ignition and combustion of materials contained in the discharge vessel and collection vessel, - sequencing systems to minimize mechanical shock to the reactor apparatus.

16. Method, according to any one of claims 1 to 15, CHARACTERIZED in that the reaction temperature is at least: 380°C, 400°C, 450°C or 500°C.

17. Method according to any one of claims 1 to 16, CHARACTERIZED in that the hydrocarbon product comprises any one or more of: (i) a naphtha component with a boiling point between 10°C and 210°C equivalent to atmospheric pressure Petition 870260053158, dated 01 / 06 / 2026, p. 119 / 148 7 / 10 (AEBP), and wherein the naphtha component comprises: - more than 10%, 20%, 30%, 40% by mass of olefins; and / or - more than 10%, 20%, 30%, 40% by mass of n-paraffins; and / or - more than 10%, 20%, 30%, 40% by mass of cycloalkanes or cycloalkenes; and / or - more than 10%, 20%, 30%, 40% by mass of aromatics; (ii) a diesel component with a boiling point between 210°C and 360°C equivalent boiling point at atmospheric pressure (AEBP), wherein the diesel component comprises: - more than 10%, 20%, 30%, 40% by mass of olefins; and / or - more than 10%, 20%, 30%, 40% by mass of n-paraffins; and / or - more than 10%, 20%, 30%, 40% by mass of cycloalkanes or cycloalkenes;and / or - more than 10%, 20%, 30%, 40% by mass of aromatics; (iii) a heavy diesel component with a boiling point between 360°C and 550°C equivalent boiling point at atmospheric pressure (AEBP), and the heavy diesel component comprises: - more than 10%, 20%, 30%, 40% by mass of olefins; and / or - more than 10%, 20%, 30%, 40% by mass of n-paraffins; and / or - more than 10%, 20%, 30%, 40% by mass of cycloalkanes or cycloalkenes; and / or - more than 10%, 20%, 30%, 40% by mass of aromatics. Petition 870260053158, dated 01 / 06 / 2026, p. 120 / 148 8 / 10; 18. Method, according to any one of claims 1 to 17, CHARACTERIZED in that: - the synthetic polymeric material used to generate said reaction mixture is a molten extruded polymeric material; - the extruded synthetic polymeric material is diverted to a collection vessel before generating said reaction mixture; - the collection vessel is provided with an inert atmosphere preventing combustion of the molten extruded polymeric material; and - the collection vessel is connected to a reactor apparatus by one or more lines providing double valve isolation in each line to prevent reverse flow of the molten extruded polymeric material from the reactor.

19. Method according to any one of claims 1 to 18, CHARACTERIZED in that (i) the treatment is carried out under continuous flow conditions; and / or (ii) the polymeric material does not comprise any one or more of: lignocellulosic matter; naturally occurring carbohydrate polymers; lignin; cellulose; hemicellulose; combinations of any two of lignin, cellulose, hemicellulose; lignite (brown coal); subbituminous coal; any combination thereof.

20. Continuous flow reactor apparatus for treating polymeric material according to the method as defined in Petition 870260053158, dated 01 / 06 / 2026, pp. 121 / 148 9 / 10 any of claims 1 to 19, CHARACTERIZED in that it comprises: - an extruder (110-EX-001) for producing an extrudate comprising a molten stream of synthetic polymeric material; - a boiler apparatus (130-EX-002) for preparing and adding supercritical water to the extrudate; - a mechanical mixing device (110-MX-001) configured to mix the extrudate with the supercritical water to thereby form a reaction mixture; - a reaction zone (120-RC-001A to I) in communication with the mechanical mixing device and with indirect heaters (110-HX-001), wherein the reaction zone is to treat the reaction mixture at a defined temperature and pressure for a defined residence time in order to produce a fluid product stream;- a pressure reducing device for depressurizing the fluid product stream, wherein the pressure reducing device is in communication with the reaction zone and a flash vessel (190-VE-001), wherein the depressurization causes at least a portion of the fluid product stream to vaporize and generate a vapor comprising constituent parts of hydrocarbon products, vapor and gas; - a combustion superheater or steam generator to produce steam, superheated steam or supercritical water to be injected into the flash vessel to vaporize at least a portion of any remaining part of the fluid product stream in the flash vessel to generate a vapor comprising constituent parts of hydrocarbon products, vapor and gas; and - a fractionating apparatus (160-VE-001) for separating the vapor generated in the flash vessel.

21. Continuous flow reactor apparatus, according to claim 20, CHARACTERIZED in that the flash vessel (190-VE-001): - is directly coupled to the fractionation apparatus; or - is an integral part of the flash column (190-VE-001); or - and the fractionation apparatus are separate product condensers. Petition 870260053158, dated 01 / 06 / 2026, pp. 123 / 148

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