Chemically recycled plastic dry fines

Abstract

Provided herein are methods and facilities that use one or more PET-containing materials as feedstock to a chemical recycling facility, particularly a solvent decomposition facility. The PET-containing materials used as feedstock can include an amount of PET-containing dry fines. The PET-containing dry fines can be derived from a variety of processes and facilities, including PET recycling facilities and / or PET article manufacturers. For example, the dry fines can be collected from a solid-liquid separator and / or dust collector from processes including conveying, drying, densification, centrifugation processes, and / or grinding PET-containing plastic materials. Such dry fines are generally undesirable or unusable to mechanical PET recycling facilities, and are often sent to a landfill and / or incinerator. However, the methods and facilities described herein take advantage of the PET and other plastics that are present in these otherwise undesirable or unusable dry fines.

Description

BACKGROUND

[0001] Waste materials, particularly non-biodegradable waste materials, when disposed of in landfills after a single use, have a negative impact on the environment. Thus, from an environmental standpoint, it is desirable to recycle as much waste material as possible. However, there still exist low value waste streams that are almost impossible or economically infeasible to recycle using traditional recycling techniques. In addition, some traditional recycling methods generate waste streams that are themselves economically infeasible to recover or recycle, which brings about additional waste streams that must be disposed of or otherwise handled. For example, PET reclaimer facilities and / or PET article manufacturers generate a significant amount of waste plastics that are undesirable or unusable by consumer and mechanical recycling facilities. In particular, such facilities can generate a significant amount of PET-containing dry fines that are undesirable or unusable by mechanical recycling facilities in their collected form, but can contain some amount of additional desirable or usable PET and / or other plastics. However, the dry fines are typically disposed of in landfills and / or incinerators.

[0002] Thus, there is a need for a large-scale facility that is capable of chemically recycling various plastic-containing waste materials extracted from these sources in an economically feasible manner, particularly PET-containing dry fines that are otherwise undesirable or unusable from PET reclaimer facilities and / or PET article manufacturers. SUMMARY

[0003] In one aspect, the present technology relates to a method of recycling plastic waste. Generally, the method comprises: (a) feeding an amount of PET-containing dry fines separated from plastic waste to a chemical recycling facility; and (b) depolymerizing at least a portion of the PET-containing dry fines in the chemical recycling facility.

[0004] In one aspect, the present technology relates to the use of PET-containing dry fines as a feedstock to a chemical recycling facility. BRIEF DESCRIPTION OF DRAWINGS

[0005] Figure 1 is a block flow diagram illustrating the main steps of a method and facility for chemical recycling of waste plastics according to embodiments of the present technology;

[0006] Figure 2 is a block flow diagram illustrating a separation process and zones for separating mixed plastic waste according to embodiments of the present technology;

[0007] Figure 3 is a block flow diagram illustrating the main steps of a method and facility for PET solvolysis according to embodiments of the present technology;

[0008] Figure 4is a block flow diagram illustrating exemplary rPET products and byproducts derived from a PET recycling facility;

[0009] Figure 5 is a block flow diagram illustrating the main steps of a PET recycling process and the resulting products and byproducts produced therefrom;

[0010] Figure 6 is a block flow diagram illustrating an exemplary liquefaction zone of a chemical recycling facility as shown in Figure 1

[0011] Figure 7 is a block flow diagram illustrating the main steps of a pyrolysis process and facility for converting waste plastics into pyrolysis product streams according to embodiments of the present technology;

[0012] Figure 8A is a block flow diagram illustrating the main steps of an integrated pyrolysis process and facility and cracking process and facility according to embodiments of the present technology;

[0013] Figure 8B is a schematic diagram of a cracking furnace according to embodiments of the present technology;

[0014] Figure 9 is a schematic diagram of a POx reactor according to embodiments of the present technology; and

[0015] Figure 10 is a schematic diagram illustrating various definitions of the term“separation efficiency” as used herein. DETAILED DESCRIPTION

[0016] We have discovered new methods and systems for using one or more PET-containing materials from various sources as feedstock for chemical recycling facilities, particularly solvent decomposition facilities. More specifically, we have discovered that PET-containing materials used as feedstock for chemical recycling or solvent decomposition can include PET-containing dry fines that can be derived, for example, from PET recycling facilities and / or PET article manufacturers. Although these clean-up materials are generally considered undesirable or unusable by mechanical recycling facilities, they can contain an amount of recyclable and useful plastics, such as PET. The methods and systems described herein are capable of using such PET-containing dry fines as a source of feedstock in chemical recycling facilities and processes.

[0017] ​When indicating a range of numbers, it should be understood that each number is modified in the same way as the first number or the last number in the range or sentence, e.g., each number is “at least” or “at most” or “no more than” as the case can be; and each number is in the “or” relationship. For example, “at least 10, 20, 30, 40, 50, 75 wt%...” means the same as “at least 10 wt%, or at least 20 wt%, or at least 30 wt%, or at least 40 wt%, or at least 50 wt%, or at least 75 wt%”; “no more than 90 wt%, 85, 70, 60...” means the same as “no more than 90 wt%, or no more than 85 wt%, or no more than 70 wt%...”; “at least 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight...” means the same as “at least 1 wt%, or at least 2 wt%, or at least 3 wt%...”; “at least 5, 10, 15, 20 and / or no more than 99, 95, 90 weight percent” means the same as “at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or at least 20 wt%, and / or no more than 99 wt%, or no more than 95 wt%, or no more than 90 weight percent...”.

[0018] Unless otherwise indicated, all concentrations or amounts are by weight.

[0019] Integrated chemical recycling facility

[0020] Turning now to Figure 1 , a flow diagram showing the main steps of a method of chemically recycling waste plastics in a chemical recycling facility 10. It will be appreciated that, Figure 1 An example embodiment of the present technology is depicted. Figure 1 Certain features depicted in Figure 1 may be omitted and / or additional features described elsewhere herein can be added to the system depicted in

[0021] As Figure 1 shown, these steps generally include a pre-treatment step / facility 20, and at least one (or at least two or more) of: a solvolysis step / facility 30, a partial oxidation (POX) gasification step / facility 50, a pyrolysis step / facility 60, a cracking step / facility 70, and an energy recovery step / facility 80. Optionally, in one embodiment or in combination with any of the embodiments mentioned herein, these steps can also include one or more other steps, such as direct sale or use, landfilling, separation, and solidification, one or more of which are depicted in Figure 1The chemical recycling process and facility according to one or more embodiments of the present technology can include at least two, three, four, five, or all of these steps / facilities in various combinations for chemically recycling plastic waste, particularly mixed plastic waste. The chemical recycling process and facility as described herein can be used to convert plastic waste into recycled content products or chemical intermediates for use in forming a variety of end-use materials. The waste plastic fed to the chemical recycling facility / process can be mixed plastic waste (MPW), pre-sorted waste plastic, and / or pre-treated waste plastic.

[0022] As used herein, the term “chemical recycling” refers to a waste plastic recycling process that includes a step of chemically converting waste plastic polymers into lower molecular weight polymers, oligomers, monomers, and / or non-polymeric molecules (e.g., hydrogen and carbon monoxide) that are useful in their own right and / or as feedstocks for another chemical production process. A “chemical recycling facility” is a facility that produces recycled content products by chemically recycling waste plastic. As used herein, the terms “recycled content” and “r-content” mean: a composition that is directly and / or indirectly derived from waste plastic, or that contains such a composition.

[0023] As used herein, the term “directly derived” means having at least one physical component that is derived from waste plastic, while “indirectly derived” means having a specified recycled content that i) can be attributed to waste plastic, but ii) is not based on having a physical component that is derived from waste plastic.

[0024] A chemical recycling facility is not a mechanical recycling facility. As used herein, the terms “mechanical recycling” and “physical recycling” refer to a recycling process that includes a step of melting waste plastic and forming the melted plastic into new intermediate products (e.g., pellets or sheet) and / or new end-use products (e.g., bottles). Typically, mechanical recycling does not substantially change the chemical structure of the recycled plastic. In one embodiment or in combination with any of the mentioned embodiments, the chemical recycling facility described herein can be configured to receive and process waste streams from mechanical recycling facilities and / or waste streams that cannot typically be processed by mechanical recycling facilities.

[0025] Although described herein as part of a single chemical recycling facility, it is understood that one or more of the pre-treatment facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, and energy recovery facility 80, or any other facility 90, such as solidification or separation, can be located at different geographic locations and / or operated by different business entities. Each of the pre-treatment facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, energy recovery facility 80, or any other facility 90 can be operated by the same entity, while in other cases one or more of the pre-treatment facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility, energy recovery facility 80, and one or more other facilities 90, such as separation or solidification, can be operated by different business entities.

[0026] In one embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility 10 can be a commercial scale facility capable of processing a large quantity of mixed plastic waste. As used herein, the term “commercial scale facility” refers to a facility having an average annual feed rate of at least 500 pounds / hour, on average, over the course of a year. The average feed rate to the chemical recycling facility (or to any of the pre-treatment facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, POX gasification facility 50, energy recovery facility 80, and any other facility 90) can be: at least 750, at least 1,000, at least 1,500, at least 2,000, at least 2,500, at least 3,000, at least 3,500, at least 4,000, at least 4,500, at least 5,000, at least 5,500, at least 6,000, at least 6,500, at least 7,500, at least 10,000, at least 12,500, at least 15,000, at least 17,500, at least 20,000, at least 22,500, at least 25,000, at least 27,500, at least 30,000, or at least 32,500 pounds / hour, and / or, no more than 1,000,000, no more than 750,000, no more than 500,000, no more than 450,000, no more than 400,000, no more than 350,000, no more than 300,000, no more than 250,000, no more than 200,000, no more than 150,000, no more than 100,000, no more than 75,000, no more than 50,000, or no more than 40,000 pounds / hour. When the facility includes two or more feed streams, the average annual feed rate is determined based on the aggregate weight of the feed streams.

[0027] Additionally, it should be understood that each of the pre-processing facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, POX gasification facility 50, energy recovery facility 80, and any other facility 90 can include multiple units operating in series or in parallel. For example, the pyrolysis facility 60 can include multiple pyrolysis reactors / units operating in parallel, and each receives a feed containing waste plastics. When a facility is composed of multiple individual units, the average annual feed rate for the facility is calculated as the sum of the average annual feed rates for all common types of units within that facility.

[0028] Further, in one embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility 10 (or any of the pre-processing facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, POX gasification facility 50, energy recovery facility 80, and any other facility 90) can operate in a continuous manner. Additionally, or alternatively, at least a portion of the chemical recycling facility 10 (or any of the pre-processing facility 20, solvent decomposition facility 30, pyrolysis facility 60, cracking facility 70, POX gasification facility 50, energy recovery facility 80, and any other facility 90) can operate in a batch or semi-batch manner. In some cases, the facility can include multiple tanks between portions of a single facility or between two or more different facilities to manage inventory and ensure consistent flow rates into each facility or portion thereof.

[0029] Additionally, Figure 1 The two or more facilities shown can also co-locate with each other. In one embodiment or in combination with any of the embodiments mentioned herein, at least two, at least three, at least four, at least five, at least six, or all of the facilities can co-locate. As used herein, the term “co-located” refers to multiple facilities in which at least a portion of the process stream or support equipment or services are shared between two facilities. When Figure 1The two or more facilities shown in the middle can satisfy at least one of the following criteria (i) through (v) when they are co-located: (i) the facilities share at least one non-residential utility service; (ii) the facilities share at least one service group; (iii) the facilities are owned and / or operated by parties that share at least one property boundary; (iv) the facilities are connected by at least one conduit configured to carry at least one process material (e.g., solids, liquids, and / or gases fed to, used by, or produced in the facilities) from one facility to another; and (v) the facilities are within 40 miles, 35 miles, 30 miles, 20 miles, 15 miles, 12 miles, 10 miles, 8 miles, 5 miles, 2 miles, or 1 mile of each other, measured from their geographic centers. At least one, at least two, at least three, at least four, or all of the above statements (i) through (v) can be true.

[0030] With respect to (i), examples of suitable utility services include, but are not limited to: steam systems (cogeneration and distribution systems), cooling water systems, heat transfer fluid systems, plant or instrument air systems, nitrogen systems, hydrogen systems, non-residential power generation and distribution (including distribution above 8000V), non-residential wastewater / sewer systems, storage facilities, transportation pipelines, flare systems, and combinations thereof.

[0031] With respect to (ii), examples of service groups and facilities include, but are not limited to: emergency services personnel (fire and / or medical), third party vendors, state or local government oversight groups, and combinations thereof. Government oversight groups can include, for example, regulatory or environmental agencies at the city, county, and state levels, as well as municipal and tax authorities.

[0032] With respect to (iii), the boundary can be, for example, a fence line, a property line, a gate, or a common boundary with at least one boundary of a land or facility owned by a third party.

[0033] With respect to (iv), the conduits can be fluid conduits that carry gases, liquids, solid / liquid mixtures (e.g., slurries), solid / gas mixtures (e.g., pneumatic conveying), solid / liquid / gas mixtures, or solids (e.g., belt conveying). In some cases, two units can share one or more conduits selected from the above list. Fluid conduits can be used to transport process streams or utilities between two units. For example, an outlet of one utility (e.g., solvent decomposition utility 30) can be fluidly connected to an inlet of another utility (e.g., POX gasification utility 50) by a conduit. In some cases, a temporary storage system can be provided for materials transported within the conduit between the outlet of one utility and the inlet of another utility. The temporary storage system can include, for example, one or more tanks, vessels (open or closed), buildings, or containers configured to store materials carried by the conduit. In some cases, the temporary storage between the outlet of one utility and the inlet of another utility can be no more than 90 days, no more than 75 days, no more than 60 days, no more than 40 days, no more than 30 days, no more than 25 days, no more than 20 days, no more than 15 days, no more than 10 days, no more than 5 days, no more than 2 days, or no more than 1 day.

[0034] Waste plastics

[0035] Turning again Figure 1 A stream 100 of waste plastics, which can be mixed plastic waste (MPW), can be introduced into the chemical recycling facility 10. As used herein, the terms “waste plastics” and “plastic waste” refer to used, discarded, and / or disposed plastic materials, such as plastic materials that are typically sent to a landfill. Other examples of waste plastics (or plastic waste) include used, discarded, and / or disposed plastic materials that are typically sent to an incinerator. The stream 100 of waste plastics fed to the chemical recycling facility 10 can include untreated or partially treated waste plastics. As used herein, the term “untreated waste plastics” refers to waste plastics that have not been subjected to any automated or mechanized sorting, washing, or shredding. Examples of untreated waste plastics include waste plastics collected from household curbside plastic recycling bins or shared community plastic recycling receptacles. As used herein, the term “partially treated waste plastics” refers to waste plastics that have been subjected to at least one automated or mechanized sorting, washing, or shredding step or process. Partially treated waste plastics can originate, for example, from a municipal recycling facility (MRF) or a reclaimer. When partially treated waste plastics are provided to the chemical recycling facility 10, one or more pre-treatment steps can be skipped. The waste plastics can include at least one of post-industrial (or pre-consumer) plastics and / or post-consumer plastics.

[0036] As used herein, the terms "mixed plastic waste" and "MPW" refer to a mixture of at least two types of waste plastics, including but not limited to the following plastic types: polyethylene terephthalate (PET), one or more polyolefins (POs), and polyvinyl chloride (PVC). In one embodiment, or in combination with any of the embodiments mentioned herein, the MPW includes at least two different types of plastics, each type of plastic present in an amount of at least 1, at least 2, at least 5, at least 10, at least 15, or at least 20 wt%, based on the total weight of plastics in the MPW.

[0037] In one embodiment, or in combination with any of the embodiments mentioned herein, the MPW comprises at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of PET and / or at least 1, at least 2, at least 5, at least 10, at least 15, or at least 20 wt% of PO, based on the total weight of plastics in the MPW. In one or more embodiments, the MPW can also include small amounts of one or more types of plastic components other than PET and PO (and optionally PVC), the total amount of which is less than 50, less than 45, less than 40, less than 35, less than 30, less than 25, less than 20, less than 15, less than 10, less than 5, less than 2, or less than 1 wt%, based on the total weight of plastics in the MPW.

[0038] In one embodiment, or in combination with any of the embodiments mentioned herein, the MPW comprises at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of PET, based on the total weight of the stream. Alternatively, or additionally, the MPW comprises no more than 99.9, no more than 99, no more than 97, no more than 92, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, or no more than 5 wt% of PET, based on the total weight of the stream.

[0039] The MPW stream can include non-PET components in an amount of at least 0.1, at least 0.5, at least 1, at least 2, at least 5, at least 7, at least 10, at least 15, at least 20, at least 25, at least 30, or at least 35, and / or, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, or not more than 7 wt%, based on the total weight of the stream. The non-PET components can be present in an amount of 0.1 wt% to 50 wt%, 1 wt% to 20 wt%, or 2 wt% to 10 wt%, based on the total weight of the stream. Examples of such non-PET components can include, but are not limited to, ferrous and non-ferrous metals, inert materials (e.g., rock, glass, sand, etc.), plastic inert materials (e.g., titanium dioxide, silicon dioxide, etc.), olefins, binders, compatibilizers, biosludge, cellulosic materials (e.g., paperboard, paper, etc.), and combinations thereof.

[0040] In one embodiment or in combination with any of the embodiments mentioned herein, all or a portion of the MPW can be derived from a municipal source or include municipal waste. The municipal waste portion of the MPW can include, for example, PET in an amount of 45 wt% to 95 wt%, 50 wt% to 90 wt%, or 55 wt% to 85 wt%, based on the total weight of the municipal waste stream (or portion of the stream).

[0041] In one embodiment or in combination with any of the embodiments mentioned herein, all or a portion of the MPW can be derived from a municipal recycling facility (MRF) and can include, for example, PET in an amount of 65 wt% to 99.9 wt%, 70 wt% to 99 wt%, or 80 wt% to 97 wt%, based on the total weight of the stream. Non-PET components in such a stream can include, for example, other plastics in an amount of at least 1, at least 2, at least 5, at least 7, or at least 10 wt% and / or not more than 25, not more than 22, not more than 20, not more than 15, not more than 12, or not more than 10 wt%, based on the total weight of the stream, or can be present in an amount of 1 wt% to 22 wt%, 2 wt% to 15 wt%, or 5 wt% to 12 wt%, based on the total weight of the stream. In one embodiment or in combination with any of the embodiments mentioned herein, the non-PET components can include other plastics in an amount in the range of 2 wt% to 35 wt%, 5 wt% to 30 wt%, or 10 wt% to 25 wt%, based on the total weight of the stream, particularly when, for example, the MPW includes colored sorted plastics.

[0042] In one embodiment or in combination with any of the embodiments herein mentioned, all or a portion of the MPW can originate from a recycling facility and can include, for example, PET in an amount of 85 wt% - 99.9 wt%, 90 wt% - 99.9 wt%, or 95 wt% - 99 wt% based on the total weight of the stream. Non-PET components in such a stream can include, for example, other plastics in an amount of at least 1, at least 2, at least 5, at least 7, or at least 10 wt% and / or not more than 25, not more than 22, not more than 20, not more than 15, not more than 12, or not more than 10 wt% based on the total weight of the stream, or can be present in an amount of 1 wt% - 22 wt%, 2 wt% - 15 wt%, or 5 wt% - 12 wt% based on the total weight of the stream.

[0043] As used herein, the term "plastic" can include any organic synthetic polymer that is a solid at 25 °C and 1 atmosphere of pressure. In one embodiment or in combination with any of the embodiments herein mentioned, the number average molecular weight (Mn) of the polymer can be at least 75, or at least 100, or at least 125, or at least 150, or at least 300, or at least 500, or at least 1,000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000 Daltons. The weight average molecular weight (Mw) of the polymer can be at least 300, or at least 500, or at least 1,000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000, or at least 150,000, or at least 300,000 Daltons.

[0044] Examples of suitable plastics can include, but are not limited to, aromatic and aliphatic polyesters, polyolefins, polyvinyl chloride (PVC), polystyrene, polytetrafluoroethylene, acrylonitrile-butadiene-styrene (ABS), cellulosics, epoxies, polyamides, phenolics, polyacetals, polycarbonates, polyphenylene aliphatics, poly(methyl methacrylate), styrene-containing polymers, polyurethanes, vinyl polymers, styrene acrylonitrile, thermoplastic elastomers other than tires, and urea- and melamine-containing polymers.

[0045] Examples of polyesters can include those having repeating aromatic or cyclic units, such as those containing repeating terephthalate, isophthalate, or naphthalene dicarboxylate units, such as PET, modified PET, and PEN, or those containing repeating furandicarboxylate repeating units. Polyethylene terephthalate (PET) is also an example of a suitable polyester. As used herein, “PET” or “polyethylene terephthalate” refers to homopolymers of polyethylene terephthalate, or to polyethylene terephthalate modified with one or more acid and / or diol modifiers and / or containing residues or moieties other than ethylene glycol and terephthalic acid, such as isophthalic acid, 1,4-cyclohexane dicarboxylic acid, diethylene glycol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol (TMCD), cyclohexane dimethanol (CHDM), propylene glycol, isosorbide, 1,4-butanediol, 1,3-propanediol, and / or neopentyl glycol (NPG).

[0046] The definition of the terms “PET” and “polyethylene terephthalate” also includes polyesters having repeating terephthalate units (whether or not they contain repeating ethylene glycol-based units) and one or more diol residues or moieties, including, for example, TMCD, CHDM, propylene glycol or NPG, isosorbide, 1,4-butanediol, 1,3-propanediol, and / or diethylene glycol, or combinations thereof. Examples of polymers having repeating terephthalate units can include, but are not limited to, polypropylene terephthalate, polybutylene terephthalate, and copolyesters thereof. Examples of aliphatic polyesters can include, but are not limited to, polylactic acid (PLA), polyglycolic acid, polycaprolactone, and polyethylene adipate. The polymers can comprise mixed aliphatic-aromatic copolyesters, including, for example, mixed terephthalate / adipate.

[0047] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can comprise at least one type of plastic having repeating terephthalate units, wherein such plastic is present in an amount of at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, or at least 30, and / or, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, or not more than 2 wt%, or it can be present in an amount ranging from 1 wt% to 45 wt%, 2 wt% to 40 wt%, or 5 wt% to 40 wt%, based on the total weight of the stream. Similar amounts of copolyesters having multiple cyclohexane dimethanol moieties, 2,2,4,4-tetramethyl-1,3-cyclobutanediol moieties, or combinations thereof can also be present.

[0048] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can comprise at least one type of plastic having repeating terephthalate units, which is present in an amount of at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90, and / or, not more than 99.9, not more than 99, not more than 97, not more than 95, not more than 90, or not more than 85 wt%, or it can be present in an amount ranging from 30 wt% to 99.9 wt%, 50 wt% to 99.9 wt%, or 75 wt% to 99 wt%, based on the total weight of the stream.

[0049] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can comprise terephthalate repeating units in an amount of at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, or at least 45 and / or not more than 75, not more than 72, not more than 70, not more than 60, or not more than 65 wt%, based on the total weight of the plastics in the waste plastics stream, or it can comprise terephthalate repeating units in an amount ranging from 1 wt% to 75 wt%, 5 wt% to 70 wt%, or 25 wt% to 75 wt%, based on the total weight of the stream.

[0050] Examples of specific polyolefins can include: low density polyethylene (LDPE), high density polyethylene (HDPE), atactic polypropylene, isotactic polypropylene, syndiotactic polypropylene, cross-linked polyethylene, amorphous polyolefins, and copolymers of any of the foregoing polyolefins. The waste plastics can include polymers comprising: linear low density polyethylene (LLDPE), polymethylpentene, polybutene-1, and copolymers thereof. The waste plastics can comprise flash-spun high density polyethylene.

[0051] The waste plastics can comprise thermoplastic polymers, thermoset polymers, or combinations thereof. In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can comprise at least 0.1, at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, or at least 30 and / or not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, or not more than 2 wt% of one or more thermoset polymers, based on the total weight of the stream, or the thermoset polymers can be present in an amount ranging from 0.1 wt% to 45 wt%, 1 wt% to 40 wt%, 2 wt% to 35 wt%, or 2 wt% to 20 wt%, based on the total weight of the stream.

[0052] Alternatively, or additionally, the waste plastic can comprise at least 0.1, at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, or at least 30 and / or no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, or no more than 2 wt% cellulose material, or the cellulose material can be present in an amount ranging from 0.1 wt% to 45 wt%, 1 wt% to 40 wt%, or 2 wt% to 15 wt%, based on the total weight of the stream. Examples of cellulose material can include cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, cellulose acetate butyrate, and regenerated cellulose such as viscose. Additionally, the cellulose material can include cellulose derivatives having an acyl substitution degree of less than 3, no more than 2.9, no more than 2.8, no more than 2.7, or no more than 2.6, and / or at least 1.7, at least 1.8, or at least 1.9, or 1.8 to 2.8, or 1.7 to 2.9, or 1.9 to 2.9.

[0053] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic can comprise STYROFOAM (foamed polystyrene) or expanded polystyrene.

[0054] The waste plastic can be derived from one or more of several sources. In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic can be derived from plastic bottles, diapers, eyeglass frames, films, packaging materials, carpet (residential, commercial, and / or automotive), textiles (clothing and other fabrics), and combinations thereof.

[0055] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics (e.g., MPW) fed to the chemical recycling facility can include one or more plastics having or obtained from plastics having resin ID code numbers 1-7, with the chasing arrow triangle established by SPI. The waste plastics can include one or more plastics that are not typically mechanically recycled. Such plastics can include, but are not limited to, plastics having resin ID code 3 (polyvinyl chloride), resin ID code 5 (polypropylene), resin ID code 6 (polystyrene), and / or resin ID code 7 (other). In one embodiment or in combination with any of the embodiments mentioned herein, plastics having resin ID code 3-7 or at least 1, at least 2, at least 3, at least 4, or at least 5 of 3, 5, 6, 7, or combinations thereof, can be present in the waste plastics in an amount of at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 5, at least 7, at least 10, at least 12, at least 15, at least 20, at least 25, at least 30, at least 35, or at least 40 and / or not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 wt%, or in an amount of 0.1 wt% to 90 wt%, 1 wt% to 75 wt%, 2 wt% to 50 wt%, or not more than 50 wt% based on the total weight of plastics.

[0056] In one embodiment or in combination with any of the embodiments mentioned herein, the following content of total plastics components in the waste plastics fed to the chemical recycling facility can include plastics that do not have resin ID code 3, 5, 6, and / or 7 (e.g., in the case of plastics that are not sorted): at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, or at least 35, and / or, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, or not more than 5 wt%. The following content of total plastics components in the waste plastics fed to the chemical recycling facility 10 can include plastics that do not have resin ID code 4-7: at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, or at least 35, and / or, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, or not more than 5 wt%, or in a range of 0.1 wt% to 60 wt%, 1 wt% to 55 wt%, or 2 wt% to 45 wt% based on the total weight of plastics components.

[0057] In an embodiment or in combination with any of the mentioned embodiments, the waste plastics (e.g., MPW) fed to the chemical recycling facility can include plastics that are not classified as Resin ID Code 3-7 or ID Code 3, 5, 6, or 7. The total amount of plastics in the waste plastics that are not classified as Resin ID Code 3-7 or ID Code 3, 5, 6, or 7 can be at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 and / or not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35 wt%, or can be in the range of 0.1-95, 0.5-90, or 1-80 wt% based on the total weight of plastics in the waste plastics stream.

[0058] In an embodiment or in combination with any of the mentioned embodiments, the MPW includes plastics having or obtained from plastics having at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of at least one, at least two, at least three, or at least four different kinds of Resin ID Codes.

[0059] In an embodiment or in combination with any of the mentioned embodiments, the MPW includes multi-component polymers. As used herein, the term “multi-component polymers” refers to articles and / or particles that include at least one synthetic or natural polymer that is combined with, attached to, or otherwise physically and / or chemically associated with at least one other polymer and / or non-polymeric solid. The polymers can be synthetic polymers or plastics, such as PET, olefins, and / or nylons. The non-polymeric solids can be metals, such as aluminum, or other non-plastic solids as described herein. Multi-component polymers can include metalized plastics.

[0060] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises a multi-component plastic in the form of a multi-layer polymer. As used herein, the term "multi-layer polymer" refers to a multi-component polymer comprising PET and at least one other polymer and / or non-polymeric solid that are physically and / or chemically bound together in two or more physically distinct layers. A polymer or plastic is considered a multi-layer polymer even if a transition zone can exist between two layers, for example, can exist in the form of a layer that is adhesively adhered or a co-extruded layer. An adhesive between two layers is not considered a layer. The multi-layer polymer can comprise: a layer comprising PET and one or more additional layers, wherein at least one additional layer is a synthetic or natural polymer that is different from PET, or a polymer that does not have terephthalate repeat units, or a polymer that does not have alkylene terephthalate repeat units ("non-PET polymer layer"), or other non-polymeric solid.

[0061] Examples of non-PET polymer layers include: nylon, polylactic acid, polyolefins, polycarbonates, ethylene-vinyl alcohol, polyvinyl alcohol, and / or other plastics or plastic films associated with the PET-containing article and / or particles, and natural polymers such as whey protein. The multi-layer polymer can include a metal layer, for example, aluminum, provided that there is at least one additional polymer layer other than the PET layer. The layers can be adhered by adhesive bonding or other method, physically adjacent (i.e., the article is pressed against the film), adhesion (i.e., the plastics are heated and stuck together), co-extruded plastic film, or otherwise associated with the PET-containing article. The multi-layer polymer can comprise a PET film associated with an article containing other plastics in the same or similar manner. The MPW can comprise a multi-component polymer in the form of PET and at least one other plastic combined in a single physical phase, for example, polyolefins (e.g., polypropylene) and / or other synthetic or natural polymers. For example, the MPW comprises a heterogeneous mixture comprising a compatibilizer, PET, and at least one other synthetic or natural polymer plastic (e.g., non-PET plastic) combined in a single physical phase. As used herein, the term "compatibilizer" refers to an agent capable of combining at least two otherwise immiscible polymers together in a physical mixture (i.e., a blend).

[0062] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises no more than 20, no more than 10, no more than 5, no more than 2, no more than 1, or no more than 0.1 wt% of nylon on a dry plastics basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises 0.01 wt% to 20 wt%, 0.05 wt% to 10 wt%, 0.1 wt% to 5 wt%, or 1 wt% to 2 wt% of nylon on a dry plastics basis.

[0063] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises no more than 40, no more than 20, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of multi-component plastics, on a dry plastics basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises 0.1 wt% to 40 wt%, 1 wt% to 20 wt%, or 2 wt% to 10 wt% of multi-component plastics, on a dry plastics basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises no more than 40, no more than 20, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of multi-layered plastics, on a dry plastics basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises 0.1 wt% to 40 wt%, 1 wt% to 20 wt%, or 2 wt% to 10 wt% of multi-layered plastics, on a dry plastics basis.

[0064] In one embodiment or in combination with any of the mentioned embodiments, the MPW feedstock that enters the chemical recycling facility 10 in stream 100 comprises no more than 20, no more than 15, no more than 12, no more than 10, no more than 8, no more than 6, no more than 5, no more than 4, no more than 3, no more than 2, or no more than 1 wt% of bio-waste material, the total weight of the MPW feedstock on a dry basis taken as 100 wt%. The MPW feedstock comprises 0.01 wt% to 20 wt%, 0.1 wt% to 10 wt%, 0.2 wt% to 5 wt%, or 0.5 wt% to 1 wt% of bio-waste material, the total weight of the MPW feedstock on a dry basis taken as 100 wt%. As used herein, the term “bio-waste” refers to material derived from a living organism or organic source. Exemplary bio-waste materials include, but are not limited to, cotton, wood, sawdust, food scraps, animals and animal parts, plants and plant parts, and manure.

[0065] In one embodiment or in combination with any of the mentioned embodiments, the MPW feedstock comprises no more than 20, no more than 15, no more than 12, no more than 10, no more than 8, no more than 6, no more than 5, no more than 4, no more than 3, no more than 2, or no more than 1 wt% of manufactured cellulosic products, the total weight of the MPW feedstock on a dry basis taken as 100 wt%. The MPW feedstock comprises 0.01 wt% to 20 wt%, 0.1 wt% to 10 wt%, 0.2 wt% to 5 wt%, or 0.5 wt% to 1 wt% of manufactured cellulosic products, the total weight of the MPW feedstock on a dry basis taken as 100 wt%. As used herein, the term “manufactured cellulosic products” refers to non-natural (i.e., man-made or machine-made) articles and their waste, including cellulosic fibers. Exemplary manufactured cellulosic products include, but are not limited to, paper and paperboard.

[0066] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics (e.g., MPW) fed to the chemical recycling facility can include at least 0.001, at least 0.01, at least 0.05, at least 0.1, or at least 0.25 wt% and / or no more than 10, no more than 5, no more than 4, no more than 3, no more than 2, no more than 1, no more than 0.75, or no more than 0.5 wt% of polyvinyl chloride (PVC), based on the total weight of plastics in the waste plastics feed.

[0067] Additionally, or alternatively, the waste plastics (e.g., MPW) fed to the chemical recycling facility can include at least 0.1, at least 1, at least 2, at least 4, or at least 6 wt% and / or no more than 25, no more than 15, no more than 10, no more than 5, or no more than 2.5 wt% of non-plastic solids. The non-plastic solids can include inert filler materials (e.g., calcium carbonate, hydrated aluminum silicate, aluminum oxide trihydrate, calcium sulfate), rocks, glass, and / or additives (e.g., thixotropic agents, pigments and colorants, flame retardants, explosion suppressants, UV inhibitors & stabilizers, electrically conductive metals or carbon, mold release agents such as zinc stearate, waxes, and silicones).

[0068] In one embodiment or in combination with any of the embodiments mentioned herein, the MPW can include at least 0.01, at least 0.1, at least 0.5, or at least 1 and / or no more than 25, no more than 20, no more than 25, no more than 10, no more than 5, or no more than 2.5 wt% of liquids, based on the total weight of the MPW stream or composition. The amount of liquids in the MPW can be in the range of 0.01-25 wt%, 0.5-10 wt%, or 1-5 wt%, based on the total weight of the MPW stream 100.

[0069] In one embodiment or in combination with any of the embodiments mentioned herein, the MPW can include at least 35, at least 40, at least 45, at least 50, or at least 55 and / or no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, or no more than 35 wt% of liquids, based on the total weight of the waste plastics. The amount of liquids in the waste plastics can be in the range of 35-65 wt%, 40-60 wt%, or 45-55 wt%, based on the total weight of the waste plastics.

[0070] In one embodiment or in combination with any of the mentioned embodiments, the amount of textile (including textile fibers) in the MPW stream in line 100 can be at least 0.1 wt%, or at least 0.5 wt%, or at least 1 wt%, or at least 2 wt%, or at least 5 wt%, or at least 8 wt%, or at least 10 wt%, or at least 15 wt%, or at least 20 wt% of the following materials, obtained from a textile or textile fiber, based on the weight of the MPW. The amount of textile (including textile fibers) in the MPW in stream 100 can be no more than 50, no more than 40, no more than 30, no more than 20, no more than 15, no more than 10, no more than 8, no more than 5, no more than 2, no more than 1, no more than 0.5, no more than 0.1, no more than 0.05, no more than 0.01, or no more than 0.001 wt%, based on the total weight of the MPW stream 100. The amount of textile in the MPW stream 100 can range from 0.1 wt% to 50 wt%, 5 wt% to 40 wt%, or 10 wt% to 30 wt%, based on the total weight of the MPW stream 100.

[0071] The MPW introduced into chemical recycling facility 10 can contain recycled textiles. The textiles can contain natural and / or synthetic fibers, rovings, yarns, nonwoven webs, cloths, fabrics, and products made from or containing any of the above. The textiles can be woven, knitted, knotted, stitched, tufted, can include pressed fibers such as felts, can include embroidered, lace, crochet, braided, or can include nonwoven webs and materials. The textiles can include fabrics, and fibers separated from textiles or other products containing fibers, scrap or off-spec fibers or yarns or fabrics, or any other source of loose fibers and yarns. The textiles can also include staple fibers, continuous fibers, threads, tow bands, twisted yarns and / or spun yarns, greige goods made from yarns, finished fabrics produced by wet processing of greige goods, and apparel made from finished fabrics or any other fabrics. The textiles include apparel, upholstery, and industrial type textiles. The textiles can include post-industrial (pre-consumer) or post-consumer textiles, or both.

[0072] In one embodiment or in combination with any of the mentioned embodiments, the textile can include apparel, which can generally be defined as an article of clothing worn by humans or made for the body. Such textiles can include: sport coats, suits, long pants and casual or work pants, shirts, socks, sportswear, dresses, intimate apparel, outerwear (e.g., rainwear, cold weather jackets and coats), sweaters, protective clothing, uniforms, and accessories (e.g., scarves, hats, and gloves). Examples of textiles in the home furnishings category include: furniture upholstery and slipcovers, carpets and rugs, curtains, bed linens (e.g., sheets, pillowcases, comforters, quilts, mattress covers); linens, tablecloths, towels, washcloths, and blankets. Examples of industrial textiles include: transportation (automotive, aircraft, train, bus) seating, floor mats, trunk liners, and headliner; outdoor furniture and cushions, tents, backpacks, luggage, ropes, conveyor belts, calender roll felts, polishing cloths, wiping cloths, soil erosion fabrics and geotextiles, agricultural mats and screen, personal protective equipment, bulletproof vests, medical bandages, sutures, adhesive tapes, and the like.

[0073] Nonwoven webs classified as textiles do not include the category of wet laid nonwoven webs and articles made therefrom. While various articles having the same functionality can be made from either dry laid or wet laid processes, articles made from dry laid nonwoven webs are classified as textiles. Examples of suitable articles that can be formed from the dry laid nonwoven webs described herein can include those for personal, consumer, industrial, food service, medical, and other end uses. Specific examples can include, but are not limited to: baby wipes, flushable wipes, disposable diapers, training pants, feminine hygiene products such as sanitary napkins and tampons, adult incontinence pads, undergarments or briefs, and pet training pads. Other examples include various dry or wet wipes, including those for consumer (e.g., personal care or home) and industrial (e.g., food service, health care, or professional) uses. The nonwoven webs can also be used as fillings for pillows, mattresses, and upholstery, as well as batting for quilts and comforters. In the medical and industrial fields, the nonwoven webs of the present disclosure can be used in consumer masks, medical and industrial masks, protective clothing, hats, and shoe covers, disposable bed sheets, surgical gowns, drapes, bandages, and medical dressings.

[0074] Additionally, the nonwoven webs described herein can be used in environmental fabrics, such as geotextiles and tarps, oil and chemical absorbent pads, and building materials, such as sound or heat insulation, tents, lumber, and soil coverings and sheeting. The nonwoven webs can also be used in other consumer end uses, such as for: carpet backing, packaging of consumer, industrial, and agricultural goods, insulation or acoustical, and various types of apparel.

[0075] The dry-laid nonwoven webs as described herein can also be used in various filtration applications, including transportation (e.g., automotive or aviation), commercial, residential, industrial, or other specialty applications. Examples can include filtration elements for consumer or industrial air or liquid filters (e.g., gasoline, oil, water), including nanofiber webs for microfiltration, and end uses such as tea bags, coffee filters, and dryer sheets. Further, the nonwoven webs as described herein can be used to form various components for automobiles, including but not limited to brake pads, trunk liners, carpet tufting, and floor mats.

[0076] The textile can include a single type or multiple types of natural fibers and / or a single type or multiple types of synthetic fibers. Examples of textile fiber combinations include: all natural, all synthetic, two or more types of natural fibers, two or more types of synthetic fibers, one type of natural fiber and one type of synthetic fiber, one type of natural fiber and two or more types of synthetic fibers, two or more types of natural fibers and one type of synthetic fiber, and two or more types of natural fibers and two or more types of synthetic fibers.

[0077] Natural fibers include those of plant origin or animal origin. Natural fibers can be cellulose, hemicellulose, and lignin. Examples of plant origin natural fibers include: hardwood pulp, softwood pulp, and wood powder; and other plant fibers including those in wheat straw, rice straw, abaca, coir, cotton, flax, hemp, jute, sugar cane bagasse, kapok, papyrus, ramie, rattan, grapevine, kenaf, henequen, sisal, soybean, cereal straw, bamboo, reed, esparto grass, bagasse, Indian grass, milkweed floss fiber, pineapple leaf fiber, switchgrass, lignin-containing plants, and the like. Examples of animal origin fibers include wool, silk, mohair, cashmere, goat hair, horse hair, avian fibers, alpaca, angora, and llama hair.

[0078] Synthetic fibers are those fibers that are synthesized or derived, at least in part, through chemical reactions, or regenerated devices, including but not limited to: rayon, viscose, modal or other types of regenerated device cellulose (natural cellulose is converted into a soluble cellulose derivative and then regenerated), such as lyocell (also known as TENCEL®), Cupro, Modal, acetates such as polyvinyl acetate, polyamides including nylon, polyesters such as PET, olefin polymers such as polypropylene and polyethylene, polycarbonates, polysulfates, polysulfones, polyethers such as polyether-urea known as spandex or elastane, polyacrylates, acrylonitrile copolymers, polyvinyl chloride (PVC), polylactic acid, polyglycolic acid, sulfopolyester fibers, and combinations thereof. TM

[0079] ​Before entering a chemical recycling facility, textiles can be reduced in size by shredding, tearing, rakeing, grinding, crushing, or cutting to produce smaller textiles. Textiles can also be densified (e.g., granulation) before entering the chemical recycling facility. Examples of densification methods include extrusion (e.g., extruding into granules), molding (e.g., molding into briquettes), and coalescence (e.g., by externally applied heat, heat generated by friction, or by adding one or more binders, which may themselves be non-native polymers). Alternatively, or additionally, textiles can be any form mentioned herein and can be... Figure 1 One or more of the aforementioned steps are performed in the pretreatment facility 20 before being processed in the remaining facilities of the chemical recovery facility 10 shown.

[0080] In one embodiment or in combination with any of the embodiments mentioned herein, the combination of polyethylene terephthalate (PET) and one or more polyolefins (PO) accounts for a proportion of Figure 1 The waste plastics (e.g., MPW) fed into the chemical recycling facility from the flow 100 shall account for at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt%. Based on the total weight of the plastics in the waste plastics introduced into the chemical recycling facility 10, polyvinyl chloride (PVC) may account for at least 0.001, at least 0.01, at least 0.05, at least 0.1, at least 0.25, or at least 0.5 wt% and / or no more than 10, no more than 5, no more than 4, no more than 3, no more than 2, no more than 1, no more than 0.75, or no more than 0.5 wt% of the waste plastics.

[0081] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the plastic in the waste plastic introduced into the chemical recycling facility 10, the waste plastic may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% PET.

[0082] In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can comprise at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, and / or not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 wt% of PO, based on the total weight of plastics in the waste plastics, or the PO can be present in an amount ranging from 5 wt% to 75 wt%, 10 wt% to 60 wt%, or 20 wt% to 35 wt%, based on the total weight of plastics in the waste plastics introduced into the chemical recycling facility 10.

[0083] Waste plastics sources

[0084] In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastics (e.g., MPW) introduced into the chemical recycling facility can be provided from a variety of sources, including but not limited to: a municipal recycling facility (MRF) or a reprocessing facility, or other mechanical or chemical sorting or separation facility, a manufacturer or factory or commercial production facility, or a retailer or distributor or wholesaler that possesses post-industrial and pre-consumer recyclables, directly from households / businesses (i.e., unprocessed recyclables), a landfill, a collection center, a convenience center, or on a dock or ship or warehouse thereon. In an embodiment or in combination with any of the embodiments mentioned herein, the source of the waste plastics (e.g., MPW) does not include a deposit state return facility, by which a consumer can deposit a particular recyclable item (e.g., a plastic container, bottle, etc.) to receive a monetary refund from the state. However, in an embodiment or in combination with any of the embodiments mentioned herein, the source of the waste plastics (e.g., MPW) can include a deposit state return facility, by which a consumer can deposit a particular recyclable item (e.g., a plastic container, bottle, etc.) to receive a monetary refund from the state. For example, such return facilities can typically be found at grocery stores.

[0085] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can be provided as a waste stream from another processing facility, such as a municipal recycling facility (MRF) or a reclaimer facility, or as a plastic-containing mixture that includes waste plastics sorted by a consumer and left at a curbside or at a central convenience station for collection. In one or more such embodiments, the waste plastics include one or more MRF products or byproducts, a reclaimer byproduct, a sorted plastic-containing mixture, and / or a PET-containing waste plastic from a plastic article manufacturing facility, which one or more MRF products or byproducts, reclaimer byproduct, sorted plastic-containing mixture, and / or PET-containing waste plastic includes: at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, or at least 90 wt% PET, and / or, no more than 99.9, no more than 99, no more than 98, no more than 97, no more than 96, or no more than 95 wt% PET; or it can be in a range of 10 wt% to 99.9 wt%, 20 wt% to 99 wt%, 30 wt% to 95 wt%, or 40 wt% to 90 wt% PET. In one or more such embodiments, the waste plastics include an amount of a reclaimer byproduct or plastic-containing mixture that includes at least 1, at least 10, at least 30, at least 50, at least 60, at least 70, at least 80, or at least 90 wt% and / or no more than 99.9, no more than 99, or no more than 90 wt% PET, or it can be in a range of 1 wt% to 99.9 wt%, 1 wt% to 99 wt%, or 10 wt% to 90 wt% PET, on a dry plastics basis.

[0086] As mentioned above, exemplary sources of plastic waste introduced to a chemical recycling facility can include a PET-containing reclaimer byproduct (e.g., from a PET reclaimer facility), a PET-containing municipal recycling facility (MRF) product or byproduct, a sorted plastic-containing mixture, and / or a PET-containing waste plastic from a plastic article manufacturing facility. Accordingly, in one embodiment or in combination with any of the embodiments mentioned herein, the present technology relates to a method of recycling plastic waste, the method including feeding at least a portion of one or more PET-containing materials to a chemical recycling facility, the PET-containing materials including a reclaimer byproduct, a PET-containing MRF product or byproduct, a sorted plastic-containing mixture, and / or a PET-containing waste plastic from a plastic article manufacturing facility, wherein at least a portion of the byproduct can be used as a feedstock for a chemical recycling process (e.g., depolymerization), as described in more detail below. The chemical recycling facility can include a solvolysis facility, including but not limited to a methanolysis facility, a methanolysis facility, a glycolysis facility, and / or a hydrolysis facility.

[0087] The one or more PET-containing materials can be directly fed into the solvolysis facility within the chemical recycling facility, or can be subjected to one or more pre-treatment steps prior to being fed into the solvolysis facility. For example, as shown in Figure 1 Plastic waste stream 100 from one or more plastic waste sources can be introduced into pre-treatment facility 20 within chemical recycling facility 10, which can be configured to produce a PET-enriched stream 112 and a PET-depleted stream 114. PET-enriched stream 112 from pre-treatment facility 20 can be introduced into solvolysis facility 30. Additionally, or alternatively, plastic waste stream 100a from one or more plastic waste sources can be directly introduced into solvolysis facility 30 (i.e., not introduced into pre-treatment facility 20). Regardless of whether subjected to pre-treatment or directly fed, an amount of PET-containing material from one or more waste plastic sources is ultimately fed into solvolysis facility 30.

[0088] In one embodiment or in combination with any embodiment referred to herein, at least a portion of the one or more PET-containing materials is directly fed into a dissolver within solvolysis facility 30, where the one or more PET-containing materials are mixed with solvent 212 and at least partially liquefied (see Figure 3 ) In one or more such embodiments, and particularly when directly fed into a dissolver, at least a portion of the one or more PET-containing materials can include less than 10, 8, 6, 5, 4, 2, or 1 wt% of the following materials: nylon, polycarbonate, cross-linking agents (e.g., TMA), carpet glue, high filler content materials, acetate, spandex, latex, styrene butadiene rubber, non-reactive materials (i.e., materials that do not react or will not react to such an extent that a substantial reaction product is formed in the solvolysis reactor), including non-reactive metal oxides (e.g., titanium dioxide, silicon dioxide, and aluminum oxide), calcium carbonate, talc, silica, glass, glass beads, reactive metal oxides (which can be methylated or ethanolated in the reactor), and / or materials that form azeotropes with water, methanol, and / or ethylene glycol. A caustic component, such as a hydroxide solution or other caustic solution as defined herein, can be added to the solvolysis facility, such as to the solvolysis reactor and / or the solvolysis reactor outlet.

[0089] In one embodiment or in combination with any embodiment referred to herein, at least a portion of the one or more PET-containing materials can be liquefied, such as by melting and / or one or more other liquefaction methods described herein, and subsequently fed to reaction 210 within solvolysis facility 30 (see Figure 3 ) In such embodiments, at least a portion of the one or more PET-containing materials can be fed to a melt extruder, which serves as a feed system for the solvolysis facility reactor.

[0090] In one embodiment or in combination with any of the embodiments mentioned herein, the one or more PET-containing materials described above can be the only plastic-containing feedstock to the solvolysis facility 30 (i.e., no PET-enriched stream 112 from the pre-treatment facility 20 described herein is fed to the solvolysis facility 30 along with the one or more PET-containing materials). However, in one embodiment or in combination with any of the embodiments mentioned herein, the one or more PET-containing materials can be fed to the solvolysis facility 30 along with one or more other plastic-containing feedstocks (e.g., a PET-enriched stream 112 from the pre-treatment facility 20 described herein). The one or more PET-containing materials can comprise at least 5, at least 10, at least 20, at least 40, at least 60, at least 80, or at least 90 wt% of the plastic-containing feedstock(s) fed to the solvolysis facility 30.

[0091] As described above, the one or more PET-containing materials can be subjected to one or more pre-treatment steps prior to being fed to the solvolysis facility 30. The pre-treatment steps can include feeding the one or more PET-containing materials to the pre-treatment facility 20 described herein, and / or can include performing one or more of the processes described in the pre-treatment section herein. In one or more embodiments, the pre-treatment includes any one or more of: (i) separating at least a portion of the PET from the PET-containing material using one or more density separation processes (e.g., sink-float or centrifugal force); and / or (ii) drying the PET-containing material; and / or (iii) densifying (e.g., pelletizing) at least a portion of the PET-containing material.

[0092] The one or more PET-containing materials can be provided to the chemical recycling facility 10 in a variety of shipping methods and in a variety of forms. For example, in one embodiment or in combination with any of the embodiments mentioned herein, the PET-containing materials can be shipped to the chemical recycling facility in the form of whole articles, pellets, baled packages, unbaled articles, containers, and / or piles by truck, rail, and / or conveyor. For example, the PET-containing materials can be provided directly to the chemical recycling facility 10 from a recycling facility and / or a municipal recycling facility using a conveyor system interconnecting the chemical recycling facility 10 with the recycling facility and / or the MRF facility.

[0093] The composition of the PET-containing material(s) will vary depending on the specific source of the material, as described in more detail below. However, in one embodiment or in combination with any of the embodiments mentioned herein, a portion of the PET-containing material can include at least 10, at least 20, at least 40, at least 60, at least 80, or at least 90 wt% of PET, on a dry basis. A portion of the PET-containing material can include no more than 10, no more than 8, no more than 6, no more than 4, no more than 2, or no more than 1 wt% of halogen, on a dry basis. A portion of the PET-containing material can include no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 5, or no more than 1 wt% of polyolefin, on a dry basis.

[0094] Sorted plastic-containing mixtures

[0095] As more and more municipalities encourage or require the recycling of various materials, including plastics, the supply of sorted PET-containing plastic-containing mixtures is growing. As used herein, the term “sorted plastic-containing mixture” refers to an amount of mixed plastic waste sorted by a consumer and left at a curbside or central convenience station for collection, and can include clear and / or colored plastic articles, or sorted by a trash collector or municipality. In one embodiment or in combination with any of the embodiments mentioned herein, the sorted plastic-containing mixture does not include waste plastics from a deposit-return facility, as described above. However, in one embodiment or in combination with any of the embodiments mentioned herein, the sorted plastic-containing mixture can include waste plastics from a deposit-return facility. The sorted plastic-containing mixture typically requires further processing and / or purification before the plastic materials can be used in a mechanical recycling process, although this is not always the case.

[0096] PET-containing MRF products and / or byproducts

[0097] The sorted plastic-containing mixture can be collected by a sanitation provider and sent to a municipal recycling facility (also known as a material recovery facility or MRF), where at least some attempts are made to sort the mixture into a number of like materials. Typically, at least some initial aspects of this sorting are performed manually. In other aspects, machines - including optical pickers, magnetic pickers, and eddy current pickers - are used to make more refined selections of the various materials present in the plastic-containing mixture. For example, colored plastics can be separated from clear plastics. Typically, “clear plastics” are considered to be plastics that appear to have no color to an average human observer and are typically transparent to light in the visible spectrum. “Colored plastics” are typically considered to be any non-clear plastic. Glass, paper, and metal can also be separated from the plastics.

[0098] The PET-containing plastics can be separated from other types of plastics to form an amount of PET-enriched plastic material. The other separated materials described above and / or any other materials from the MRF (i.e., other than the PET-enriched product) can be extracted as MRF byproducts. However, one or more of the MRF byproducts will typically contain an amount of PET. The MRF products and / or byproducts can be in the form of: whole articles, particulates (e.g., shredded, pelletized, fibrous plastic particulates), baled packages (e.g., compressed and strapped whole articles), unbaled items (i.e., not in a bundle or package), containers (e.g., boxes, sacks, trailers, railcars, loader buckets), piles (e.g., on a concrete slab of a building), and / or physically conveyed loose material (e.g., particulates on a conveyor belt) or pneumatically conveyed loose material (e.g., particulates mixed with air in a conveying pipe).

[0099] PET-containing recycling plant byproducts

[0100] Recycling facilities, particularly PET recycling facilities, typically operate by receiving plastic waste (e.g., from a MRF) and producing r-PET that contains at least 99 wt% or at least 99.9 wt% PET that is used by mechanical recycling facilities to produce r-PET products. The recycling facilities produce r-PET by subjecting the plastic waste to various processes that separate the PET from non-plastic components and plastic materials other than PET. However, these separation processes are typically less than 100% efficient and often result in an amount of PET being present in byproducts. The recycling facilities can also include processes that produce high purity PET (at least 99 wt% or at least 99.9 wt%) recycling plant byproducts, but the form of the recycling plant byproducts is undesirable to mechanical recycling facilities. As used herein, the term “recycling plant byproduct” refers to any material separated or extracted by a recycling facility that is not extracted as a clear rPET product, including colored rPET. The recycling plant byproducts described above and below are typically considered waste products and can often be sent to landfills and / or incinerators.

[0101] PET-containing waste plastics from plastic article manufacturing facilities

[0102] Another source of PET-containing waste plastics includes plastic article manufacturing facilities. These facilities can produce, for example, plastic bottles, plastic containers, plastic caps, plastic lids, plastic straws, plastic bags, plastic films, and various standard and custom plastic articles. A variety of manufacturing methods can be used, including but not limited to, casting, rotational molding, injection molding, blow molding, thermoforming (vacuum forming), extrusion, and 3D printing. These processes can generate waste plastics due to errors in the process or as an inherent result of the process. For example, the waste plastics can include portions of defective plastic articles having deformities, surface defects, and / or brittle portions. The waste plastics can also include other products of the molding process, such as intermediate molded products, for example, bottle preforms or sheeting. The waste plastics can also be scrap plastics removed from plastic articles during the manufacturing process, for example, edge trim from film or sheeting plastic. These waste plastics can typically include an amount (or even a majority) of PET. The waste plastics can also be removed or discharged from manufacturing equipment used to produce plastic articles as part of a manufacturing start-up or shut-down process.

[0103] PET recycling facilities

[0104] As described above, the one or more PET-containing materials used as feedstock for a chemical recycling facility, particularly a solvolysis facility, can include one or more byproducts from a recycling facility, particularly a PET recycling facility. In one embodiment or in combination with any embodiment mentioned herein, the portion of PET-containing materials can include at least two PET-containing recycling plant byproducts.

[0105] Figure 4 A schematic of an exemplary recycling facility 800 is shown, which illustrates typical rPET products and byproducts derived from the recycling facility 800. As shown, a plastic feed 802 (e.g., from a MRF) can be fed to a recycling plant zone 810. The recycling plant zone 810 typically includes various separation processes (described below) that produce a substantially pure r-PET plastic stream 812 that includes at least 99 wt% or at least 99.9 wt% PET on a dry plastic basis. The recycling plant zone 810 can also produce one or more recycling plant byproducts, including a wet fines 803, colored plastics 804, vortex rejects 805, flake sorting rejects 806, and / or dry fines 807.

[0106] r-PET plastic stream 812 may contain a quantity of rPET plastic flakes, which can be extracted as rPET flake stream 814. Additionally, or alternatively, at least a portion of r-PET plastic stream 812 may be fed to densification (e.g., granulation) zone 820. Densification zone 820 typically includes various processes (described below) for converting the rPET flakes from stream 812 into desired rPET pellets 818. Densification zone 820 may also generate one or more recycling device byproducts, including PET cleaned material 815, wet pellets 816, and / or dry pellets 817.

[0107] Figure 5 A schematic diagram of an exemplary recycling facility 800 is shown, illustrating some specific processing steps performed within the recycling facility 800 and the resulting products and byproducts. Although the processing steps are shown and described below in a specific order, it should be understood that other recycling facilities may perform one or more of the processing steps in a different order than that shown in the figures and described herein, and / or omit the processing steps shown and described, and / or include additional processing steps not shown or described.

[0108] like Figure 5 As shown, a certain amount of packaged plastic 801 can be supplied from the MRF facility to the recycling facility 800 and fed to a de-seal device 830 and / or a de-packing machine 832 to produce a certain amount of loose plastic waste material. The de-seal device 830 can be used to avoid the risk of injury associated with manual de-sealing. The de-packing machine 832 typically includes one or more wide blades that contact the de-sealled packages and break them down into loose plastic waste material. The loose plastic waste can then be conveyed, for example, by a belt or pneumatic conveyor 834 to a heavy removal process 836. Heavy removal 836 can utilize gravity and / or pneumatic conveyors to remove “heavier” components (e.g., those with a density greater than 2 g / cc) from the conveyor stream. These heavier components may include metals, rocks, sand, etc. However, a certain amount of PET and / or other plastic material may also be intentionally or unintentionally removed along with the heavier components, and thus the metals, plastics, and other components removed at this stage can be extracted as a byproduct 837 of the recycling facility containing heavy materials (e.g., containing metals).

[0109] The plastic waste, with the heavier components removed, can then be passed to a friction washer 838 where food or other material stuck to the plastic waste is washed off with a stream of water and / or by contacting the plastic waste with a buffer to remove food or material from the plastic. In this and other steps that include a water washing or rinsing step, the resulting water stream 839 can be filtered 840, either alone or with water streams from other steps described herein. The filter 840 will occasionally be cleaned, and the removed solids can include PET. Additionally, or alternatively, the filtrate can contain an amount of PET and / or other plastic material. One or both of the solids from the filtration process and / or the PET-containing filtrate can be in the form of a wet fines 841, which can be extracted as a recycling plant byproduct. As used herein, the term "filtration" refers to methods and / or equipment used to perform solid / liquid separation, including but not limited to the use of media, centrifugal separation, and / or sedimentation.

[0110] After the friction washer 838, the plastic waste can be subjected to one or more near infrared (NIR), optical, and / or manual sorting steps to remove colored plastic and / or other plastic and non-plastic materials that are not identified by the (manual or mechanical) sorter as PET-containing plastic material. As shown, the process includes two NIR sorters 842, 844 and manual sorting steps 846, 848, resulting in four streams of colored plastic mixtures 843, 845, 847, 849 as recycling plant byproducts. The NIR and optical sorters will typically reject anything that the sensor does not fully identify as clear PET material. Such rejected waste can include PET bottles with labels and / or colored caps. However, certain NIR and / or optical sorters can not have the ability to "see" and reject black plastic, such as clamshell containers with carbon black portions. Thus, black plastic will typically not be rejected by these sorters. Additionally, a certain amount of clear PET material can also be rejected with the colored PET material by air blowers downstream of the sensor. The manual sorters will typically "pull out" or reject any material that is not obviously a clear PET bottle or material, as well as PET bottles with liners or other known problem components, for use in downstream recycling processes. Thus, the colored plastic mixtures resulting from these processes will typically contain an amount of PET and / or other plastic material, in the form of a colored plastic-containing mixture, which can be extracted as a recycling plant byproduct.

[0111] After the NIR, optical, and / or manual sorting steps, the plastic waste can then be passed to an optional eddy current separator 850 to remove any metals remaining in the waste plastic and protect downstream processes from damage. Eddy current separators use an electric field at the end of a conveyor belt to repel electrically conductive non-ferrous metals (e.g., aluminum) and do not affect non-conductive materials (e.g., plastic). As the stream of plastic waste approaches the end of the conveyor belt, the eddy current changes the natural, gravity-induced trajectory of non-ferrous metals and expels them from the stream along a different trajectory than non-conductive materials. A separation plate is positioned between the paths defined by the two trajectories, allowing the expelled and unexpelled components to separate. During separation, some plastic articles and / or plastic flake can come into contact with the non-ferrous metal components and be inadvertently expelled along the incorrect trajectory. As a result, the separated non-ferrous metals can contain an amount of PET and / or other plastic materials, which can be extracted as a metal-containing reclaimer byproduct 851. Additionally, the eddy current separator can be connected with a grinder 852 (upstream or downstream of the eddy current separator 850), which can produce plastic fines that can also be extracted as a reclaimer byproduct.

[0112] After the optional eddy current separator 850 and / or grinder 852, the plastic waste can then be passed to a density separation stage 854, such as a sink-float separation stage, which typically separates components with a density lower than PET (e.g., polyolefins) from the plastic waste material, and a mechanical dewatering process 856. As described above, the waste water from these processes is filtered 840, 860 and the solids and / or filtrate can be extracted as wet fines 841, 861 or other reclaimer byproducts (e.g., a polyolefin stream 859).

[0113] The plastic waste can then be passed to another NIR 862 and / or optical sorter, which typically rejects anything that the sensors did not fully identify as clear PET again. The plastic waste material at this stage has typically undergone a size reduction process, such as grinding, so the rejected material is typically in the form of plastic flake (defined below). This process is intended to remove PVC, such as from labels, and other plastic materials that have a similar density to PET and were not removed in the density separation process. However, similar to the previous NIR and optical sorters, the rejected flake can include an amount of PET and can be extracted as a flake scrap reclaimer byproduct 863.

[0114] At this point, the plastic waste typically has a high PET content (e.g., at least 99 wt% or at least 99.9 wt%) and can be dried 864 and prepared as an rPET flake product 814 for packaging 870. When a dryer 864 is used, a quantity of dry fines (defined below) can be separated from the flake product in the dryer 864 or in a downstream conveyor 866 and / or dust collector 868. Although the dry fines also typically have a high PET content, they are undesirable as rPET feedstock for mechanical recycling facilities. However, the dry fines can be extracted as a dry fines regeneration plant byproduct 865, 869. It should be understood that dryers and dust collectors can be used elsewhere upstream or downstream in a regeneration facility, and dry fines extracted from these locations can also be extracted as a regeneration plant byproduct.

[0115] Some regeneration facilities also include a densification process to convert the rPET flake into a desired rPET pellet. As used herein, “densification” refers to a process that agglomerates and pellets, coalesces, or partially melts a quantity of plastic particles having a D90 particle size of less than 0.32 cm (1 / 8 inch) to form solid particles (e.g., pellets) having a D90 particle size of 0.32 cm (1 / 8 inch) to 2.54 cm (1 inch). The densification process typically includes an extruder 880 in which the rPET flake is melted and conveyed through an extruder barrel. A pelletizer 882 is then operated to cause the extruded rPET to form pellets (typically having a D90 of no more than 2.54 cm (1 inch)). The pellets are then rinsed (which can result in extractable PET-containing wet fines), dried (which can result in extractable PET-containing dry fines), and packaged 890 for shipment to a mechanical recycling facility as an rPEt pellet product 892. However, when the extruder is shut down, a quantity of molten rPET is purged and allowed to solidify, e.g., into a block of PET material, rather than being converted into pellets. This purged material can be extracted as a PET purged material regeneration plant byproduct 881. Additionally, the pelletization is typically performed in water, and filtrate and / or solids from the filtered water stream can be extracted as a regeneration plant byproduct (e.g., wet fines 883). Finally, dryers 884 and conveyors 886, 888 used in the pellet packaging process are typically equipped with dust collectors, and dry fines can also be extracted as dry fines regeneration plant byproducts 885, 887, 889.

[0116] The composition and processing steps of the regeneration plant byproducts in a chemical recycling facility are described in more detail below. However, it should be understood that the following description can also describe the composition and processing of other PET-containing materials (i.e., PET-containing MRF products or byproducts, sorted plastic-containing mixtures, and / or PET-containing waste plastics from plastic article manufacturing facilities) within the scope of the present technology.

[0117] Wet fines

[0118] As described above, a regeneration plant wet fines can be separated and extracted from plastic waste, for example as a filtrate and / or solids from a filtration process. As used herein, “regeneration plant wet fines” refers to a stream or batch of PET-containing plastic particles separated from waste plastic within a regeneration facility, and which has a water content of at least 2 wt% based on the total weight of the regeneration plant wet fines, and a D90 of the plastic particles of less than 0.32 cm (1 / 8 inch), when first separated from waste plastic within the regeneration facility. In one embodiment or in combination with any embodiment mentioned herein, an amount of regeneration plant wet fines is fed to a chemical recycling facility, and at least a portion of the amount of regeneration plant wet fines is depolymerized therein.

[0119] In one embodiment or in combination with any embodiment mentioned herein, an amount of PET-containing regeneration plant wet fines comprises a water content of at least 2, at least 5, at least 10, at least 20, at least 30, at least 40, or at least 50 wt%. The amount of PET-containing regeneration plant wet fines can comprise at least 1, at least 5, at least 10, at least 20, at least 30, at least 40, or at least 50 wt% of plastic particles having a D90 of less than 0.32 cm (1 / 8 inch). The amount of PET-containing regeneration plant wet fines can comprise at least 90, at least 95, or at least 99 wt% of PET, on a dry basis (i.e., excluding the moisture content).

[0120] In one embodiment or in combination with any embodiment mentioned herein, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, at least 95, or at least 99 wt% of the water content can be removed from the amount of PET-containing regeneration plant wet fines prior to depolymerization. The water content can be removed by passive drying (e.g., placed in storage) or using a dryer or other active drying method. In one or more embodiments, at least a portion of the plastic particles from the PET-containing regeneration plant wet fines can be densified (e.g., agglomerated or pelletized) prior to depolymerization to form an amount of densified PET-containing particles having a D90 of 0.32 cm (1 / 8 inch) to 2.54 (1 inch). The amount of densified PET-containing particles can be liquefied (e.g., dissolved or melted) prior to depolymerization to form a liquefied plastic material. One or more of the water removal, densification, and / or liquefaction can be performed within the chemical recycling facility or prior to feeding the amount of wet fines to the chemical recycling facility.

[0121] In one embodiment or in combination with any of the embodiments mentioned herein, an amount of PET-containing regeneration plant wet fines (including an amount of densified PET-containing particles and / or liquefied plastic material) can be fed to a solvolysis facility within a chemical recycling facility, where depolymerization occurs. The amount of PET-containing regeneration plant wet fines (including an amount of densified PET-containing particles and / or liquefied plastic material) can include at least 90, at least 95, or at least 99 wt% PET on a dry basis. The amount of PET-containing regeneration plant wet fines (including an amount of densified PET-containing particles and / or liquefied plastic material) can include no more than 10, no more than 8, no more than 6, no more than 4, no more than 2, or no more than 1 wt% halogen on a dry basis. The amount of PET-containing regeneration plant wet fines (including an amount of densified PET-containing particles and / or liquefied plastic material) can include no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 5, or no more than 1 wt% polyolefin on a dry basis.

[0122] Colored plastic-containing mixture

[0123] As described above, a colored plastic-containing mixture can be separated from plastic waste and extracted in a PET regeneration plant. Additionally, or alternatively, a colored plastic-containing mixture can be separated and similarly extracted in a MRF facility. As used herein, the term “colored plastic-containing mixture” refers to: (a) plastic-containing material identified as colored plastic by a regeneration plant or MRF or identified as opaque rPET by a regeneration plant or MRF; or (b) any plastic-containing material separated by a regeneration plant or MRF other than dry fines, wet fines, regeneration plant clear rPET product, rock, biomass, metal, or fiber. In one embodiment or in combination with any of the embodiments mentioned herein, an amount of PET-containing regeneration plant colored plastic-containing mixture and / or MRF colored plastic-containing mixture is fed to a chemical recycling facility and at least a portion of the amount of PET-containing regeneration plant colored plastic-containing mixture and / or MRF colored plastic-containing mixture is depolymerized therein.

[0124] In one embodiment or in combination with any of the embodiments referred to herein, an amount of the mixture containing colored plastics comprises at least 1, at least 10, at least 20, at least 40, at least 60, at least 80, or at least 90 and / or not more than 99.9 or not more than 99 wt% PET on a dry basis. An amount of the mixture containing colored plastics can comprise 1-99.9 wt% or 50-99 wt% PET on a dry basis. An amount of the mixture containing colored plastics can comprise at least 1, at least 10, at least 20, at least 40, at least 60, at least 80, at least 90, at least 95, at least 99, or at least 99.9 wt% opaque PET (e.g., green PET) on a dry basis. An amount of the mixture containing colored plastics can comprise not more than 10, not more than 8, not more than 6, not more than 4, not more than 2, or not more than 1 wt% halogen on a dry basis. An amount of the mixture containing colored plastics can comprise at least 1, at least 2, at least 4, at least 6, or at least 8 wt% and / or not more than 90, not more than 80, not more than 70, not more than 60, not more than 50, not more than 40, not more than 30, not more than 20, or not more than 10 wt% polyolefin on a dry basis. An amount of the mixture containing colored plastics can comprise 1-90 wt%, 2-70 wt%, 4-50 wt%, 6-30 wt%, or 8-10 wt% polyolefin on a dry basis. An amount of the mixture containing colored plastics can comprise at least 0.1, at least 1, at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, or at least 90 wt% opaque PET and / or other colored plastic materials on a dry plastic basis. An amount of the mixture containing colored plastics can comprise at least 0.1, at least 1, at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, or at least 90 wt% PVC, nylon, and / or copolyester on a dry basis.

[0125] In one embodiment or in combination with any of the embodiments referred to herein, an amount of the mixture containing colored plastics can be directly fed to a solvolysis facility within a chemical recycling facility without being: fed to a pre-treatment and / or separation facility, or subjected to a pre-treatment and / or separation process within or separate from the chemical recycling facility. However, at least a portion of an amount of the mixture containing colored plastics can be fed to at least one density separation stage prior to depolymerization, thereby producing a PET-enriched stream that is fed to a solvolysis facility within a chemical recycling facility. The at least one density separation stage can comprise at least two density separation stages.

[0126] PET and metal containing regeneration plant byproducts

[0127] As described above, metal components can be separated from plastic waste in a recycling facility, for example in a heavy removal process and / or a cyclone separator, and these metal components can include an amount of PET material and be extracted as a PET and metal containing recycling plant byproduct. As used herein, the term “PET and metal containing recycling plant byproduct” refers to material from a magnetic separator, cyclone separator, or other metal separator in a PET recycling facility that is not extracted as a rPET product. In one embodiment or in combination with any embodiment mentioned herein, an amount of PET and metal containing recycling plant byproduct can be fed to a chemical recycling facility and at least a portion of the amount of PET and metal containing recycling plant byproduct is depolymerized therein.

[0128] In one embodiment or in combination with any embodiment mentioned herein, the amount of PET and metal containing recycling plant byproduct comprises at least 0.1, at least 1, at least 5, at least 10, or at least 15 wt% metal on a dry basis. However, the metal content that is fed to a solvolysis facility for depolymerization can be limited. Accordingly, at least a portion, at least 90 wt%, at least 95 wt%, at least 99 wt%, or at least 99.9 wt% of the metal can be separated and removed from the plastic prior to depolymerization, as described below. The separation or removal can be performed as a continuous separation process (e.g., a solid / liquid separator) and / or as a batch separation process (e.g., a purifying process) and can be performed in a pre-treatment facility and / or a solvolysis facility, for example a front end of a solvolysis facility. Regardless of whether a separation step is used, the feedstock to the solvolysis facility and / or depolymerization process can be no more than 10, no more than 8, no more than 6, no more than 4, no more than 2, or no more than 1 wt% metal on a dry basis. The metal can comprise one type of metal or more than one type of metal and can comprise iron and / or non-ferrous metals. The metal can comprise one or more non-ferrous metals, for example aluminum, copper, lead, nickel, tin, titanium, zinc, and / or alloys thereof. The metal can comprise one or more ferrous metals, for example iron, steel, stainless steel, carbon steel, austenitic, martensitic, duplex stainless steel, ferritic stainless steel, and / or alloys thereof. The amount of PET and metal containing recycling plant byproduct can comprise at least 0.1, at least 1, at least 10, at least 20, at least 40, at least 60, or at least 80 wt% PET on a dry basis.

[0129] In one embodiment or in combination with any of the embodiments mentioned herein, the amount of the PET and metal containing regeneration plant byproduct comprises plastic flake and at least 0.1, at least 1, at least 5, at least 10, or at least 15 wt% metal on a dry basis. As used herein, the term “plastic flake” refers to plastic particles having a D90 particle size of 0.32 cm (1 / 8 inch) to 2.54 cm (1 inch). At least a portion of the plastic flake can be separated from the metal prior to depolymerization. The separation can be performed within the chemical recycling facility (e.g., in a pretreatment facility and / or a solvolysis facility) or prior to feeding the PET and metal containing regeneration plant byproduct to the chemical recycling facility. The separation can comprise feeding at least a portion of the amount of the regeneration plant byproduct to at least one density separation stage to separate at least a portion of the plastic flake from the metal. The separated portion of the plastic flake can be fed to a solvolysis facility within the chemical recycling facility. The metal from which the portion of the plastic flake was separated can be fed to a partial oxidation (POX) gasifier.

[0130] In one embodiment or in combination with any of the embodiments mentioned herein, the amount of the PET and metal containing regeneration plant byproduct does not undergo separation prior to being fed to the chemical recycling facility. For example, both the metal and the plastic flake can be fed to a solvolysis facility within the chemical recycling facility and the metal can be removed by a solid / liquid separator (e.g., a filter) and / or purification in the solvolysis facility. Additionally, the metal can be fed to a POX gasifier without separating a portion of the plastic flake therefrom.

[0131] In one embodiment or in combination with any of the embodiments mentioned herein, the amount of the PET and metal containing regeneration plant byproduct comprises plastic articles and at least 0.1, at least 1, at least 5, at least 10, or at least 15 wt% metal on a dry basis. As used herein, the term “plastic articles” refers to baled or unbaled plastic material having a D90 particle size greater than 2.54 cm (1 inch). The plastic articles can be in the form of compressed bales. The plastic articles can be processed, for example, by de-baling, grinding, chopping, shredding, and / or pulverizing to produce a de-baled amount of plastic articles and metal and / or to reduce the size of the plastic articles to form plastic particulate solids having a D90 particle size of less than 2.54 cm (1 inch).

[0132] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the plastic articles and / or plastic particulate solids can be separated from the metals prior to depolymerization. The separation can be performed within the chemical recycling facility (e.g., in the pre-treatment facility and / or the solvolysis facility) or prior to feeding the PET and metal containing recycling plant byproduct to the chemical recycling facility. The separation can comprise: feeding at least a portion of the plastic articles and / or plastic particulate solids to at least one density separation stage to separate at least a portion of the plastic articles and / or plastic particulate solids from the metals. The separated portion of the plastic articles and / or plastic particulate solids can be fed to a solvolysis facility within the chemical recycling facility. The metals from which a portion of the plastic articles and / or plastic particulate solids were separated can be fed to a partial oxidation (POX) gasifier.

[0133] Similar to the plastic flakes, in one embodiment or in combination with any of the embodiments mentioned herein, both the metals and the plastic articles and / or plastic particulate solids can be fed to a solvolysis facility within the chemical recycling facility and the metals can be removed by filtration and / or purification in the solvolysis hydrolysis facility. Additionally, the metals can be fed to a POX gasifier without separating a portion of the plastic articles and / or plastic particulate solids therefrom.

[0134] In one embodiment or in combination with any of the embodiments mentioned herein, an amount of the PET and metal containing recycling plant byproduct comprises plastic fines and at least 0.1, at least 1, at least 5, at least 10, or at least 15 wt% metals on a dry basis. As used herein, the term “plastic fines” refers to plastic particles having a D90 particle size of less than 0.32 cm (1 / 8 inch). At least a portion of the plastic fines can be densified (e.g., agglomerated or pelletized) prior to depolymerization to produce densified PET containing particles. The densification can occur within the chemical recycling facility or prior to feeding the PET and metal containing recycling plant byproduct to the chemical recycling facility. The densified PET containing particles can have a D90 particle size of 1 to 10 mm, 2 to 8 mm, or 3 to 5 mm. The densification can occur without separating all or a portion of the metals in the recycling plant byproduct and thus the densified PET containing particles can comprise at least a portion of the metals. The densified PET containing particles can be directly fed to a solvolysis facility within the chemical recycling facility (i.e., without being subjected to a pre-treatment or separation process within or separate from the chemical recycling facility).

[0135] In one embodiment or in combination with any of the embodiments mentioned herein, the metals separated from the plastic material comprising PET and metals from the recycling plant by-product (i.e., the metals separated from the plastic flakes, plastic articles, and / or plastic fines using any one or more of the pre-treatment or separation methods described in this section or elsewhere in this application) can be extracted in a metal-containing stream, for example, with a portion of the plastic flakes, plastic articles, and / or plastic fines or other plastic material, and fed to a pyrolysis facility, and in one or more embodiments, to a pyrolysis reactor within the pyrolysis facility.

[0136] Recycling plant flake waste

[0137] As described above, recycling plant flake waste comprising PET and PVC can be separated from plastic waste in a PET recycling facility and extracted. As used herein, “recycling plant flake waste” refers to a plastic waste mixture from a recycling facility comprising at least PET and at least 0.1 wt% PVC on a dry basis, and a D90 particle size of 0.32 cm (1 / 8 inch) to 2.54 cm (1 inch). In one embodiment or in combination with any of the embodiments mentioned herein, an amount of flake waste comprising PET and PVC is fed to a chemical recycling facility, and at least a portion of the amount of flake waste comprising PET and PVC is depolymerized therein.

[0138] In one embodiment or in combination with any of the embodiments mentioned herein, an amount of recycling plant flake waste is enriched in PVC and depleted in polyolefins relative to plastic waste. An amount of recycling plant flake waste can comprise at least 0.1, at least 1, at least 10, at least 20, at least 40, at least 60, or at least 80 wt% PET on a dry basis. An amount of recycling plant flake waste can comprise at least 1, at least 5, at least 10, or at least 15 wt% PVC on a dry basis. An amount of recycling plant flake waste can comprise at least 0.1, at least 1, or at least 5 wt% and / or not more than 20, not more than 15, or not more than 10 wt% polyolefins on a dry basis. An amount of recycling plant flake waste can comprise 0.1 wt% to 20 wt%, 1 wt% to 15 wt%, or 5 wt% to 10 wt% polyolefins on a dry basis.

[0139] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the amount of the recycling plant flake waste can be fed to at least one density separation stage prior to depolymerization, wherein a PET-enriched stream and a polyolefin-enriched stream can be produced from the waste plastic stream comprising the flake waste. In one embodiment or in combination with any of the embodiments mentioned herein, the portion of the amount of the recycling plant flake waste can be the only plastic material in the waste plastic stream fed to the at least one density separation stage. However, in other embodiments, the portion of the amount of the recycling plant flake waste can be mixed with one or more other plastic materials in the waste plastic stream fed to the at least one density separation stage. The PET-enriched stream can be fed to a solvolysis facility. The polyolefin-enriched stream can be fed to a partial oxidation (POX) gasifier. The polyolefin-enriched stream can be fed to a pyrolysis facility, and can be fed to a pyrolysis reactor within the pyrolysis facility. Additionally, or alternatively, the polyolefin-enriched stream can be fed to an energy recovery facility.

[0140] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the amount of the recycling plant flake waste comprising PET and PVC can be fed to a mechanical dewatering apparatus prior to depolymerization. Then, a portion of the amount of the recycling plant flake waste can be fed to a hot dryer after the mechanical dewatering apparatus.

[0141] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the amount of the recycling plant flake waste comprising PET and PVC can be directly fed to a solvolysis facility within the chemical recycling facility (i.e., without having to undergo a pre-treatment or separation process within or separate from the chemical recycling facility).

[0142] Solidified purifying material

[0143] As described above, the solidified purge material can be from a liquified plastic material that is not usable or not desired, such as from a PET (rPET) recycling facility, a PET article manufacturer (molding machine), and / or a polymer manufacturing facility, which material is allowed to solidify and can be extracted. As used herein, the term “solidified purge material” refers to plastic waste or portions thereof removed from any molten polymer processing equipment that does not produce an intended product (e.g., pellets, bottles, and other plastic articles) including, but not limited to, extruders, filters, pelletizers, reactors, conduits, and the like, which plastic waste is molten within the molten polymer processing equipment but is allowed to solidify outside. The solidified material can generally be unshaped and / or unpelletized, and can be in the form of a solid plastic mass (e.g., a plastic mass removed from an extruder barrel that does not pass through an extruder die). The solidified plastic material can also include intermediate molded products. The solidified plastic material can include transparent and / or colored plastic. In one embodiment or in combination with any embodiment mentioned herein, an amount of PET-containing solidified purge material is fed to a chemical recycling facility, and at least a portion of the amount of PET-containing solidified purge material is depolymerized therein.

[0144] In one embodiment or in combination with any embodiment mentioned herein, the amount of PET-containing solidified purge material comprises at least 90, at least 95, at least 99, or at least 99.9 wt% PET on a dry basis. The amount of PET-containing solidified purge material comprises at least 0.1, at least 1, at least 10, at least 20, at least 40, at least 60, or at least 80 wt% copolyester on a dry basis. The amount of PET-containing solidified purge material can comprise at least 95, at least 98, at least 99, or at least 99.9 wt% of materials that are solid (e.g., glass, metals, and other fillers) at the processing temperature of the molten polymer processing equipment. The amount of PET-containing solidified purge material comprises no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, or no more than 1 wt% polyolefin on a dry basis. The amount of PET-containing solidified purge material comprises no more than 20, no more than 15, no more than 10, no more than 5, or no more than 1 wt% PVC on a dry basis.

[0145] In one embodiment or in combination with any of the embodiments described herein, at least a portion of the quantity of solidified purified material containing PET can be directly fed to a solvolysis facility within a chemical recycling facility (i.e., without being subjected to a pre-treatment or separation process within or separate from the chemical recycling facility). At least a portion of the quantity of solidified purified material containing PET can be reduced in size, for example, by a mechanical size reduction process. The mechanical size reduction process can include shredding (e.g., using a plastic chopper), chopping, grinding, dicing, dropping, and / or breaking the partially solidified purified material to form a quantity of plastic particulate solids prior to depolymerization.

[0146] In one embodiment or in combination with any of the embodiments described herein, the D90 particle size of the resulting plastic particulate solids can be less than 15.24 cm (6 inches), no more than 12.7 cm (5 inches), no more than 10.16 cm (4 inches), no more than 7.62 cm (3 inches), no more than 5.08 cm (2 inches), or no more than 2.54 cm (1 inch). When a chopper is used, the solidified purified material can produce plastic particulate solids having a D90 particle size of less than 5.08 cm (2 inches) or less than 2.54 cm (1 inch). During the size reduction processes described above, or upon collection of the purified material, a quantity of dry fines, string, thread, and / or fibrous material can be produced and extracted from the solidified purified material. For example, when a chopper is used, the process can produce a quantity of plastic fines. However, the use of a grinder can be avoided, and thus the process can produce less than 10%, less than 5%, less than 2%, or less than 1% of plastic fines. Prior to depolymerization, a quantity of these extracted materials can be densified into plastic particulates having a D90 particle size of 0.32 cm (1 / 8 inch) to 2.54 cm (1 inch). For example, a sifter can be used to extract large particulates (more than 2.54 cm (1 inch)) and fines (less than 0.32 cm (1 / 8 inch)). The large particulates can be recycled back to the chopper. The fines can be densified as described above.

[0147] Dry fines

[0148] As described above, dry fines can be produced from the handling (e.g., conveying, drying, densifying, extruding, packaging, centrifuging processes, and / or grinding) and / or conveying of plastic materials, which can be collected in a dryer or dust collector and extracted. As used herein, the term “dry fines” refers to waste plastic particulates from a PET recycling facility and / or a PET article manufacturer having an average particle size of less than 0.32 cm (1 / 8 inch) and a moisture content of less than 2 wt%. In one embodiment or in combination with any of the embodiments described herein, a quantity of dry fines containing PET is fed to a chemical recycling facility and at least a portion of the quantity of dry fines containing PET is depolymerized therein.

[0149] In one embodiment or in combination with any of the embodiments mentioned herein, the amount of PET-containing dry fines comprises at least 90, at least 95, at least 99, or at least 99.9 wt% PET on a dry basis. The amount of PET-containing dry fines can comprise at least 0.1, at least 1, at least 10, at least 20, at least 40, at least 60, or at least 80 wt% copolyester on a dry basis. The amount of PET-containing dry fines can comprise no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, or no more than 1 wt% polyolefin on a dry basis. The amount of PET-containing dry fines can comprise no more than 20, no more than 15, no more than 10, no more than 5, or no more than 1 wt% PVC on a dry basis.

[0150] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the amount of PET-containing dry fines is fed directly to a chemical recycling facility (i.e., without being subjected to a pre-treatment or separation process within or separate from the chemical recycling facility). This can be accomplished using a conveyance system that interconnects the chemical recycling facility with a PET reclamation facility, a manufacturer of PET articles, and / or a polymer manufacturing facility. The dry fines can also be delivered in burlap sacks or bags.

[0151] Dry fines can pose some risk of explosion. While dry fines typically do not reach an explosive state, conveying dry fines can cause segregation and air exposure, rendering the dry fines potentially explosive. Explosive concentrations can also exist in storage piles. Accordingly, the dry fines can be screened to remove and extract dry fines having a particle size of less than 1000 pm, less than 800 pm, less than 600 pm, or less than 420 pm. At least a portion of the PET-containing dry fines extracted in the above screening or other process can be densified (e.g., agglomerated or pelletized) prior to depolymerization to produce densified PET-containing particles, thereby reducing or eliminating the risk of explosion. In one embodiment or in combination with any of the embodiments described herein, the densified plastic particles have a D90 particle size of 0.32 cm (1 / 8 inch) to 2.54 cm (1 inch). In one or more embodiments, the densified plastic particles can be fed to a solvolysis facility within a chemical recycling facility.

[0152] Delivery of waste plastics

[0153] The chemical recycling facility 10 can also include infrastructure for receiving waste plastics (e.g., PET-containing reclaimer byproducts, PET-containing municipal recycling facility (MRF) products or byproducts, sorted plastic-containing mixtures, PET-containing waste plastics from plastic article manufacturing facilities, and / or other MPW) as described herein to facilitate delivery of the waste plastics by any suitable type of conveyance, including, for example, trains, trucks, and / or ships. Such infrastructure can include facilities to assist in unloading the waste plastics from the conveyance, as well as storage facilities and one or more conveyance systems for transporting the waste plastics from the unloading area to a downstream processing area. Such conveyance systems can include, for example, pneumatic conveyors, belt conveyors, bucket conveyors, vibratory conveyors, screw conveyors, cart-on-track conveyors, drag conveyors, suspended conveyors, front-end loaders, trucks, and chain conveyors.

[0154] The waste introduced into the chemical recycling facility 10 (e.g., PET-containing reclaimer byproducts, PET-containing municipal recycling facility (MRF) products or byproducts, sorted plastic-containing mixtures, PET-containing waste plastics from plastic article manufacturing facilities, and / or other MPW) can be in several forms, including but not limited to: whole articles, particulates (e.g., shredded, pelletized, fibrous plastic particulates), baled packages (e.g., compressed and strapped whole articles), unbaled items (i.e., not in bundles or packages), containers (e.g., boxes, burlap sacks, trailers, railcars, loader buckets), piles (e.g., on a concrete slab at a building), solid / liquid slurries (e.g., a pumped slurry of plastics in water), and / or physically conveyed loose materials (e.g., particulates on a conveyor belt) or pneumatically conveyed loose materials (e.g., particulates mixed with air and / or inert gas in a conveying pipe).

[0155] As used herein, the term “waste plastic particulate” refers to waste plastic having a D90 of less than 1 inch. In an embodiment, or in combination with any embodiment mentioned herein, the waste plastic particulate can be an MPW particulate. The waste plastic or MPW particulate can include, for example, shredded or chopped plastic particulates, or plastic pellets. When all or almost all of the articles are introduced to the chemical recycling facility 10 (or pre-processing facility 20), one or more shredding or pelletizing steps can be used therein to form the waste plastic particulate (e.g., MPW particulate). Alternatively, or additionally, at least a portion of the waste plastic introduced to the chemical recycling facility 10 (or pre-processing facility 20) can already be in particulate form.

[0156] The general configuration and operation of each of the illustrated chemical recycling facilities, starting with the pre-processing facility, will now be described in further detail below. Optionally, although not shown, the pre-processing facility 20 can be omitted, and the waste plastics can be introduced directly to the chemical recycling facility 10. Figure 1 The general configuration and operation of each of the illustrated chemical recycling facilities, starting with the pre-processing facility, will now be described in further detail below. Optionally, although not shown, the pre-processing facility 20 can be omitted, and the waste plastics can be introduced directly to the chemical recycling facility 10. Figure 1As shown in FIG. 1, at least one stream from the chemical recycling facility can be sent to an industrial landfill or other similar type of treatment or disposal facility.

[0157] Pre-treatment

[0158] As shown in FIG. 1, at least one stream from the chemical recycling facility can be sent to an industrial landfill or other similar type of treatment or disposal facility. Figure 1 As shown, untreated and / or partially treated waste plastics, such as mixed plastic waste (MPW), can first be introduced into a pre-treatment facility 20 via stream 100. In the pre-treatment facility 20, the stream can undergo one or more treatment steps to prepare the waste plastics for chemical recycling. As used herein, the term “pre-treatment” refers to the preparation of waste plastics for chemical recycling using one or more of the following steps: (i) shredding, (ii) pelletizing, (iii) washing, (iv) drying, and / or (v) separation. As used herein, the term “pre-treatment facility” refers to a facility that includes all equipment, piping, and control devices necessary to perform pre-treatment of waste plastics. The pre-treatment facility as described herein can employ any suitable method to use one or more of these steps for the preparation of waste plastics for chemical recycling, which will be described in further detail below.

[0159] Shredding and pelletization

[0160] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics (e.g., MPW) can be provided in bales or other large aggregated forms of unsorted or pre-sorted plastics. The baled or aggregated plastics undergo an initial process in which they are broken apart. The plastic bales can be sent to a bale breaker, which includes, for example, one or more rotating shafts equipped with teeth or blades configured to break apart the bales and, in some cases, shred the plastics that make up the bales. In one or more other embodiments, the baled or aggregated plastics can be sent to a guillotine, where they are cut into smaller sized plastic pieces. The baled and / or guillotined plastics solids can then be subjected to a sorting process in which various non-plastic heavy materials, such as glass, metal, and rock, are removed. This sorting process can be performed manually or by machine. The sorting machine can rely on optical sensors, magnets, eddy currents, pneumatic elevators or conveyors based on drag coefficient separation, or screens to identify and remove the heavy materials.

[0161] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic feedstock comprises plastic solids having a D90 greater than one inch, greater than 0.75 inches, or greater than 0.5 inches, such as used containers. Alternatively, or additionally, the waste plastic feedstock can also comprise a plurality of plastic solids that at some time had at least one dimension greater than one inch, but which solids can have been compacted, pressed, or otherwise gathered into larger units, such as bales. In embodiments where at least a portion or all of the plastic solids have at least one dimension greater than one inch, greater than 0.75 inches, or 0.5 inches, the feedstock can be subjected to a mechanical size reduction operation, such as grinding / pelletizing, shredding, slitting, chopping, or other comminution process, to provide MPW particles having a reduced size. Such mechanical size reduction operations can include a size reduction step, rather than compacting, pressing, or forming bales of the plastic.

[0162] In one or more other embodiments, the waste plastic can have already undergone some initial separation and / or size reduction process. In particular, the waste plastic can be in the form of particles or flakes and provided in some container, such as a burlap bag or box. Depending on the composition of these plastic solids and what pre-treatment they can have been subjected to, the plastic feedstock can bypass the bale breaker, slitter, and / or heavy fraction removal station and proceed directly to the pelletizing equipment for further size reduction.

[0163] In one embodiment or in combination with any of the embodiments mentioned herein, the baled or broken plastic solids can be fed to a comminution or pelletizing equipment in which the plastic solids are ground, shredded, or otherwise reduced in size. The plastic material can be made into particles having a D90 particle size of less than 1 inch, less than 3 / 4 inch, or less than 1 / 2 inch. In one or more other embodiments, the plastic material exiting the pelletizing equipment has a D90 particle size of 1 / 16 inch to 1 inch, 1 / 8 inch to 3 / 4 inch, 1 / 4 inch to 5 / 8 inch, or 3 / 8 inch to 1 / 2 inch.

[0164] Washing and drying

[0165] In one embodiment or in combination with any of the embodiments mentioned herein, the untreated or partially treated waste plastic provided to the chemical recycling facility can include various organic contaminants or residues that can be associated with the prior use of the waste plastic. For example, the waste plastic can include food or beverage stains, particularly if the plastic material was used for food or beverage packaging. As a result, the waste plastic can also contain microbial contaminants and / or compounds produced by microorganisms. Exemplary microorganisms that can be present on the surface of the plastic solids making up the waste plastic include: E. coli, Salmonella, C. difficile, Staphylococcus aureus, Listeria monocytogenes, Staphylococcus epidermidis, Pseudomonas aeruginosa, and Pseudomonas fluorescens.

[0166] Various microorganisms can produce compounds that cause malodors. Exemplary odor causing compounds include hydrogen sulfide, dimethyl sulfide, methyl mercaptan, putrescine, cadaverine, trimethylamine, ammonia, acetaldehyde, acetic acid, propionic acid, and / or butyric acid. Thus, it can be appreciated that waste plastics can present odor nuisance problems. Accordingly, waste plastics can be stored within an enclosed space, such as a shipping container, an enclosed rail car, or an enclosed trailer, until it can be further processed. In certain embodiments, the unprocessed or partially processed waste plastics can be stored in an enclosed space for no more than one week, no more than 5 days, no more than 3 days, no more than 2 days, or no more than 1 day once it reaches the location where the waste plastics are to be processed (e.g., shredded, washed, and sorted).

[0167] In one embodiment or in combination with any of the embodiments mentioned herein, the pre-treatment facility 20 can also include a device or step to treat the waste plastics with a chemical composition having antimicrobial properties, thereby forming treated particulate plastic solids. In some embodiments, this can include treating the waste plastics with sodium hydroxide, a high pH salt solution (e.g., potassium carbonate), or other antimicrobial composition.

[0168] Additionally, in one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics (e.g., MPW) can optionally be washed to remove inorganic non-plastic solids, such as dirt, glass, fillers, and other non-plastic solid materials, and / or to remove biological components such as bacteria and / or food. The resulting washed waste plastics can also be dried to a moisture content of no more than 5, no more than 3, no more than 2, no more than 1, no more than 0.5, no more than 0.25 wt% water (or liquid) based on the total weight of the waste plastics. Drying can be performed in any suitable manner, including by heating and / or air flow, mechanical drying (e.g., centrifugation), or by allowing the liquid to evaporate over a specified time.

[0169] Separation

[0170] In one embodiment or in combination with any of the embodiments mentioned herein, the pre-treatment facility 20 or a step of the chemical recycling process or the chemical recycling facility 10 can include at least one separation step or separation zone. The separation step or separation zone can be configured to separate the waste plastics stream into two or more streams enriched in certain types of plastics. Such separation is particularly advantageous when the waste plastics fed to the pre-treatment facility 20 is MPW.

[0171] In one embodiment or in combination with any of the embodiments mentioned herein, the separation zone 22 (see Figure 2 ) of the pre-treatment facility 20 can separate the waste plastics (e.g., MPW) into streams enriched in Figure 2The PET-enriched stream 112 and the PET-depleted stream 114 are shown. As used herein, the term “enriched” refers to having a concentration (on an undiluted dry weight basis) of a particular component that is greater than the concentration of that component in a reference material or stream. As used herein, the term “depleted” refers to having a concentration (on an undiluted dry weight basis) of a particular component that is less than the concentration of that component in a reference material or stream. Unless otherwise specified, all weight percentages used herein are on an undiluted dry weight basis.

[0172] When the enriched or depleted component is a solid, the concentration is on an undiluted solid dry weight basis; when the enriched or depleted component is a liquid, the concentration is on an undiluted liquid dry weight basis; when the enriched or depleted component is a gas, the concentration is on an undiluted gas dry weight basis. In addition, enrichment and depletion can be expressed in terms of mass balance rather than concentration. Thus, a stream that is enriched in a particular component can have a greater mass of the component than the mass of the component in a reference stream (e.g., a feed stream or other product stream), and a stream that is depleted in a particular component can have a smaller mass of the component than the mass of the component in a reference stream (e.g., a feed stream or other product stream).

[0173] Referring again to FIG. 1 Figure 2 The PET concentration or mass of the PET-enriched stream 112 of waste plastics removed from the pre-treatment facility 20 (or separation zone 22) can be higher than the PET concentration or mass in the waste plastics feed stream 100 introduced to the pre-treatment facility 20 (or separation zone 22). Similarly, the PET-depleted stream 114 removed from the pre-treatment facility 20 (or separation zone 22) can be PET-depleted and have a lower PET concentration or mass than the PET concentration or mass in the waste plastics introduced to the pre-treatment facility 20 (or separation zone 22). The PET-depleted stream 114 can also be PO-enriched and have a higher PO concentration or mass than the concentration or mass of PO in the waste plastics (e.g., MPW) stream introduced to the pre-treatment facility 20 (or separation zone 22).

[0174] In one embodiment or in combination with any of the embodiments mentioned herein, the PET-enriched stream can be enriched in concentration or mass of PET relative to the concentration or mass of PET in the MPW stream or the PET-depleted stream or both on a solids dry basis, when the MPW stream 100 is fed to the pretreatment facility 20 (or separation zone 22). For example, if the PET-enriched stream is diluted with liquid or other solids after separation, the enrichment will be based on the concentration in the undiluted PET-enriched stream and on a dry basis. In one embodiment or in combination with any of the embodiments mentioned, the PET-enriched stream 112 has a percent PET enrichment of at least 10%, at least 20%, at least 40%, at least 50%, at least 60%, at least 80%, at least 100%, at least 125%, at least 150%, at least 175%, at least 200%, at least 225%, at least 250%, at least 300%, at least 350%, at least 400%, at least 500%, at least 600%, at least 700%, at least 800%, at least 900%, or at least 1000% relative to the MPW feed stream (PET enrichment % on feed basis), the PET-depleted product stream 114 (PET enrichment % on product basis), or both, determined by:

[0175]

[0176] and

[0177]

[0178] where PETe is the concentration of PET in the PET-enriched product stream 112 on an undiluted dry basis;

[0179] PETm is the concentration of PET in the MPW feed stream 100 on a dry basis; and

[0180] PETd is the concentration of PET in the PET-depleted product stream 114 on a dry basis.

[0181] In one embodiment or in combination with any of the embodiments mentioned herein, the PET-enriched stream is also enriched in halogens, such as fluorine (F), chlorine (CI), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, such as PVC, relative to the concentration or mass of halogens in the MPW feed stream 100 or the PET-depleted product stream 114, or both, when the stream 100 comprising MPW is fed to the pre-treatment facility 20 (or separation zone 22). In one embodiment or in combination with any of the embodiments mentioned, the PET-enriched stream 112 has a PVC enrichment percentage of at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 40%, at least 60%, at least 80%, at least 100%, at least 125%, at least 150%, at least 175%, at least 200%, at least 225%, at least 250%, at least 300%, at least 350%, at least 400%, at least 500%, relative to the MPW feed stream (PVC enrichment % based on feed), the PET-depleted product stream (PVC enrichment % based on product), or both, as determined by the following:

[0182]

[0183] and

[0184]

[0185] where PVCe is the concentration of PVC in the PET-enriched product stream 112, on an undiluted dry weight basis;

[0186] PVCm is the concentration of PVC in the MPW feed stream 100, on an undiluted dry weight basis; and

[0187] where PVCd is the concentration of PVC in the PET-depleted product stream 114, on an undiluted dry weight basis.

[0188] In one embodiment or in combination with any of the mentioned embodiments, the PET-depleted stream 114 is enriched in polyolefins relative to the concentration or mass of polyolefins in the MPW feed stream 100, the PET-enriched product stream 112, or both, on an undiluted solids dry weight basis when the MPW stream 100 is fed to the pretreatment facility 20 (or separation zone 22). In one embodiment or in combination with any of the mentioned embodiments, the polyolefin enrichment percentage of the PET-depleted stream 114 is at least 10%, at least 20%, at least 40%, at least 50%, at least 60%, at least 80%, at least 100%, at least 125%, at least 150%, at least 175%, at least 200%, at least 225%, at least 250%, at least 300%, at least 350%, at least 400%, at least 500%, at least 600%, at least 700%, at least 800%, at least 900%, or at least 1000% relative to the MPW feed stream 100 (PO enrichment % based on feed), or relative to the PET-enriched product stream 112 (PO enrichment % based on product), or both, as determined by the following equation:

[0189]

[0190] and

[0191]

[0192] where POd is the concentration of polyolefins in the PET-depleted product stream 114 on an undiluted dry weight basis;

[0193] POm is the concentration of PO in the MPW feed stream 100 on a dry basis; and

[0194] POe is the concentration of PO in the PET-enriched product stream 112 on a dry basis.

[0195] In one embodiment or in combination with any other embodiment, the PET-depleted stream 114 is also depleted in halogens, such as fluorine (F), chlorine (CI), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, such as PVC, relative to the concentration or mass of halogens in the MPW stream 100, the PET-enriched stream 112, or both, when the MPW stream 100 is fed to the pre-treatment facility 20 (or separation zone 22). In one embodiment or in combination with any of the mentioned embodiments, the percentage of PVC depletion of the PET-depleted stream 114 is at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90%, relative to the MPW feed stream 100 (PVC depletion % based on feed) or the PET-enriched product stream 112 (PVC depletion % based on product), determined by:

[0196]

[0197] and

[0198]

[0199] where PVCm is the concentration of PVC in the MPW feed stream 100, on an undiluted dry weight basis;

[0200] PVCd is the concentration of PVC in the PET-depleted product stream 114, on an undiluted dry weight basis; and

[0201] PVCe is the concentration of PVC in the PET-enriched product stream 112, on an undiluted dry weight basis.

[0202] The PET-depleted stream 114 is depleted in PET relative to the concentration or mass of PET in the MPW stream 100, the PET-enriched stream 112, or both. In one embodiment or in combination with any of the mentioned embodiments, the percentage of PET depletion of the PET-depleted stream 114 is at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90%, relative to the MPW feed stream 100 (PET depletion % based on feed) or the PET-enriched product stream 112 (PET depletion % based on product), determined by:

[0203]

[0204] and

[0205]

[0206] where PETm is the concentration of PET in the MPW feed stream 100 on an undiluted dry basis;

[0207] PETd is the concentration of PET in the PET depleted product stream 114 on an undiluted dry basis; and

[0208] PETe is the concentration of PET in the PET enriched product stream 112 on an undiluted dry weight basis.

[0209] The percentage enrichment or depletion in any of the embodiments described above can be an average over a week, or over 3 days, or over 1 day, and can be measured in a manner that reasonably relates the samples taken at the outlet of the process to the MPW as a whole in which the samples were taken, taking into account the residence time of the MPW from inlet to outlet. For example, if the average residence time of the MPW is 2 minutes, then the outlet samples are taken two minutes after the input samples, such that the samples are related to each other.

[0210] In one embodiment or in combination with any of the embodiments mentioned herein, the PET enriched stream that exits the separation zone 22 or the pre-treatment facility 20 can comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 97, at least 99, at least 99.5, or at least 99.9 wt% PET, based on the total weight of plastics in the PET enriched stream 112. The PET enriched stream 112 can also be enriched in PVC, and can include, for example, at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 5, and / or no more than 10, no more than 8, no more than 6, no more than 5, no more than 3 wt% halogen (including PVC), based on the total weight of plastics in the PET enriched stream, or it can be in the range of 0.1-10, 0.5-8, or 1-5 wt%, based on the total weight of plastics in the PET enriched stream. The PET enriched stream can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 99, or at least 99.5 wt% of the total amount of PET introduced into the pre-treatment facility 20 (or separation zone 22).

[0211] The PET-enriched stream 112 can also be depleted in PO and / or heavier plastics, such as polytetrafluoroethylene (PTFE), polyamide (PA 12, PA 46, PA 66), polyacrylamide (PARA), polyhydroxybutyrate (PHB), polycarbonate- polybutylene terephthalate blend (PC / PBT), polyvinyl chloride (PVC), polyimide (PI), polycarbonate (PC), polyether sulfone (PESU), polyether ether ketone (PEEK), polyamide-imide (PAI), polyethylenimine (PEI), polysulfone (PSU), polyoxymethylene (POM), polyglycolide (polyglycolic acid, PGA), polyphenylene sulfide (PPS), thermoplastic styrene elastomer (TPS), amorphous thermoplastic polyimide (TPI), liquid crystalline polymer (LCP), glass fiber reinforced PET, chlorinated polyvinyl chloride (CPVC), polybutylene terephthalate (PBT), polyphthalamide (PPA), polyvinylidene chloride (PVDC), ethylene tetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene (FEP), polychlorotrifluoroethylene (PCTFE), and perfluoroalkoxy (PFA), any of which can include carbon, glass, and / or mineral fillers, and have a density higher than PET and PVC.

[0212] In one embodiment or in combination with any of the embodiments mentioned herein, the PET-enriched stream 112 can include no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, no more than 1, no more than 0.5 wt% of PO, based on the total weight of plastics in the PET-enriched stream 112. The PET-enriched stream 112 can include no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, or no more than 1 wt% of the total amount of PO introduced into the pre-treatment facility 20 (or separation zone 22). The PET-enriched stream 112 can include no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, no more than 1 wt% of components other than PET, based on the total weight of the PET-enriched stream 112.

[0213] Additionally, or alternatively, the PET-enriched stream 112 can include no more than 2, no more than 1, no more than 0.5, or no more than 0.1 wt% of adhesives, on a dry basis. Typical adhesives include carpet glue, latex, styrene butadiene rubber, and the like. Additionally, the PET-enriched stream 112 can include no more than 4, no more than 3, no more than 2, no more than 1, no more than 0.5, or no more than 0.1 wt% of plastic fillers and solid additives, on a dry basis. Exemplary fillers and additives include silicon dioxide, calcium carbonate, talc, silica, glass, glass beads, alumina, and other solid inert materials that do not chemically react with the plastics or other components in the processes described herein.

[0214] In one embodiment or in combination with any of the embodiments mentioned herein, the PET-depleted (or PO-enriched) stream 114 exiting the separation zone 22 or the pre-treatment facility 20 can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 97, at least 99, or at least 99.5 wt% of PO, based on the total weight of plastics in the PET-depleted (or PO-enriched) stream. The PET-depleted (or PO-enriched stream) can be depleted in PVC, and can include, for example, no more than 5, no more than 2, no more than 1, no more than 0.5, no more than 0.1, no more than 0.05, or no more than 0.01 wt% of halogens, including chlorine in PVC, based on the total weight of plastics in the PET-depleted (or PO-enriched) stream. The PET-depleted or PO-enriched stream can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 99, or at least 99.9 wt% of the total amount of PO introduced into the pre-treatment facility 20 or the separation facility 22.

[0215] The PO-enriched stream 114 can also be depleted in PET and / or other plastics, including PVC. In one embodiment or in combination with any of the embodiments mentioned herein, the PET-depleted (or PO-enriched stream) can include no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, no more than 1, no more than 0.5 wt% of PET, based on the total weight of plastics in the PET-depleted or PO-enriched stream. The PO-enriched (or PET-depleted) stream 114 can include no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, or no more than 1 wt% of the total amount of PET introduced into the pre-treatment facility.

[0216] In one embodiment or in combination with any of the embodiments mentioned herein, the PET-depleted or PO-enriched stream 114 can comprise no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, no more than 1 wt% of components other than PO, based on the total weight of the PET-depleted or PO-enriched stream 114. The PET-depleted or PO-enriched stream 114 comprises no more than 4, no more than 2, no more than 1, no more than 0.5, no more than 0.1 wt% of a binding agent, based on the total weight of the stream.

[0217] In one embodiment or in combination with any of the embodiments mentioned herein, the PET-depleted or PO-enriched stream 114 can have a melt viscosity of at least 1, at least 5, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 600, at least 700, at least 800, at least 900, at least 1000, at least 1500, at least 2000, at least 2500, at least 3000, at least 3500, at least 4000, at least 4500, at least 5000, at least 5500, at least 6000, at least 6500, at least 7000, at least 7500, at least 8000, at least 8500, at least 9000, at least 9500, or at least 10,000 poise, measured using a Brookfield R / S Rheometer with a V80-40 paddle rotor, operated at a shear rate of 10 rad / s and a temperature of 350 °C. Alternatively, or additionally, the PET-depleted or PO-enriched stream can have a melt viscosity of no more than 25,000, no more than 24,000, no more than 23,000, no more than 22,000, no more than 21,000, no more than 20,000, no more than 19,000, no more than 18,000, or no more than 17,000 poise (measured at 10 rad / s and 350 °C). Alternatively, the stream can have a melt viscosity in the range of 1 to 25,000, 500 to 22,000, or 1000 to 17,000 poise (measured at 10 rad / s and 350 °C).

[0218] Any suitable type of separation device, system, or facility can be used to separate the waste plastic into two or more streams enriched in certain types of plastic, such as the PET-enriched stream 112 and the PO-enriched stream 114. Examples of suitable types of separation include mechanical separation and density separation, which can include sink-float separation and / or centrifugal density separation. As used herein, the term “sink-float separation” refers to a density separation process in which the separation of materials is primarily caused by floating or sinking in a selected liquid medium, while the term “centrifugal density separation” refers to a density separation process in which the separation of materials is primarily caused by centrifugal forces. In general, the term “density separation process” refers to a process in which materials are separated into at least a higher density output and a lower density output based at least in part on the respective densities of the materials, and includes sink-float separation and centrifugal density separation.

[0219] When sink-float separation is used, the liquid medium can include water. Salt, sugar, and / or other additives can be added to the liquid medium, for example, to increase the density of the liquid medium and to adjust the target separation density of the sink-float separation stage. The liquid medium can include a concentrated salt solution. In one or more such embodiments, the salt is sodium chloride. However, in one or more other embodiments, the salt is a non-halogenated salt, such as an acetate, carbonate, citrate, nitrate, nitrite, phosphate, and / or sulfate. The liquid medium can include a concentrated salt solution that includes sodium bromide, sodium phosphate monobasic, sodium hydroxide, sodium iodide, sodium nitrate, sodium thiosulfate, potassium acetate, potassium bromide, potassium carbonate, potassium hydroxide, potassium iodide, calcium chloride, cesium chloride, ferric chloride, strontium chloride, zinc chloride, manganese sulfate, zinc sulfate, and / or silver nitrate. In one embodiment or in combination with any embodiment mentioned herein, the salt is a caustic component. The salt can include sodium hydroxide, potassium hydroxide, and / or potassium carbonate. The pH of the concentrated salt solution can be greater than 7, greater than 8, greater than 9, or greater than 10.

[0220] In one embodiment or in combination with any embodiment mentioned herein, the liquid medium can include a sugar, such as sucrose. The liquid medium can include carbon tetrachloride, chloroform, dichlorobenzene, dimethyl sulfate, and / or trichloroethylene. The particular components and concentrations of the liquid medium can be selected according to the desired target separation density of the separation stage. Centrifugal density separation processes can also utilize liquid media as described above to improve separation efficiency at the target separation density.

[0221] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic separation process includes at least two density separation stages. In certain such embodiments, the process generally includes introducing waste plastic particles to a first density separation stage and feeding the output from the first density separation stage to a second density separation stage. A density separation stage can be any system or unit operation that performs a density separation process as defined herein. At least one of the density separation stages includes a centrifugal force separation stage or a sink-float separation stage. Each of the first and second density separation stages includes a centrifugal force separation stage and / or a sink-float separation stage.

[0222] To produce a PET-enriched material stream, one of the density separation stages can include a low density separation stage and the other generally includes a high density separation stage. As defined herein, the target separation density of a low density separation stage is less than the target separation density of a high density separation stage. The target separation density of a low density separation stage is less than the density of PET and the target separation density of a high density separation stage is greater than the density of PET.

[0223] As used herein, the term "target separation density" means that at a density above this value, material subjected to a density separation process separates preferentially into a higher density output and at a density below this value, the material separates in a lower density output. The target separation density specifies a density value where all plastics and other solid materials having a density above this value separate into a higher density output and all plastics and other solid materials having a density below this value separate into a lower density output. However, the actual separation efficiency of materials in a density separation process can depend on various factors including residence time and the relative closeness of a particular material's density to the target density separation value, as well as factors related to the form of the particles, such as area mass ratio, sphericity, and porosity.

[0224] In one embodiment or in combination with any of the embodiments mentioned herein, the target separation density of the low density separation stage is less than 1.35, less than 1.34, less than 1.33, less than 1.32, less than 1.31, or less than 1.30 g / cc and / or at least 1.25, at least 1.26, at least 1.27, at least 1.28, or at least 1.29 g / cc. The target separation density of the high density separation stage is at least 0.01, at least 0.025, at least 0.05, at least 0.075, at least 0.1, at least 0.15, or at least 0.2 g / cc greater than the target separation density of the low density separation stage. The target separation density of the high density separation stage is at least 1.31, at least 1.32, at least 1.33, at least 1.34, at least 1.35, at least 1.36, at least 1.37, at least 1.38, at least 1.39, or at least 1.40 g / cc and / or no more than 1.45, no more than 1.44, no more than 1.43, no more than 1.42, or no more than 1.41 g / cc. The target separation density of the low density separation stage is in the range of 1.25 to 1.35 g / cc and the target separation density of the high density separation stage is in the range of 1.35 to 1.45 g / cc.

[0225] Referring again to FIG. 1 Figure 1 The PET-rich stream 112 and the PO-rich stream 114 can be introduced into one or more downstream processing facilities (or subjected to one or more downstream processing steps) within the chemical recycling facility 10. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PET-rich stream 112 can be introduced into the solvolysis facility 30, while at least a portion of the PO-rich stream 114 can be introduced directly or indirectly into one or more of the pyrolysis facility 60, the cracking facility 70, the partial oxidation (POX) gasification facility 50, the energy recovery facility 80, or other facility 90 (such as a solidification or separation facility). Additional details for each of the steps and facility types, as well as the general integration of each of these steps and facilities with one or more of the other steps and facilities, according to one or more embodiments of the present technology, will be discussed in further detail below.

[0226] Solvolysis

[0227] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PET-rich stream 112 from the pre-treatment facility 20 can be introduced into the solvolysis facility 30. As used herein, the term “solvolysis” or “ester solvolysis” refers to a reaction in which an ester-containing feed is chemically decomposed in the presence of a solvent to form a major carboxyl product and a major diol product. A “solvolysis facility” is a facility that includes all equipment, piping, and control devices necessary to solvolyze waste plastics and feedstocks derived therefrom.

[0228] When the ester undergoing solvolysis comprises PET, the solvolysis performed in the solvolysis facility can be PET solvolysis. As used herein, the term “PET solvolysis” refers to a reaction in which a polyterephthalate-containing feed is chemically decomposed in the presence of a solvent to form a major terephthaloyl product and a major diol product. As used herein, the term “major terephthaloyl” refers to the major or key terephthaloyl product withdrawn from the solvolysis facility. As used herein, the term “major diol” refers to the major diol product withdrawn from the solvolysis facility. As used herein, the term “diol” refers to a component that comprises two or more -OH functional groups per molecule. As used herein, the term “terephthaloyl” refers to a molecule comprising the following group:

[0229]

[0230] In one embodiment or in combination with any of the embodiments mentioned herein, the major terephthaloyl product comprises terephthaloyl, such as terephthalic acid or dimethyl terephthalate (or oligomers thereof), and the major diol comprises a diol, such as ethylene glycol and / or diethylene glycol. The major steps of a PET solvolysis facility 30 according to one or more embodiments of the present technology are generally illustrated in Figure 3

[0231] In one embodiment or in combination with any of the embodiments mentioned herein, the major solvent used in the solvolysis comprises a compound having at least one -OH group. Examples of suitable solvents can include, but are not limited to: (i) water (in which case the solvolysis can be referred to as “hydrolysis”), (ii) an alcohol (in which case the solvolysis can be referred to as “alcoholysis”), such as methanol (in which case the solvolysis can be referred to as “methanolysis”) or ethanol (in which case the solvolysis can be referred to as “ethanolysis”), (iii) a diol, such as ethylene glycol or diethylene glycol (in which case the solvolysis can be referred to as “diolysis”), or (iv) ammonia (in which case the solvolysis can be referred to as “ammonolysis”).

[0232] In one embodiment or in combination with any of the embodiments mentioned herein, the solvolysis solvent can comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least, or at least 99 wt% of the major solvent, based on the total weight of the solvent stream. In one embodiment or in combination with any of the embodiments mentioned herein, the solvent can comprise no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of other solvents or components, based on the total weight of the solvent stream.

[0233] ​When solvent decomposition facility 30 uses a glycol (e.g., ethylene glycol) as the primary solvent, the facility may be referred to as a glycol decomposition facility. In one embodiment or in combination with any of the embodiments mentioned herein, Figure 1 Chemical recycling facilities may include glycol decomposition facilities. In a glycol decomposition facility, PET can be chemically decomposed to form ethylene glycol (EG) as the main glycol and dimethyl terephthalate (DMT) as the main terephthaloyl group. When the PET contains waste plastics, both the EG and DMT formed in the solvent decomposition facility can contain recycled ethylene glycol (r-EG) and recycled dimethyl terephthalate (r-DMT). When formed via glycol decomposition, EG and DMT can exist in a single product stream.

[0234] When a solvent decomposition facility uses methanol as the primary solvent, it can be called a methanol decomposition facility. Figure 1 Chemical recovery facilities may include methanol decomposition facilities. One example of a methanol decomposition facility is... Figure 3 The diagram schematically depicts that PET can be chemically decomposed to form ethylene glycol (EG) as the main diol and dimethyl terephthalate (DMT) as the main terephthaloyl group. When PET contains waste plastics, both EG and DMT formed in the solvent decomposition facility can contain recycled components of ethylene glycol (r-EG) and dimethyl terephthalate (r-DMT).

[0235] In one embodiment or in combination with any of the embodiments mentioned herein, the stream 154 of recovered component diol (r-diol) removed from solvent decomposition facility 30 may contain at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of the primary diol formed in the solvent decomposition facility. Based on the total weight of the stream, it may also include no more than 99.9%, no more than 99%, no more than 95%, no more than 90%, no more than 85%, no more than 80%, or no more than 75 wt% of a major diol (e.g., r-EG), and / or may include at least 0.5%, at least 1%, at least 2%, at least 5%, at least 7%, at least 10%, at least 12%, at least 15%, at least 20%, or at least 25 wt% and / or no more than 45%, at least 40%, at least 35%, at least 30%, at least 25%, at least 20%, or no more than 15 wt% of components other than the major diol, or, based on the total weight of the stream, these may be present in amounts ranging from 0.5 wt% to 45 wt%, 1 wt% to 40 wt%, or 2 wt% to 15 wt%. Based on the total weight of stream 154, r-diol may be present in stream 154 in amounts ranging from 45 wt% to 99.9 wt%, 55 wt% to 99.9 wt%, or 80 wt% to 99.9 wt%.

[0236] In one embodiment or in combination with any of the embodiments mentioned herein, the recovered content primarily terephthaloyl (r-terephthaloyl) stream 158 removed from the solvolysis facility can comprise at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of the primarily terephthaloyl (e.g., DMT) formed in the solvolysis facility 30. It can also include no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, or no more than 75 wt% of the primarily terephthaloyl, based on the total weight of the stream, or the primarily terephthaloyl can be present in an amount ranging from 45 wt% to 99 wt%, 50 wt% to 95 wt%, or 55 wt% to 90 wt%. Additionally, or alternatively, the stream can include at least 0.5, at least 1, at least 2, at least 5, at least 7, at least 10, at least 12, at least 15, at least 20, or at least 25 wt% and / or no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, or no more than 15 wt% of components other than the primary terephthaloyl, based on the total weight of the stream. The r-terephthaloyl (or terephthaloyl) can be present in the stream 154 in an amount ranging from 45 wt% to 99.9 wt%, 55 wt% to 99.9 wt%, or 80 wt% to 99.9 wt%, based on the total weight of the stream 154.

[0237] In addition to providing a recovered content primarily glycol stream, a recovered content primarily terephthaloyl stream, the solvolysis facility can also provide one or more solvolysis byproduct streams, such as Figure 1 As shown in stream 110 in FIG. 1, these streams can also be removed from one or more locations within the solvolysis facility. As used herein, the term “byproduct” or “solvolysis byproduct” refers to any compound from the solvolysis facility that is not the primary carboxyl (or terephthaloyl) product of the solvolysis facility, the primary glycol product of the solvolysis facility, or the primary solvent fed to the solvolysis facility. The solvolysis byproduct stream can comprise at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of one or more solvolysis byproducts, based on the total weight of the stream.

[0238] The solvolysis byproducts can comprise a heavy organic solvolysis byproduct stream or a light organic solvolysis byproduct stream. As used herein, the term “heavy organic solvolysis byproduct” refers to a solvolysis byproduct having a boiling point higher than the boiling point of the primary terephthaloyl product of the solvolysis facility, while the term “light organic solvolysis byproduct” refers to a solvolysis byproduct having a boiling point lower than the boiling point of the primary terephthaloyl product of the solvolysis facility.

[0239] When the solventysis facility is a methanolysis facility, one or more methanolysis byproducts can be removed from the facility. As used herein, the term "methanolysis byproduct" refers to any compound from a methanolysis facility that is not DMT, EG, or methanol. The methanolysis byproduct stream can include at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of one or more solventysis byproducts, based on the total weight of the stream. In one embodiment or in combination with any embodiment mentioned herein, the methanolysis byproduct stream can include heavy organic methanolysis byproducts or light organic methanolysis byproducts. As used herein, the term "heavy organic methanolysis byproduct" refers to a methanolysis byproduct having a boiling point higher than DMT, while the term "light methanolysis byproduct" refers to a methanolysis byproduct having a boiling point lower than DMT.

[0240] In one embodiment or in combination with any embodiment mentioned herein, the solventysis facility can produce at least one stream of heavy organic solventysis byproducts. The stream of heavy organic solventysis byproducts can include at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of organic compounds having a boiling point higher than the boiling point of the primary terephthaloyl (e.g., DMT) produced by the solventysis facility 30, based on the total weight of the organic compounds in the stream.

[0241] Additionally, or alternatively, the solventysis facility can produce at least one stream of light organic solventysis byproducts. The stream of light organic solventysis byproducts can include at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of organic compounds having a boiling point lower than the boiling point of the primary terephthaloyl (e.g., DMT) produced by the solventysis facility 30, based on the total weight of the organic compounds in the stream.

[0242] Turning again to Figure 3In operation, the mixed plastic waste stream and solvent introduced (alone or together) into the solvent decomposition facility can first be conveyed through an optional non-PET separation zone 208, in which at least 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 wt% of the total weight of components other than PET are separated. The boiling point of the non-PET components may be lower than that of PET and they can be removed as vapor from zone 208. Alternatively, or additionally, at least a portion of the non-PET components may have a density slightly higher or lower than that of PET and can be separated by forming a two-phase liquid stream and then removing one or both non-PET phases. Finally, in some embodiments, the non-PET components may be separated as solids from the PET-containing liquid phase.

[0243] In one embodiment or in combination with any embodiment mentioned herein, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the non-PET component separated from the PET-containing stream comprises a polyolefin, such as polyethylene and / or polypropylene. Figure 3 As generally indicated by the dashed lines, all or part of the non-PET separation zone 208 may be located upstream of the reaction zone 210, and all or part of the non-PET separation zone 208 may also be located downstream of the reaction zone 210. Separation techniques such as extraction, solid / liquid separation, decantation, hydrocyclone or centrifugation, manual removal, magnetic removal, eddy current removal, chemical degradation, evaporation and degassing, distillation, and combinations thereof may be used to separate non-PET components from the PET-containing stream in the non-PET separation zone 208.

[0244] like Figure 3 As shown, based on the total weight of the PET-containing stream, the PET-containing stream 138 exiting the non-PET separation zone 208 may contain no more than 25, 20, 15, 10, 5, 2, 1, or 0.5 wt% of components other than PET (or its oligomer and monomer degradation products) and solvents. The PET-containing stream 138 exiting the non-PET separation zone 208 may contain no more than 25, 20, 15, 10, 5, 2, or 1 wt% of other types of plastics (e.g., polyolefins). The PET-containing stream 138 exiting the non-PET separation zone 208 may include no more than 45, 40, 35, 30, 25, 20, 10, 5, or 2 wt% of the total amount of non-PET components introduced into the non-PET separation zone 208.

[0245] Non-PET components can be removed from the solvent decomposition (or methanol decomposition) facility 30 as a byproduct stream 140 containing polyolefins, such as...Figure 3 The polyolefin-containing byproduct stream (or decanter olefin byproduct stream) 140 can comprise at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, at least 99, or at least 99.5 wt% polyolefin, based on the total weight of the byproduct stream 140.

[0246] The polyolefin present in the polyolefin-containing byproduct stream 140 can comprise polyethylene, polypropylene, or a combination of polyethylene and polypropylene. The polyolefin in the polyolefin-containing byproduct stream comprises at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 94, at least 95, at least 97, at least 98, or at least 99 wt% polyethylene, based on the total weight of the polyolefin in the polyolefin-containing byproduct stream 140. Alternatively, the polyolefin in the polyolefin-containing byproduct stream comprises at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 94, at least 95, at least 97, at least 98, or at least 99 wt% polypropylene, based on the total weight of the polyolefin in the polyolefin-containing byproduct stream 140.

[0247] The polyolefin-containing byproduct stream comprises no more than 10, no more than 5, no more than 2, no more than 1, no more than 0.75, no more than 0.50, no more than 0.25, no more than 0.10, or no more than 0.05 wt% PET, based on the total weight of the polyolefin-containing byproduct stream 140. Additionally, the polyolefin-containing byproduct stream comprises at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, or at least 1.5 and / or no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, or no more than 2 wt% of components other than polyolefin, based on the total weight of the polyolefin-containing byproduct stream 140.

[0248] In general, the polyolefin-containing byproduct stream 140 comprises at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% organic compounds, based on the total weight of the polyolefin-containing byproduct stream 140. The polyolefin-containing byproduct stream 140 can comprise at least 0.5, at least 1, at least 2, at least 3, at least 5, at least 10, or at least 15 and / or no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, or no more than 1 wt% inorganic components, based on the total weight of the polyolefin-containing byproduct stream 140.

[0249] ​The polyolefin-containing byproduct stream can include at least 0.1, at least 0.5, at least 1, at least 1.5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, at least 5, at least 8, at least 10, at least 12, at least 15, at least 18, at least 20, at least 22, or at least 25 wt% and / or not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, or not more than 2 wt% of one or more non-reactive solids, based on the total weight of the polyolefin-containing byproduct stream 140. Non-reactive solids refer to solid components that do not chemically react with PET. Examples of non-reactive solids include, but are not limited to, sand, dirt, glass, plastic fillers, and combinations thereof.

[0250] The polyolefin-containing byproduct stream 140 includes one or more fillers in an amount of at least 100, at least 250, at least 500, at least 750, at least 1000, at least 1500, at least 2000, at least 2500, at least 5000, at least 7500 ppm by weight, or at least 1, at least 1.5, at least 2, at least 5, at least 10, at least 15, at least 20, or at least 25 wt%, and / or not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, not more than 2, or not more than 1 wt%, based on the total weight of the polyolefin-containing byproduct stream 140. The polyolefin-containing byproduct stream 140 can include fillers in an amount ranging from 100 ppm to 50 wt%, 500 ppm to 10 wt%, or 1000 ppm to 5 wt%.

[0251] Examples of fillers can include, but are not limited to, thixotropic agents such as silica microsilica and clay (kaolin), pigments, colorants, flame retardants such as aluminum trihydrate, bromine-based, chlorine-based, borate-based, and phosphorus-based, inhibitors such as wax-based materials, UV inhibitors, or stabilizers, conductive additives such as metal particles, carbon particles, or conductive fibers, mold release agents such as zinc stearate, waxes, and silicones, calcium carbonate, and calcium sulfate.

[0252] In one embodiment or in combination with any of the embodiments mentioned herein, the polyolefin-containing byproduct stream 140 can have a density of at least 0.75, at least 0.80, at least 0.85, at least 0.90, at least 0.95, at least 0.99, and / or not more than 1.5, not more than 1.4, not more than 1.3, not more than 1.2, not more than 1.1, not more than 1.05, or not more than 1.01 g / cm3. 3 The density can be from 0.80 to 1.4, from 0.90 to 1.2, or from 0.95 to 1.1 g / cm3. 3When removed from the non-PET separation zone 208, the polyolefin-containing byproduct stream 140 can have a temperature of at least 200, at least 205, at least 210, at least 215, at least 220, at least 225, at least 230, or at least 235 °C and / or not more than 350, not more than 340, not more than 335, not more than 330, not more than 325, not more than 320, not more than 315, not more than 310, not more than 305, or not more than 300 °C. The polyolefin-containing byproduct stream 140 can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of components having a boiling point higher than the primary terephthalyl or DMT, based on the total weight of the stream.

[0253] As discussed in further detail herein, all or a portion of the polyolefin-containing byproduct stream can be introduced into one or more downstream chemical recycling facilities, either alone or with one or more other byproduct streams, streams obtained from one or more other downstream chemical recycling facilities, and / or waste plastic streams (including unprocessed, partially processed, and / or processed mixed plastic waste).

[0254] Turning again to FIG. 1, the polyolefin-containing byproduct stream 140 can be introduced into a non-PET separation zone 208, which can be upstream of a reaction zone 210. In some embodiments, the non-PET separation zone 208 can be a separation zone that separates the polyolefin-containing byproduct stream 140 from other components of the stream 140, such as the primary terephthalyl or DMT. In some embodiments, the non-PET separation zone 208 can be a separation zone that separates the polyolefin-containing byproduct stream 140 from other components of the stream 140, such as the primary terephthalyl or DMT, and / or other components of the stream 140, such as the PET and / or its degradation products. In some embodiments, the non-PET separation zone 208 can be a separation zone that separates the polyolefin-containing byproduct stream 140 from other components of the stream 140, such as the primary terephthalyl or DMT, and / or other components of the stream 140, such as the PET and / or its degradation products, and / or other components of the stream 140, such as the waste plastic stream (including unprocessed, partially processed, and / or processed mixed plastic waste). Figure 3 The PET-containing stream 138 (which includes dissolved PET and its degradation products) that exits the non-PET separation zone 208 (upstream of the reaction zone 210) can then be transferred to the reaction zone 210, where at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the PET introduced into the reaction zone decomposes. In some embodiments, the reaction medium within the reaction zone 210 can be agitated or stirred, and one or more temperature control devices (such as heat exchangers) can be used to maintain a target reaction temperature. In one embodiment or in combination with any of the embodiments mentioned herein, the target reaction temperature in the reaction zone 210 can be at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85 °C and / or not more than 350, not more than 345, not more than 340, not more than 335, not more than 330, not more than 325, not more than 320, not more than 315, not more than 310, not more than 300, or not more than 295 °C.

[0255] In an embodiment or in combination with any of the embodiments herein, the solvolysis process can be a low pressure solvolysis process, and the pressure in the solvolysis reactor (or reaction zone) 210 can be within 5, within 10, within 15, within 20, within 25, within 30, within 35, within 40, within 45, or within 50 psi of atmospheric pressure, or it can be within 55, within 75, within 90, within 100, within 125, within 150, within 200, or within 250 psi of atmospheric pressure. The pressure in the solvolysis reactor (or reaction zone) 210 can be within 0.35, within 0.70, within 1, within 1.4, within 1.75, within 2, within 2.5, within 2.75, within 3, within 3.5, within 3.75, within 5, or within 6.25 bar gauge (bar) of atmospheric pressure and / or no more than 6.9, no more than 8.6, or no more than 10.35 bars. The pressure in the solvolysis reactor (or reaction zone) 210 can be at least 100 psig (6.7 barg), at least 150 psig (10.3 barg), at least 200 psig (13.8 barg), at least 250 psig (17.2 barg), at least 300 psig (20.7 barg), at least 350 psig (24.1 barg), at least 400 psig (27.5 barg), and / or no more than 725 psig (50 barg), no more than 650 psig (44.7 barg), no more than 600 psig (41.3 barg), no more than 550 psig (37.8 barg), no more than 500 psig (34.5 barg), no more than 450 psig (31 barg), no more than 400 psig (27.6 barg), or no more than 350 psig (24.1 barg).

[0256] In an embodiment or in combination with any of the embodiments mentioned herein, the solvolysis process conducted in reaction zone 210 or facility 30 can be a high pressure solvolysis process, and the pressure in the solvolysis reactor can be at least 50 barg (725 psig), at least 70 barg (1015 psig), at least 75 barg (1088 psig), at least 80 barg (1161 psig), at least 85 barg (1233 psig), at least 90 barg (1307 psig), at least 95 barg (1378 psig), at least 100 barg (1451 psig), at least 110 barg (1596), at least 120 barg (1741 psig), or at least 125 barg (1814 psig) and / or no more than 150 barg (2177 barg), no more than 145 barg (2104), no more than 140 barg (2032 psig), no more than 1959 barg (1959), no more than 130 barg (1886 psig), or no more than 125 barg (1814 psig).

[0257] In an embodiment or in combination with any of the embodiments mentioned herein, the average residence time of the reaction medium in reaction zone 210 can be at least 1, at least 2, at least 5, at least 10, or at least 15 minutes and / or no more than 12, no more than 11, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, or no more than 4 hours. At least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the total weight of PET introduced into the solvolysis or methanolysis facility 30 can be decomposed when exiting reaction zone 210 in reactor effluent stream 144.

[0258] In an embodiment or in combination with any of the embodiments mentioned herein, reactor purge stream 142 can be removed from reaction zone 210, and at least a portion can be passed to one or more downstream facilities within chemical recycling facility 10 as reactor purge byproduct stream 142. The boiling point of reactor purge byproduct stream 142 can be higher than the boiling point of the primary terephthalyl (or DMT in the case of methanolysis) produced from solvolysis facility 30.

[0259] In one embodiment or in combination with any of the embodiments described herein, the reactor purge byproduct stream 142 comprises at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of the primary terephthaloyl groups, based on the total weight of stream 142. When the solventysis facility is a methanolysis facility, the reactor purge byproduct stream 142 can comprise at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of DMT, based on the total weight of stream 142.

[0260] In addition, the reactor purge byproduct stream 142 can include at least 100 ppm and no more than 25 wt% of one or more non-terephthaloyl solids, based on the total weight of stream 142. In one embodiment or in combination with any of the embodiments mentioned herein, the total amount of non-terephthaloyl solids in the reactor purge byproduct stream 142 can be at least 150, at least 200, at least 250, at least 300, at least 350, at least 400, at least 500, at least 600, at least 700, at least 800, at least 900, at least 1000, at least 1500, at least 2000, at least 2500, at least 3000, at least 3500, at least 4000, at least 4500, at least 5000, at least 5500, at least 6000, at least 7000, at least 8000, at least 9000, at least 10,000, or at least 12,500 ppm and / or no more than 25, no more than 22, no more than 20, no more than 18, no more than 15, no more than 12, no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, or no more than 1 wt%, based on the total weight of stream.

[0261] In one embodiment or in combination with any of the embodiments herein, the reactor purge byproduct stream 142 has a total solids content of at least 100, at least 250, at least 500, at least 750, at least 1000, at least 1500, at least 2000, at least 2500, at least 3000, at least 3500, at least 4000, at least 4500, at least 5000, at least 5500, at least 6000, at least 6500, at least 7000, at least 7500, at least 8000, at least 8500, at least 9000, at least 9500 ppm (ppm by weight) or at least 1, at least 2, at least 5, at least 8, at least 10, or at least 12 wt% and / or not more than 25, not more than 22, not more than 20, not more than 17, not more than 15, not more than 12, not more than 10, not more than 8, not more than 6, not more than 5, not more than 3, not more than 2, or not more than 1 wt% or not more than 7500, not more than 5000, not more than 2500 ppm (ppm by weight) based on the total weight of the stream.

[0262] Examples of solids can include, but are not limited to, non-volatile catalyst compounds. In one embodiment or in combination with any of the embodiments herein, the reactor purge byproduct stream can include at least 100, at least 250, at least 500, at least 750, at least 1000, at least 1500, at least 2000, at least 2500, at least 3000, at least 3500, at least 4000, at least 4500, at least 5000, at least 7500, at least 10,000, or at least 12,500 ppm and / or not more than 60,000, not more than 50,000, not more than 40,000, not more than 35,000, not more than 30,000, not more than 25,000, not more than 20,000, not more than 15,000, or not more than 10,000 ppm of non-volatile catalyst metals.

[0263] Examples of suitable non-volatile catalyst metals can include, but are not limited to, titanium, zinc, manganese, lithium, magnesium, sodium, methanolate, alkali metals, alkaline earth metals, tin, residual esterification or transesterification catalysts, residual polycondensation catalysts, aluminum, depolymerization catalysts, and combinations thereof. As discussed in further detail herein, all or a portion of the reactor purge byproduct stream 142 can be introduced into one or more downstream chemical recycling facilities, either alone or with one or more other byproduct streams, streams resulting from one or more other downstream chemical recycling facilities, and / or waste plastic streams, including unprocessed, partially processed, and / or processed mixed plastic waste.

[0264] In one embodiment or in combination with any of the embodiments herein, as Figure 3As generally indicated, the effluent stream 144 from reaction zone 210 in solvent decomposition facility 30 may optionally be fed through a non-PET separation zone 208 located downstream of the reactor, as previously discussed. The resulting effluent stream 144 from the reactor or (if present) from the non-PET separation zone 208 may be conveyed through product separation zone 220, whereby at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of heavy organic material is separated from the feed stream 144 to form a stream primarily composed of light organic material 146 and a stream primarily composed of heavy organic material 148. Any suitable method for separating these streams may be used, including, for example, distillation, extraction, decantation, crystallization, membrane separation, solid / liquid separation such as filtration (e.g., belt filter), and combinations thereof.

[0265] like Figure 3 As shown, a heavy organic stream 148 extracted from product separation zone 220 can be introduced into heavy organic matter separation zone 240. Based on the total weight of the stream, this heavy organic stream may include, for example, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% heavy organic components. In heavy organic matter separation zone 240, a predominantly terephthaloyl product stream 158 can be separated from a terephthaloyl bottom or “sludge” byproduct stream 160. This separation can be achieved by, for example, distillation, extraction, decantation, membrane separation, melt crystallization, zone purification, and combinations thereof. As a result, based on the total weight of the stream, stream 158 contains at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% predominantly terephthaloyl (or DMT). In one embodiment or in combination with any of the embodiments mentioned herein, at least some or all of the major terephthaloyl group may comprise a recycled terephthaloyl group (r-terephthaloyl group), such as the recycled DMT (r-DMT).

[0266] Also removed from the heavy organic matter separation zone 240 is the terephthaloyl bottom by-product stream (also known as the "terephthaloyl tower bottom by-product stream," "terephthaloyl sludge by-product stream," or "terephthaloyl residue by-product stream"). By-product stream 160 can also be removed from the heavy organic matter separation zone 240. When the solvent decomposition facility is a methanol decomposition facility, this stream can be referred to as the DMT bottom by-product stream, DMT tower bottom by-product stream, DMT sludge by-product stream, or DMT residue stream.

[0267] In an embodiment or in combination with any of the embodiments herein, the byproduct stream can include, for example, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, at least 98, at least 99, or at least 99.5 wt% of oligomers, based on the total weight of the composition (e.g., PET oligomers), the oligomers comprising portions of the polyester subjected to solvolysis. As used herein, the term “portions of polyester” or “portions of polyester” refers to portions or residues of a polyester, or reaction products of portions or residues of a polyester. The number average chain length of these oligomers can be at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8 monomeric units (acid + diol) and / or no more than 30, no more than 27, no more than 25, no more than 22, no more than 20, no more than 17, no more than 15, no more than 12, or no more than 10 monomeric units (acid + diol), and can include portions of the polyester (e.g., PET) being treated.

[0268] In an embodiment or in combination with any of the embodiments described herein, the terephthaloyl bottoms (or DMT bottoms) byproduct stream 160 can include oligomers and at least one substituted terephthaloyl component. As used herein, the term “substituted terephthaloyl” refers to a terephthaloyl component having at least one substituted atom or group. The terephthaloyl bottoms byproduct stream 160 can include, based on the total weight of the terephthaloyl bottoms byproduct stream 160, at least 1, at least 100, at least 500 ppb (ppb, parts per billion), or at least 1, at least 50, at least 1000, at least 2500, at least 5000, at least 7500, or at least 10,000 ppm (ppm, parts per million) by weight, or at least 1, at least 2, or at least 5 wt% and / or no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, no more than 1, no more than 0.5, no more than 0.1, no more than 0.05, or no more than 0.01 wt% of substituted terephthaloyl components.

[0269] As discussed in further detail herein, all or a portion of the terephthaloyl bottoms byproduct stream 160 can be introduced into one or more downstream chemical recycling facilities, either alone or with one or more other byproduct streams, streams obtained from one or more other downstream chemical recycling facilities, and / or waste plastic streams (including unprocessed, partially processed, and / or processed mixed plastic waste).

[0270] Referring again to Figure 3The stream 146, which is primarily light organics from the product separation zone 220, can be introduced to a light organics separation zone 230. In the light organics separation zone 230, the stream 146 can be separated to remove the primary solvent (e.g., methanol in a methanolysis) and to separate the primary diol (e.g., ethylene glycol in a methanolysis) from organic byproducts (or multiple byproducts) that are lighter and heavier than the primary diol.

[0271] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent stream 150 taken from the light organics separation zone 230 can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of the primary solvent, based on the total weight of the stream 150. When the solventysis facility 30 is a methanolysis facility, the stream 150 can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of methanol, based on the total weight of the stream. All or a portion of the stream can be recovered back into the solventysis facility at one or more locations for further use.

[0272] In one embodiment or in combination with any of the embodiments mentioned herein, at least one light organics solventysis byproduct stream 152 (also referred to as a “light organics” stream) can also be taken from the light organics separation zone 230 and can include at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of components having a boiling point lower than the boiling point of the primary terephthaloyl group (or DMT) that are not the primary diol (or ethylene glycol) or the primary solvent (or methanol). Additionally, or alternatively, the byproduct stream can include no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 3, no more than 2, no more than 1 wt% of components having a boiling point higher than the boiling point of DMT, and the stream 152 itself can have a boiling point lower than the boiling point of the primary terephthaloyl group (or DMT).

[0273] In one embodiment or in combination with any of the embodiments herein, the light organics solvolysis byproduct stream 152 can be produced in a solvolysis facility that includes a primary solvent (e.g., methanol). For example, the light organics byproduct stream 152 can include at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, or at least 55 wt% and / or not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, or not more than 30 wt% of the primary solvent.

[0274] Further, the byproduct stream 152 can also include acetaldehyde in an amount of at least 1, at least 5, at least 10, at least 50, at least 100, at least 250, at least 500, at least 750, or at least 1000 ppm and / or not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, not more than 3, not more than 2, not more than 1, not more than 0.5, not more than 0.1, or not more than 0.05 wt% based on the total weight of the byproduct stream, or acetaldehyde can be present in an amount of 1 ppm to 50 wt%, 50 ppm to 0.5 wt%, or 100 ppm to 0.05 wt% based on the total weight of the byproduct stream.

[0275] Further, the light organics byproduct stream 152 can also include 1,4-dioxane (para-dioxane or p-dioxane) in an amount of at least 1, at least 5, at least 10, at least 50, at least 100, at least 250, at least 500, at least 750, or at least 1000 ppm and / or not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, not more than 3, not more than 2, not more than 1, not more than 0.5, not more than 0.1, or not more than 0.05 wt% based on the total weight of the byproduct stream, or 1,4-dioxane can be present in an amount of 1 ppm to 50 wt%, 50 ppm to 0.5 wt%, or 100 ppm to 0.05 wt% based on the total weight of the byproduct stream.

[0276] The light organics byproduct stream 152 can further include at least one additional component selected from the group consisting of tetrahydrofuran (THF), methyl acetate, silicates, 2,5-methyldioxolane, 1,4-cyclohexanedimethanol, 2-ethyl-1- hexanol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, 2,2,4-trimethyl-3-pentenal, 2,2,4- trimethyl-3-pentenol, 2,2,4-trimethylpentane, 2,4-dimethyl-3-pentanone (DIPK), isobutyl isobutyrate, methyl formate, n-butanol, acetic acid, dibutyl ether, heptane, dibutyl terephthalate, dimethyl phthalate, dimethyl 1,4-cyclohexanedicarboxylate, 2-methoxyethanol, 2-methyl-1,3-dioxolane, 1,1-dimethoxy-2-butene, 1,1-dimethoxyethane, 1,3-propanediol, 2,5-dimethyl-1,3,5-hexatriene, 2,5-dimethyl-2,4-hexadiene, alpha-methylstyrene, diethylene glycol methyl ether, diethylene glycol formal, dimethoxydimethylsilane, dimethyl ether, diisopropyl ketone, EG benzoate, hexamethylcyclotrisiloxane, hexamethyldisiloxane, methoxytrimethylsilane, methyl 4-ethylbenzoate, methyl octanoate, methyl glycolate, methyl lactate, methyl laurate, methyl methoxyethyl terephthalate, methyl nonanoate, methyl oleate, methyl palmitate, methyl stearate, methyl 4-acetylbenzoate, octamethylcyclotetrasiloxane, styrene, trimethylsilanol, 1,1-dimethoxy-2-butene, 4-methylmorpholine, 1,3,3-trimethoxypropane, methyl myristate, dimethyl adipate, N-methyl caprolactam, dimethyl azelate, neopentyl glycol, and combinations thereof.

[0277] As discussed in further detail herein, all or a portion of one or more light organics byproduct streams can be introduced into one or more downstream chemical recycling facilities, alone or with one or more other byproduct streams, streams obtained from one or more other downstream chemical recycling facilities, and / or waste plastic streams, including mixed plastic waste (unprocessed, partially processed, and / or processed).

[0278] Additionally, the stream primarily comprising the major diol 154 can also be withdrawn from the light organic matter separation zone 230. In one embodiment or in combination with any of the embodiments mentioned herein, the stream of major diol 154 (e.g., ethylene glycol) may comprise at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of the major diol based on the total weight of the stream. The major diol stream 154 may also include a recovered component, such that the recovered component of the major diol product stream 154 is at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% based on the total weight of the stream. The major diol (or ethylene glycol) may include γ-diol (or γ-ethylene glycol).

[0279] like Figure 1 As shown, the bottom byproduct stream 156 containing diols can also be taken from the light organic matter separation zone 230. The terms "diol bottoms" or "diol sludge" (or, more specifically, EG bottoms or EG sludge in methanol decomposition) refer to components with a boiling point (or azeotropic point) higher than that of the major diol but lower than that of the major terephthaloyl group.

[0280] In one embodiment or in combination with any embodiment mentioned herein, the glycol bottom byproduct stream 156 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of a component with a boiling point higher than that of the major glycol (e.g., ethylene glycol) and lower than that of the major terephthaloyl group. The glycol bottom byproduct stream 156 may contain no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of a component with a boiling point lower than that of the major glycol (e.g., ethylene glycol). The boiling point of the glycol bottom byproduct stream 156 may be higher than that of the major glycol (e.g., EG) and lower than that of the major terephthaloyl group (e.g., DMT).

[0281] In one embodiment or in combination with any of the embodiments mentioned herein, the bottom diol byproduct stream 156 may comprise a primary diol and at least one other diol. For example, based on the total weight of the byproduct stream 156, the bottom diol byproduct stream 156 may comprise at least 0.5, at least 1, at least 2, at least 3, at least 5, or at least 8 and / or no more than 30, no more than 25, no more than 20, no more than 15, no more than 12, or no more than 10 wt% of a primary diol (or ethylene glycol). The primary diol (or ethylene glycol) may be present either on its own (in a free state) or as part of another compound.

[0282] Examples of other possible primary diols (depending on the PET or other treated polymer) can include, but are not limited to, diethylene glycol, triethylene glycol, 1,4-cyclohexane-dimethanol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentanediol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropanediol-(1,3), hexanediol-(1,3), 1,4-di-(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, 2,2,4,4-tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone, BDS-(2,2-(sulfonylbis)4,1-phenyleneoxy))bis(ethanol), and combinations thereof. Other diols can not be or include ethylene glycol. Portions of these diols can also be present in any oligomers of the polyester in the byproduct stream or other byproduct streams. Additionally, other non-terephthaloyl and / or non-diol components can also be present in these streams. Examples of such components include isophthalate esters and other acid residues having a higher boiling point than the primary terephthaloyl.

[0283] In one embodiment or in combination with any of the embodiments mentioned herein, diols other than the primary diol (or ethylene glycol in the case of methanolysis) can be present in the diol bottoms byproduct stream 156 in an amount of at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 and / or not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 wt% based on the total weight of diols in the diol bottoms byproduct stream 156.

[0284] In one embodiment or in combination with any of the embodiments mentioned herein, the weight ratio of at least one diol other than the primary diol to the primary diol in the diol bottoms byproduct stream 156 is at least 0.5: 1, at least 0.55: 1, at least 0.65: 1, at least 0.70: 1, at least 0.75: 1, at least 0.80: 1, at least 0.85: 1, at least 0.90: 1, at least 0.95: 1, at least 0.97: 1, at least 0.99: 1, at least 1: 1, at least 1.05: 1, at least 1.1: 1, at least 1.15: 1, at least 1.2: 1, at least, or at least 1.25: 1. Additionally, or alternatively, the weight ratio of at least one diol other than the primary diol to the primary diol in the diol bottoms byproduct stream 156 is no more than 5: 1, no more than 4.5: 1, no more than 4: 1, no more than 3.5: 1, no more than 3: 1, no more than 2.5: 1, no more than 2: 1, no more than 1.5: 1, no more than 1.25: 1, or no more than 1: 1, or within a range of 0.5: 1 to 5: 1, 0.70: 1 to 3: 1, or 0.80: 1 to 2.5: 1.

[0285] In one embodiment or in combination with any of the embodiments mentioned herein, the solventysis facility 30 can produce two or more byproduct streams, which can include two or more heavy organic byproduct streams, two or more light organic byproduct streams, or a combination of light and heavy organic byproduct streams. All or a portion of one or more of the solventysis byproduct streams (as shown in stream 110 in Figure 1 may be introduced into at least one downstream processing facility, including, for example, the pyrolysis facility 60, the cracking facility 70, the POX gasification facility 50, the energy recovery facility 80, and any of the other optional facilities mentioned previously.

[0286] In one embodiment or in combination with any of the embodiments mentioned herein, two or more (or portions of two or more) solventysis byproduct streams can be introduced into the same downstream processing facility, while in other cases, two or more (or portions of two or more) solventysis byproduct streams can be introduced into different downstream processing facilities. In some embodiments, at least 90, at least 95, at least 97, at least 99 wt% or all of a single byproduct stream can be introduced into one downstream facility, while in other embodiments, the stream can be split between two or more downstream facilities, such that no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, or no more than 30 wt% of a single byproduct stream can be introduced into one downstream process facility.

[0287] Referring again to Figure 1In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the at least one solvolysis byproduct stream 110 can be combined with at least a portion of the PO-enriched plastic stream 114 withdrawn from the pre-treatment facility 20, as shown in FIG. 1. The amount of the single byproduct stream 110 (or all byproduct streams when two or more are combined) in the combined stream with PO-enriched plastic can vary and, based on the total weight of the combined stream, can be, for example, at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, or at least 50 and / or not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, or not more than 40 wt.%. As shown in FIG. 1, the combined stream can then be introduced to one or more locations of the chemical recycling facility, including, for example, to the POX gasification facility 50, the pyrolysis facility 60, the cracker facility 70, and / or the energy generation facility 80. Figure 1 Figure 1 As shown in FIG. 1, the combined stream can then be introduced to one or more locations of the chemical recycling facility, including, for example, to the POX gasification facility 50, the pyrolysis facility 60, the cracker facility 70, and / or the energy generation facility 80.

[0288] Liquefaction / dehalogenation

[0289] As shown in FIG. 1, the combined stream can then be introduced to one or more locations of the chemical recycling facility, including, for example, to the POX gasification facility 50, the pyrolysis facility 60, the cracker facility 70, and / or the energy generation facility 80. Figure 1 As shown in FIG. 1, the combined stream can then be introduced to one or more locations of the chemical recycling facility, including, for example, to the POX gasification facility 50, the pyrolysis facility 60, the cracker facility 70, and / or the energy generation facility 80.

[0290] When introduced to the liquefaction zone 40, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt.% of the plastic (typically waste plastic) undergoes a reduction in viscosity. In some cases, the reduction in viscosity can be facilitated by heating (e.g., by the addition of steam that directly or indirectly contacts the plastic), while in other cases, the reduction in viscosity can be facilitated by combining the plastic with a solvent that is capable of dissolving it. Examples of suitable solvents can include, but are not limited to: alcohols such as methanol or ethanol, glycols such as ethylene glycol, diethylene glycol, triethylene glycol, neopentyl glycol, cyclohexane dimethanol, glycerol, pyrolysis oil, motor oil, and water. As shown in FIG. 1, the liquefied plastic can then be introduced to one or more locations of the chemical recycling facility, including, for example, to the POX gasification facility 50, the pyrolysis facility 60, the cracker facility 70, and / or the energy generation facility 80.​Figure 1 As shown, solvent stream 141 can be added directly to liquefaction zone 40, or it can be combined with one or more streams fed to liquefaction zone 40 (not shown). Figure 1

[0291] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent can include streams withdrawn from one or more other facilities within the chemical recycling facility. For example, the solvent can include streams withdrawn from at least one of solvent decomposition facility 30, pyrolysis facility 60, and cracking facility 70. The solvent can be or include at least one of the solvent decomposition byproducts described herein, or it can be or include pyrolysis oil.

[0292] In some cases, the plastic can be depolymerized such that the number average chain length of the plastic is reduced, for example, by contact with a depolymerization agent. In one embodiment or in combination with any of the embodiments mentioned herein, at least one of the previously listed solvents can be used as a depolymerization agent, while in one or more other embodiments, the depolymerization agent can include an organic acid (e.g., acetic acid, citric acid, butyric acid, formic acid, lactic acid, oleic acid, oxalic acid, stearic acid, tartaric acid, and / or uric acid) or an inorganic acid such as sulfuric acid (for polyolefins). The depolymerization agent can reduce the melting point and / or viscosity of the polymer by reducing its number average chain length.

[0293] Alternatively, or in addition, a plasticizer can be used in the liquefaction zone to reduce the viscosity of the plastic. Plasticizers for polyethylene include, for example, dioctyl phthalate, dioctyl terephthalate, glycerol tribenzoate, polyethylene glycol with a molecular weight of up to 8,000 Daltons, sunflower oil, paraffin wax with a molecular weight of 400-1,000 Daltons, paraffinic oil, mineral oil, glycerol, EPDM, and EVA. Plasticizers for polypropylene include, for example, dioctyl sebacate, paraffinic oil, isooctyl resin acid, plasticizing oil (Drakeol 34), naphthenic and aromatic treating oils, and glycerol. Plasticizers for polyesters include, for example, polyalkylene ether with a molecular weight in the range of 400-1500 Daltons (e.g., polyethylene glycol, poly(tetrahydrofuran), polypropylene glycol, or mixtures thereof), glycerol monostearate, epoxy soybean oil fatty acid octyl ester, epoxidized soybean oil, epoxidized tall oil acid ester, epoxidized linseed oil, polyhydroxyaliphatic acid, glycols (e.g., ethylene glycol, pentane diol, hexane diol, etc.), phthalates, terephthalates, trimellitates, and polyethylene glycol di-(2-ethylhexanoate). When used, the plasticizer can be present in an amount of at least 0.1, at least 0.5, at least 1, at least 2, or at least 5 wt% and / or not more than 10, not more than 8, not more than 5, not more than 3, not more than 2, or not more than 1 wt% based on the total weight of the stream, or it can be in the range of 0.1-10 wt%, 0.5-8 wt%, or 1-5 wt% based on the total weight of the stream.

[0294] ​Additionally, one or more methods of liquefying the waste plastic stream can also include adding at least one blending agent to the plastic prior to, during, or after the liquefaction process. Such a blending agent can include, for example, an emulsifier and / or a surfactant, and can be used to more fully blend the liquefied plastic into a single phase, particularly when density differences between the plastic components of the mixed plastic stream result in multiple liquid or semi-liquid phases. When used, the blending agent can be present in an amount of at least 0.1, at least 0.5, at least 1, at least 2, or at least 5 wt%, and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, or no more than 1 wt%, based on the total weight of the stream, or it can be in the range of 0.1-10, 0.5-8, or 1-5 wt%, based on the total weight of the stream.

[0295] As generally shown in Figure 1 , a solventysis byproduct stream (which can include one or more of the solventysis byproducts described herein) can be added prior to introducing the PO-enriched plastic stream 114 into the liquefaction zone 40 (as shown in line 113) and / or after removing the liquefied plastic stream from the liquefaction zone 40 (as shown in line 115) when combined with the PO-enriched plastic stream 114. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion or all of the one or more byproduct streams can also be introduced directly into the liquefaction zone, as shown in Figure 1 . In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PO-enriched plastic stream 114 can bypass the liquefaction zone 40 entirely in line 117 and can optionally be combined with at least one solventysis byproduct stream 110, as also shown in Figure 1 .

[0296] Additionally, as shown in Figure 6 , a portion of the pyrolysis oil stream 143 removed from the pyrolysis facility 60 can be combined with the PO-enriched plastic stream 114 to form a liquefied plastic. While shown as being introduced directly into the liquefaction zone 40, all or a portion of the pyrolysis oil stream 143 can be combined with the PO-enriched plastic stream 114 prior to introduction into the liquefaction zone 40 or after the PO-enriched plastic stream 114 exits the liquefaction zone 40. When used, the pyrolysis oil can be added alone or in combination with one or more other solvent streams at one or more of the locations described herein.

[0297] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream from the liquefaction zone 40 to the one or more downstream chemical recycling facilities can comprise at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of the one or more solvolysis byproduct streams, based on the total weight of the feed stream introduced to the one or more downstream processing facilities. For example, the feed stream 116, 118, 120, and 122 to each of the POX facility 50, pyrolysis facility 60, cracking facility 70, energy recovery facility 80, and / or any other facility 90 of the chemical recycling facility 10 can include PO-enriched waste plastic and an amount of one or more solvolysis byproducts described herein.

[0298] Additionally, or alternatively, the feed stream to the pyrolysis facility 60, POX facility 50, cracking facility 70, energy recovery facility 80, and / or any other facility 90 can comprise no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of the one or more solvolysis byproduct streams, based on the total weight of the feed stream introduced to the one or more downstream processing facilities.

[0299] Alternatively, or additionally, the liquefied (or reduced viscosity) plastic stream withdrawn from the liquefaction zone 40 can comprise at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% and / or no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of PO, based on the total weight of the stream, or the amount of PO can be in the range of 1 wt% to 95 wt%, 5 wt% to 90 wt%, 10 wt% to 85 wt%, based on the total weight of the stream.

[0300] In one embodiment or in combination with any embodiment mentioned herein, the viscosity of the liquefied plastic stream leaving the liquefaction zone 40 may be less than 3,000, less than 2,500, less than 2,000, less than 1,500, less than 1,000, less than 800, less than 750, less than 700, less than 650, less than 600, less than 550, less than 500, less than 450, less than 400, less than 350, less than 300, less than 250, less than 150, less than 100, less than 75, less than 50, less than 25, less than 10, less than 5, or less than 1 poise, as measured using a Borelfeld R / S rheometer with a V80-40 paddle rotor, which operates at a shear rate of 10 rad / s and a temperature of 350°C. In one embodiment or in combination with any embodiment mentioned herein, the viscosity of the liquefied plastic stream leaving the liquefaction zone (measured at 350°C and 10 rad / s and expressed in poise) is no more than 95%, no more than 90%, no more than 75%, no more than 50%, no more than 25%, no more than 10%, no more than 5%, or no more than 1% of the viscosity of the PO enriched stream introduced into the liquefaction zone.

[0301] Figure 1 The basic components of a liquefaction system are shown, which can be used as... Figure 6 The liquefaction zone 40 is shown in the chemical recovery facility. It should be understood that... Figure 6 An exemplary embodiment of a liquefaction system is described. Figure 6 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 6 The system described in the text.

[0302] like Figure 6 As shown, the waste plastic feed, such as PO-enriched waste plastic stream 114, can be derived from a waste plastic source, such as the pretreatment facility 20 described herein. The waste plastic feed (e.g., PO-enriched waste plastic stream 114) can be introduced into the liquefaction zone 40. Figure 6 It is described as comprising at least one melting tank 310, at least one circulating loop pump 312, at least one external heat exchanger 340, at least one stripping tower 330, and at least one separation vessel 320. These various exemplary components and their functions in the liquefaction zone 40 will be discussed in more detail below.

[0303] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 6As shown, liquefaction zone 40 includes a melt tank 310 and a heater. Melt tank 310 receives a waste plastic feed, such as PO-enriched waste plastic stream 114, and the heater heats the waste plastic. In one embodiment or in combination with any embodiment mentioned herein, melt tank 310 can include one or more continuously stirred tanks. When one or more rheology modifiers (e.g., solvents, depolymerizers, plasticizers, and blending agents) are used in the liquefaction zone, such rheology modifiers can be added to and / or mixed with the PO-enriched plastic in melt tank 310 or before melt tank 310.

[0304] In one embodiment or in combination with any embodiment mentioned herein Figure 6 (not shown), the heater of liquefaction zone 40 can take the form of internal heat exchange coils located in melt tank 310, a jacket on the outside of melt tank 310, heat tracing on the outside of melt tank 310, and / or electric heating elements on the outside of melt tank 310. Alternatively, as Figure 6 shown, the heater of liquefaction zone 40 can include an external heat exchanger 340 that receives a stream of liquefied plastic 171 from melt tank 310, heats it, and returns at least a portion of the heated liquefied plastic stream 173 to melt tank 310.

[0305] As Figure 6 shown, when an external heat exchanger 340 is used to provide heat to liquefaction zone 40, a circulation loop can be used to continuously add heat to the PO-enriched material. In one embodiment or in combination with any embodiment mentioned herein, the circulation loop includes melt tank 310, external heat exchanger 340, a conduit (shown as line 171) connecting the melt tank and the external heat exchanger, and a pump 151 for circulating the liquefied waste plastic in the circulation loop. When a circulation loop is used, the resulting liquefied PO-enriched material can be continuously removed from liquefaction zone 40 as part of a circulating PO-enriched stream via a conduit 161 as shown in Figure 6

[0306] In one embodiment or in combination with any embodiment mentioned herein, liquefaction zone 40 can optionally contain equipment for removing halogens from the PO-enriched material. When the PO-enriched material is heated in liquefaction zone 40, halogen-enriched gases can evolve. By separating the evolved halogen-enriched gases from the liquefied PO-enriched material, the concentration of halogens in the PO-enriched material can be reduced.

[0307] In one embodiment or in combination with any embodiment mentioned herein, dehalogenation can be facilitated by sparging a stripping gas (e.g., steam) into the liquefied PO-enriched material in melt tank 310 or at another location in the circulation loop. As Figure 6 ​As shown, the stripping tower 330 and the separation vessel 320 can be arranged in the circulation loop, downstream of the external heat exchanger 340 and upstream of the melting tank 310. Figure 1 As shown, the stripping tower 330 can receive heated liquefied plastic stream 173 from an external heat exchanger 340 and inject stripping gas 153 into the liquefied plastic. Injecting stripping gas 153 into the liquefied plastic can generate a two-phase medium in the stripping tower 330.

[0308] This two-phase medium, introduced into the separation vessel 320 via stream 175, can then flow (e.g., by gravity) through the separation vessel 320, where the halogen-enriched gaseous phase separates from the halogen-depleted liquid phase and is removed from the separation vessel 320 via stream 162. Alternatively, a portion of the liquefied plastic 173 heated from an external heat exchanger 340 can bypass the stripping tower 330 and be introduced directly into the separation vessel 320. In one embodiment or in combination with any of the embodiments mentioned herein, a first portion of the halogen-depleted liquid phase discharged from the outlet of the separation vessel can be returned to the melting tank 310 via line 159, while a second portion of the halogen-depleted liquid phase can be discharged from the liquefaction zone as a dehalogenated, liquefied, PO-enriched product stream 161. The separated halogen-enriched gaseous streams from the separation vessel 162 and from the melting tank 310 via line 164 can be removed from the liquefaction zone 40 for further processing and / or disposal.

[0309] In one embodiment or in combination with any embodiment mentioned herein, the halogen content of the dehalogenated liquefied waste plastic stream 161 leaving the liquefaction zone 40 may be less than 500, less than 400, less than 300, less than 200, less than 100, less than 50, less than 10, less than 5, less than 2, less than 1, less than 0.5, or less than 0.1 ppmw. The halogen content of the liquefied plastic stream 161 leaving the liquefaction zone 40 is no more than 95%, no more than 90%, no more than 75%, no more than 50%, no more than 25%, no more than 10%, or no more than 5% (by weight) of the halogen content of the PO enriched stream introduced into the liquefaction zone.

[0310] like Figure 1 As shown, at least a portion of the dehalogenated liquefied waste plastic stream 161 can be introduced into a downstream POX gasifier at the POX gasification facility 50 to produce a syngas composition and / or into a downstream pyrolysis reactor at the pyrolysis facility 60 to produce pyrolysis vapors (i.e., pyrolysis gas and pyrolysis oil) and pyrolysis residues. Alternatively, or additionally, at least a portion of the dehalogenated liquefied waste plastic stream 161 can be introduced into an energy recovery facility 80 and / or one or more other facilities 90, such as separation or solidification facilities.

[0311] In an embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility 10 can not include a liquefaction zone 40. Alternatively, the chemical recycling facility can include a liquefaction zone 40, but can not include any type of dehalogenation zone or equipment.

[0312] Referring again to Figure 7 At least a portion of the PO-enriched plastic stream 114 from the pretreatment facility 20 and / or from the liquefaction zone 40 (alone or in combination with one or more solvolysis byproduct streams 110) can be introduced into one or more downstream processing facilities, including, for example, a pyrolysis facility 60, a cracking facility 70, a POX gasification facility 50, an energy recovery facility 80, and any other optional facility 90, as discussed in detail below.

[0313] Pyrolysis

[0314] In an embodiment or in combination with any of the embodiments mentioned herein, Figure 7 The chemical recycling facility 10 generally described in the Background can include a pyrolysis facility. As used herein, the term “pyrolysis” refers to the thermal decomposition of one or more organic materials at elevated temperatures in an inert (i.e., substantially oxygen-free) atmosphere. A “pyrolysis facility” is a facility that includes all equipment, piping, and control devices necessary to perform pyrolysis of waste plastics and feedstocks derived therefrom.

[0315] Figure 7 An exemplary pyrolysis facility 60 for converting a waste plastic stream 116 (e.g., liquefied waste plastic from a liquefaction zone) into pyrolysis gas, pyrolysis oil, and pyrolysis residue is described. It will be understood that, Figure 7 An exemplary embodiment of the present technology is depicted. Thus, Figure 7 Certain features depicted in the Background can be omitted and / or additional features described elsewhere herein can be added to Figure 7 the system depicted in the Background.

[0316] In an embodiment or in combination with any of the embodiments mentioned herein, the feed stream 116 to the pyrolysis facility 60 can include at least one of (i) at least one solvolysis byproduct stream as previously described, and (ii) a PO-enriched stream of waste plastics. One or more of these streams can be introduced into the pyrolysis facility 60 continuously, or one or more of these streams can be introduced intermittently. When multiple types of feed streams are present, each feed stream can be introduced separately, or all or a portion of the feed streams can be combined, such that the combined stream can be introduced into the pyrolysis facility 60. When combining is performed, it can be performed in a continuous or intermittent manner. The feed introduced into the pyrolysis facility 60 can be in the form of liquefied plastic (e.g., liquefied, molten, plasticized, depolymerized, or a combination thereof), plastic pellets or granules, or a slurry thereof.

[0317] Generally, as Figure 1In some embodiments, pyrolysis facility 60 includes a pyrolysis reactor 510 and a separator 520 for separating product streams from the reactor. Although not depicted in Figure 1 In some embodiments, separator 520 of pyrolysis facility 60 can include various types of equipment, including but not limited to filtration systems, multi-stage separators, condensers, and / or quench towers.

[0318] At least a portion of the feedstock can undergo a pyrolysis reaction while in pyrolysis reactor 510 that produces a pyrolysis effluent comprising pyrolysis oil, pyrolysis gas, and pyrolysis residue. As used herein, the term "pyrolysis gas" refers to a composition obtained from pyrolysis that is gaseous at 25 °C and 1 atm. As used herein, the term "pyrolysis oil" refers to a composition obtained from pyrolysis that is liquid at 25 °C and 1 atm. As used herein, the term "pyrolysis residue" refers to a composition obtained from pyrolysis that is not pyrolysis gas or pyrolysis oil and that primarily comprises pyrolysis coke and pyrolysis heavy wax. As used herein, the term "pyrolysis coke" refers to a carbonaceous composition obtained from pyrolysis that is solid at 200 °C and 1 atm. As used herein, the term "pyrolysis heavy wax" refers to C20+ hydrocarbons obtained from pyrolysis that are not pyrolysis coke, pyrolysis gas, or pyrolysis oil. Pyrolysis gas and pyrolysis oil can exit pyrolysis reactor 500 as a pyrolysis vapor stream 170.

[0319] Pyrolysis is a process that involves the chemical and thermal decomposition of an introduced feedstock. Although all pyrolysis processes can generally be characterized by a substantially oxygen-free reaction environment, a pyrolysis process can be further defined by, for example, the pyrolysis reaction temperature within the reactor, the residence time in the pyrolysis reactor, the reactor type, the pressure within the pyrolysis reactor, and the presence or absence of a pyrolysis catalyst.

[0320] In one embodiment or in combination with any of the mentioned embodiments, pyrolysis reactor 510 can be, for example, a membrane reactor, a screw extruder, a tubular reactor, a tank, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, a vacuum reactor, a microwave reactor, or an autoclave. Pyrolysis reactor 510 comprises a membrane reactor, such as a falling film reactor or an upflow membrane reactor.

[0321] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reaction can include heating and converting the feedstock in an atmosphere that is substantially free of oxygen or in an atmosphere that contains less oxygen relative to ambient air. For example, the atmosphere within pyrolysis reactor 510 can contain no more than 5, no more than 4, no more than 3, no more than 2, no more than 1, or no more than 0.5 vol% of oxygen, based on the internal volume of the reactor.

[0322] In one embodiment or in combination with any of the embodiments mentioned herein, a lift gas and / or a feed gas can be used to introduce the feedstock into the pyrolysis reactor 510 and / or to facilitate various reactions within the pyrolysis reactor 510. For example, the lift gas and / or the feed gas can include, consist essentially of, or consist of nitrogen, carbon dioxide, and / or steam. The lift gas and / or the feed gas can be added with the waste plastic stream 116 prior to introduction into the pyrolysis reactor 510 and / or can be added directly into the pyrolysis reactor 510. The lift gas and / or the feed gas can include steam and / or a reducing gas, such as hydrogen, carbon monoxide, and combinations thereof.

[0323] Additionally, the temperature in the pyrolysis reactor 510 can be adjusted to facilitate the production of certain end products. In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis temperature in the pyrolysis reactor 510 can be at least 325°C, at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, at least 650°C, at least 675°C, at least 700°C, at least 725°C, at least 750°C, at least 775°C, or at least 800°C.

[0324] Additionally, or alternatively, the pyrolysis temperature in the pyrolysis reactor can be no more than 1,100°C, no more than 1,050°C, no more than 1,000°C, no more than 950°C, no more than 900°C, no more than 850°C, no more than 800°C, no more than 750°C, no more than 700°C, no more than 650°C, no more than 600°C, no more than 550°C, no more than 525°C, no more than 500°C, no more than 475°C, no more than 450°C, or no more than 425°C. More particularly, the pyrolysis temperature in the pyrolysis reactor can be in the range of 325 to 1,100°C, 350 to 900°C, 350 to 700°C, 350 to 550°C, 350 to 475°C, 425 to 1,100°C, 425 to 800°C, 500 to 1,100°C, 500 to 800°C, 600 to 1,100°C, 600 to 800°C, 650 to 1,000°C, or 650 to 800°C.

[0325] In one embodiment or in combination with any of the embodiments herein, the residence time of the feedstock within the pyrolysis reactor can be at least 0.1, at least 0.2, at least 0.3, at least 0.5, at least 1, at least 1.2, at least 1.3, at least 2, at least 3, or at least 4 seconds. Alternatively, the residence time of the feedstock within the pyrolysis reactor can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 20, at least 30, at least 45, at least 60, at least 75, or at least 90 minutes. Additionally, or alternatively, the residence time of the feedstock within the pyrolysis reactor can be less than 6, less than 5, less than 4, less than 3, less than 2, less than 1, or less than 0.5 hours. Further, the residence time of the feedstock within the pyrolysis reactor can be less than 100, less than 90, less than 80, less than 70, less than 60, less than 50, less than 40, less than 30, less than 20, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 second. More particularly, the residence time of the feedstock within the pyrolysis reactor can be in the range of 0.1-10 seconds, 0.5-10 seconds, 30 minutes-4 hours, or 30 minutes-3 hours or 1 hour-2 hours.

[0326] In one embodiment or in combination with any of the embodiments herein, the pressure within the pyrolysis reactor can be maintained at a pressure of at least 0.1, at least 0.2, at least or 0.3 bar and / or no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 8, no more than 5, no more than 2, no more than 1.5, or no more than 1.1 bar. The pressure within the pyrolysis reactor can be maintained at atmospheric pressure or in the range of 0.1 to 100 bar, or 0.1 to 60 bar, or 0.1 to 30 bar, or 0.1 to 10 bar, or 1.5 bar, 0.2 to 1.5 bar, or 0.3 to 1.1 bar. The pressure within the pyrolysis reactor can be at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, or at least 70 bar and / or no more than 100, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, or no more than 60 bar. As used herein, the term “bar” refers to gauge pressure, unless otherwise specified.

[0327] In an embodiment or in combination with any of the embodiments herein, the pyrolysis catalyst can be introduced into the feed stream 116 prior to introduction into the pyrolysis reactor 510 and / or directly into the pyrolysis reactor 510. The catalyst can be homogeneous or heterogeneous and can include, for example, certain types of zeolites and other mesostructured catalysts. In some embodiments, the pyrolysis reaction can not be catalyzed (e.g., performed in the absence of a pyrolysis catalyst), but can include non-catalytic, heat-retaining inert additives, such as sand, in the reactor 510 to facilitate heat transfer. Such a non-catalyzed pyrolysis process can be referred to as “thermal pyrolysis.”

[0328] In an embodiment or in combination with any of the embodiments herein, the pyrolysis reaction in the pyrolysis reactor 510 can occur in the substantial absence of a pyrolysis catalyst at a temperature in the range of 350 to 600 °C, at a pressure in the range of 0.1 to 100 bar, and at a residence time of 0.2 seconds to 4 hours or 0.5 hours to 3 hours.

[0329] In an embodiment or in combination with any of the embodiments herein, the pyrolysis effluent or pyrolysis vapor can include at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 wt% of pyrolysis oil that can be in vapor form in the pyrolysis effluent upon exiting the heated reactor; however, these vapors can subsequently condense into the resulting pyrolysis oil. Additionally, or alternatively, the pyrolysis effluent or pyrolysis vapor can include no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, or no more than 25 wt% of pyrolysis oil that can be in vapor form in the pyrolysis effluent upon exiting the heated reactor. The pyrolysis effluent or pyrolysis vapor can include 20-99 wt%, 25-80 wt%, 30-85 wt%, 30-80 wt%, 30-75 wt%, 30-70 wt%, or 30-65 wt% of pyrolysis oil, based on the total weight of the pyrolysis effluent or pyrolysis vapor.

[0330] In an embodiment, or in combination with any of the embodiments herein, the pyrolysis effluent or pyrolysis vapor can comprise at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, or at least 80 wt% pyrolysis gas. Additionally, or alternatively, the pyrolysis effluent or pyrolysis vapor can comprise no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, or no more than 45 wt% pyrolysis gas. The pyrolysis effluent can comprise 1-90 wt%, 10-85 wt%, 15-85 wt%, 20-80 wt%, 25-80 wt%, 30-75 wt%, or 35-75 wt% pyrolysis gas, based on the total weight of the stream.

[0331] In an embodiment, or in combination with any of the embodiments herein, the pyrolysis effluent or pyrolysis vapor can comprise at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 wt% pyrolysis residue. Additionally, or alternatively, the pyrolysis effluent can comprise no more than 60, no more than 50, no more than 40, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, or no more than 5 wt% pyrolysis residue. The pyrolysis effluent can comprise pyrolysis residue in the range of 0.1-25 wt%, 1-15 wt%, 1-8 wt%, or 1-5 wt%, based on the total weight of the stream.

[0332] In an embodiment, or in combination with any of the embodiments herein, the pyrolysis effluent or pyrolysis vapor can comprise no more than 15, no more than 14, no more than 13, no more than 12, no more than 11, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, no more than 4, no more than 3, no more than 2, no more than 1, or no more than 0.5 wt% free water. As used herein, “free water” refers to water that is pre-charged (as a liquid or vapor) into the pyrolysis unit and water that is produced in the pyrolysis unit.

[0333] The pyrolysis systems described herein can produce a pyrolysis effluent that can be separated into a pyrolysis oil stream 174, a pyrolysis gas stream 172, and a pyrolysis residue stream 176, each of which can be used directly in various downstream applications based on their formulation. Various features and characteristics of the pyrolysis oil, pyrolysis gas, and pyrolysis residue are described below. It should be noted that while all of the following features and characteristics can be listed separately, it is contemplated that each of the following features and / or characteristics of the pyrolysis gas, pyrolysis oil, and / or pyrolysis residue are not mutually exclusive and can be combined and exist in any combination.

[0334] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil can predominantly include hydrocarbons having 4 to 30 carbon atoms per molecule (e.g., C4-C30 hydrocarbons). As used herein, the term “Cx” or “Cx hydrocarbons” refers to hydrocarbon compounds that include a total of “x” carbons per molecule and encompasses all alkenes, alkanes, aromatic hydrocarbons, heterocycles, and isomers having that number of carbon atoms. For example, each of n-butane, isobutane, and tert-butane, as well as butene and butadiene molecules, would fall within the general description “C4.” The C4-C30 hydrocarbon content of the pyrolysis oil can be at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% based on the total weight of the pyrolysis oil stream 174.

[0335] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil can predominantly include C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons. For example, the pyrolysis oil can include at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons based on the total weight of the pyrolysis oil. The C5-C12 hydrocarbon content of the pyrolysis oil can be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, or at least 55 wt% based on the total weight of the pyrolysis oil. Additionally, or alternatively, the C5-C12 hydrocarbon content of the pyrolysis oil can be no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, or no more than 50 wt%. The C5-C12 hydrocarbon content of the pyrolysis oil can be in the range of 10-95 wt%, 20-80 wt%, or 35-80 wt% based on the total weight of the stream.

[0336] In one embodiment or in combination with any of the embodiments mentioned herein, depending on the reactor conditions and whether a catalyst is used, the pyrolysis oil can also include various amounts of olefins and aromatics. The pyrolysis oil includes at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, or at least 40 wt% of olefins and / or aromatics, based on the total weight of the pyrolysis oil. Additionally, or alternatively, the pyrolysis oil can include no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, or no more than 1 wt% of olefins and / or aromatics. As used herein, the term "aromatics" refers to the total amount (by weight) of any compounds containing aromatic moieties, such as benzene, toluene, xylene, and styrene.

[0337] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil can have a paraffin (e.g., straight chain or branched alkane) content of at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, or at least 65 wt%, based on the total weight of the pyrolysis oil. Additionally, or alternatively, the pyrolysis oil can have a paraffin content of no more than 99, no more than 97, no more than 95, no more than 93, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, or no more than 30 wt%. The pyrolysis oil can have a paraffin content in the range of 25-90 wt%, 35-90 wt%, or 50-80 wt%.

[0338] In an embodiment, or in combination with any of the embodiments herein, the medium boiling point of the pyrolysis oil can be at least 75°C, at least 80°C, at least 85°C, at least 90°C, at least 95°C, at least 100°C, at least 105°C, at least 110°C, or at least 115°C and / or no more than 250°C, no more than 245°C, no more than 240°C, no more than 235°C, no more than 230°C, no more than 225°C, no more than 220°C, no more than 215°C, no more than 210°C, no more than 205°C, no more than 200°C, no more than 195°C, no more than 190°C, no more than 185°C, no more than 180°C, no more than 175°C, no more than 170°C, no more than 165°C, no more than 160°C, no more than 155°C, no more than 150°C, no more than 145°C, no more than 140°C, no more than 135°C, no more than 130°C, no more than 125°C, or no more than 120°C, as measured according to ASTM D5399. The medium boiling point of the pyrolysis oil can be in the range of 75 to 250°C, 90 to 225°C, or 115 to 190°C. As used herein, “medium boiling point” refers to the median boiling point temperature of the pyrolysis oil, wherein 50% by volume of the pyrolysis oil boils above the medium boiling point and 50% by volume of the pyrolysis oil boils below the medium boiling point.

[0339] In an embodiment, or in combination with any of the embodiments herein, the boiling point range of the pyrolysis oil can be such that at least 90% of the pyrolysis oil vaporizes at a temperature of 250°C, 280°C, 290°C, 300°C, or 310°C, as measured according to ASTM D-5399.

[0340] Turning to the pyrolysis gas, the methane content of the pyrolysis gas can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, or at least 15 and / or no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, or no more than 20 wt%, based on the total weight of the pyrolysis gas. In an embodiment, or in combination with any of the embodiments herein, the methane content of the pyrolysis gas can be in the range of 1 wt% to 50 wt%, 5 wt% to 50 wt%, or 15 wt% to 45 wt%.

[0341] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C3and / or C4hydrocarbon content (including all hydrocarbons having 3 or 4 carbon atoms per molecule) of at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, or at least 60 and / or not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, or not more than 65 wt% based on the total weight of the pyrolysis gas. The C3hydrocarbon content, C4hydrocarbon content, or combined C3and C4hydrocarbon content of the pyrolysis gas can be in the range of 10-90 wt%, 25-90 wt%, or 25-80 wt%.

[0342] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can comprise at least 10, at least 20, at least 30, at least 40, or at least 50 wt% of the total effluent from the pyrolysis reactor, and the combined ethylene and propylene content of the pyrolysis gas can be at least 25, at least 40, at least 50, at least 60, at least 70, or at least 75 wt%.

[0343] Turning to the pyrolysis residue, in one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis residue comprises at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85 wt% C20+hydrocarbons based on the total weight of the pyrolysis residue. As used herein, “C20+hydrocarbons” refers to hydrocarbon compounds containing at least 20 carbons in total per molecule and encompasses all olefins, paraffins, and isomers having that number of carbon atoms.

[0344] In an embodiment, or in combination with any of the embodiments herein, the pyrolysis residue comprises at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% carbon-containing solids, based on the total weight of the pyrolysis residue. Additionally, or alternatively, the pyrolysis residue comprises no more than 99, no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, or no more than 4 wt% carbon-containing solids. As used herein, “carbon-containing solids” refers to carbon-containing compositions derived from pyrolysis that are solid at 25°C and 1 atm. The carbon-containing solids comprise at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, or at least 90 wt% carbon, based on the total weight of the carbon-containing solids.

[0345] In an embodiment, or in combination with any of the embodiments herein, at least a portion of the pyrolysis gas, pyrolysis oil, and pyrolysis residue can be sent to one or more other chemical processing facilities, including, for example, the energy recovery facility 80, the partial oxidation facility 50, one or more of the other facilities 90 previously discussed, and the cracking facility 70. In some embodiments, at least a portion of the pyrolysis gas stream 172 and / or at least a portion of the pyrolysis oil (pyoil) stream 174 can be introduced into the energy recovery facility 80, the cracking facility 70, the POX gasification facility 50, and combinations thereof, while the pyrolysis residue stream 176 can be introduced into the POX gasification facility 50 and / or the energy recovery facility 80. In some embodiments, at least a portion of the pyrolysis gas stream 172, the pyrolysis oil stream 174, and / or the pyrolysis residue stream 176 can be sent to one or more separation facilities (not shown) to form purer streams of pyrolysis gas, pyrolysis oil, and / or pyrolysis residue, which can then be sent to the energy recovery facility 80, the cracking facility 70, the POX gasification facility 50, and combinations thereof. Additionally, or alternatively, all or a portion of the pyrolysis oil stream 176 can be combined with the PO-enriched waste plastic stream 114 to provide a liquefied plastic stream that is fed to one or more downstream facilities described herein. Figure 1

[0346] Cracking

[0347] In an embodiment, or in combination with any of the embodiments herein, the pyrolysis residue stream 176 from the pyrolysis facility 60 or from the cracking facility 70 can be introduced into the POX gasification facility 50. Figure 1 ​At least a portion of one or more streams of one or more other facilities shown are introduced into the cracking facility 70. As used herein, the term "cracking" refers to the decomposition of complex organic molecules into simpler molecules by the breaking of carbon-carbon bonds. A "cracking facility" is a facility that includes all equipment, piping, and control devices necessary to perform cracking of a feedstock derived from waste plastics. The cracking facility can include one or more cracker furnaces, as well as downstream separation zones that include equipment for processing effluent from the cracker furnaces. As used herein, the terms "cracker" and "cracking" are used interchangeably.

[0348] Turning now to FIG. 8a, a cracking facility 70 configured in accordance with one or more embodiments of the present technology is shown. Generally, the cracking facility 70 includes a cracker furnace 720 and a separation zone 740 downstream of the cracker furnace 720 for separating furnace effluent into various end products, such as a recovered content olefin (r-olefin) stream 130. As shown in FIG. 8a, at least a portion of the pyrolysis gas stream 172 and / or pyrolysis oil stream 174 from the pyrolysis facility 60 can be sent to the cracking facility 70. The pyrolysis oil stream 174 can be introduced to an inlet of the cracker furnace 720, while the pyrolysis gas stream 172 can be introduced at a location upstream or downstream of the furnace 720. Also as shown in FIG. 8a, a stream of paraffins 132 (such as ethane and / or propane) can be withdrawn from the separation zone and can include recovered content paraffins (r-paraffins). All or a portion of the paraffins can be recovered to an inlet of the cracker furnace 720 via stream 134, also shown in FIG. 8a. When used, the pyrolysis oil stream, pyrolysis gas stream 172, and recovered paraffin stream 174 can optionally be combined with a cracker feed stream 136 to form a feed stream 119 to the cracking facility 720.

[0349] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 119 to the cracking facility 70 can include at least one of (i) one or more solventysis byproduct streams 110 as previously described, (ii) a PO-enriched stream 114 of waste plastics, and (iii) a pyrolysis stream (e.g., pyrolysis gas 172 and / or pyrolysis oil 174). One or more of these streams can be introduced into the cracking facility 70 continuously, or one or more of these streams can be introduced intermittently. When multiple types of feed streams are present, each feed stream can be introduced separately, or all or a portion of the feed streams can be combined so that the combined stream can be introduced into the cracking facility 70. When combining is performed, it can be performed in a continuous or intermittent manner. One or more of the feed streams introduced into the cracking facility 70 can be in the form of a primarily gaseous stream, a primarily liquid stream, or a combination thereof.

[0350] As shown in FIG. 8a, a stream of pyrolysis gas 172 and / or pyrolysis oil 174 can be introduced into the cracker facility 70 with or as the cracker feed stream 136. In some embodiments, the cracker feed stream 119 can include at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% pyrolysis gas, pyrolysis oil, or a combination of pyrolysis gas and pyrolysis oil, based on the total weight of stream 119. Alternatively, or additionally, the cracker feed stream 119 can include no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, or no more than 20 wt% pyrolysis gas, pyrolysis oil, or a combination of pyrolysis gas and pyrolysis oil, based on the total weight of stream 119, or it can include these components in an amount of 1-95, 5-90, or 10-85 wt%, based on the total weight of stream 119.

[0351] In some embodiments, the cracker feed stream 119 can include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% and / or no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, or no more than 20 wt% of a hydrocarbon feed other than pyrolysis gas and pyrolysis oil, based on the total weight of cracker feed stream 119, or it can include these components in an amount of 5-95, 10-90, 15-85 wt%, based on the total weight of cracker feed stream 119.

[0352] In an embodiment or in combination with any of the embodiments described herein, the cracker feed stream 119 can include a composition that is primarily C2-C4 hydrocarbons. As used herein, the term "primarily C2 to C4 hydrocarbons" refers to a stream or composition that contains at least 50 wt% of C2 to C4 hydrocarbon components. Examples of specific types of C2 to C4 hydrocarbon streams or compositions include propane, ethane, butanes, and LPG. The cracker feed stream 119 can include at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case wt% of C2 to C4 hydrocarbons or straight chain alkanes, based on the total weight of the feed, and / or, no more than 100, or no more than 99, or no more than 95, or no more than 92, or no more than 90, or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60, in each case wt% of C2 to C4 hydrocarbons or straight chain alkanes, based on the total weight of the feed. The cracker feed stream 119 can include primarily propane, primarily ethane, primarily butanes, or a combination of two or more of these components.

[0353] In an embodiment or in combination with any of the embodiments described herein, the cracker feed stream 119 can include a composition that is primarily C5-C22 hydrocarbons. As used herein, "primarily C5 to C22 hydrocarbons" refers to a stream or composition that contains at least 50 wt% of C5 to C22 hydrocarbon components. Examples include gasoline, naphtha, middle distillates, diesel, kerosene.

[0354] In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream 119 can include at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case wt%, and / or no more than 100, or no more than 99, or no more than 95, or no more than 92, or no more than 90, or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60, in each case wt% of C5 to C22 or C5 to C20 hydrocarbons, based on the total weight of the stream, or it can include C5 to C22 hydrocarbons in an amount ranging from 20 wt% to 100 wt%, 25 wt% to 95 wt%, or 35 wt% to 85 wt%, based on the total weight of the stream.

[0355] In one embodiment or in combination with any of the embodiments mentioned herein, the C15 and heavier (C15+) content of the cracker feed stream 119 can be at least 0.5, or at least 1, or at least 2, or at least 5, in each case percent by weight and / or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 18, or not more than 15, or not more than 12, or not more than 10, or not more than 5, or not more than 3, in each case percent by weight, or it can be in the range of 0.5-40 wt%, 1-35 wt%, or 2-30 wt%, based on the total weight of the stream.

[0356] In one embodiment or in combination with any of the embodiments mentioned herein, the feed to the cracker furnace can include vacuum gas oil (VGO), hydrogenated vacuum gas oil (HVGO), or atmospheric gas oil (AGO). The cracker feed stream 119 can include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 and / or not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, or not more than 50 wt% of at least one gas oil, based on the total weight of the stream 119, or it can be present in an amount in the range of 5-99 wt%, 10-90 wt%, 15-85 wt%, or 5-50 wt%, based on the total weight of the stream 119.

[0357] As shown in FIG. 8a, the cracker feed stream 119 is introduced into a cracker furnace 720. Turning now to FIG. 8b, a schematic of a cracker furnace 720 suitable for use in the chemical recycling facility and / or cracker facility described herein is shown. As shown in FIG. 8b, the cracking furnace 720 can include a convection section 746, a radiant section 748, and a crossover section 750 located between the convection section 746 and the radiant section 748. The convection section 746 is the portion of the furnace that receives heat from hot flue gas and includes a set of tubes or coils 752 through which the cracker stream flows. In the convection section 746, the cracker stream is heated by convection from the hot flue gas passing through it. Although shown in FIG. 8b as including horizontally oriented convection section tubes 752a and vertically oriented radiant section tubes 752b, it should be understood that the tubes can be configured in any suitable configuration. For example, the convection section tubes 752a can be vertical. The radiant section tubes 752b can be horizontal. Additionally, while shown as a single tube, the cracker furnace 720 can include one or more tubes or coils, which can include at least one split, bend, U-shape, elbow, or combination thereof. When multiple tubes or coils are present, they can be arranged in parallel and / or in series.

[0358] The radiant section 748 is the section of the furnace 720 into which heat is primarily transferred to the heating tubes by radiation from high-temperature gases. The radiant section 748 also includes a plurality of burners 756 for introducing heat into the lower portion of the furnace 720. The furnace 720 includes a firebox 754 that surrounds and houses the tubes 752b within the radiant section 748, and the burners 756 are directed into the firebox. The crossover section 750 includes piping for connecting the convection section 746 and the radiant section 748, and can transfer the heated cracker stream from one section to another section, either within the interior of the furnace 720 or outside of the interior of the furnace 720.

[0359] As the hot combustion gases rise upward through the furnace body, the gases can pass through the convection section 746, where at least a portion of the waste heat can be extracted and used to heat the cracker stream passing through the convection section 746. The cracking furnace 720 can have a single convection (preheat) section and a single radiant section, while in other embodiments the furnace can include two or more radiant sections that share one common convection section. At least one induced draft (I.D.) machine 760 in the vicinity of the furnace body can control the flow of hot flue gas and the distribution of heating through the furnace 720, and one or more heat exchangers 761 can be used to cool the furnace effluent. In addition to, or alternatively with, the exchanger 761 shown on the furnace outlet in FIG. 8b (e.g., a transfer line heat exchanger or TLE), liquid quenching (not shown) can be used to cool the cracked olefin-containing effluent 125.

[0360] In an embodiment or in combination with any of the embodiments herein, cracker facility 70 can include a single cracker furnace, or it can have at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8 or more cracker furnaces operating in parallel. Any one furnace or each furnace can be a gas cracker or a liquid cracker or a split furnace. The furnace can be a gas cracker that receives a cracker feed stream through the furnace, or through at least one coil in the furnace, or through at least one tube in the furnace, that contains at least 50 wt%, or at least 75 wt%, or at least 85 wt%, or at least 90 wt% of ethane, propane, LPG, or combinations thereof, based on the weight of all cracker feed to the furnace.

[0361] In an embodiment or in combination with any of the embodiments herein, cracker furnace 720 can be a liquid or naphtha cracker that receives a cracker feed stream that contains at least 50 wt%, or at least 75 wt%, or at least 85 wt% of liquid (when measured at 25°C and 1 atm) hydrocarbons having a carbon number of C5-C22.

[0362] In an embodiment or in combination with any of the embodiments herein, cracker feed stream 119 can be cracked in a gas furnace. A gas furnace is a furnace having at least one coil that receives (or is operated to receive or configured to receive) a feed that is predominantly in the gas phase (more than 50 wt% of the feed is vapor) at the coil inlet at the inlet of the convection section (“a gas coil”). The gas coil can receive a feed that is predominantly C2-C4, or predominantly C2-C3, to the inlet of the coil in the convection section, or alternatively, has at least one coil that receives more than 50 wt% of ethane and / or more than 50% of propane and / or more than 50% of LPG, or in any of these cases, at least 60 wt%, or at least 70 wt%, or at least 80 wt%, based on the weight of the cracker feed to the coil, or alternatively, based on the weight of the cracker feed to the convection section.

[0363] A gas furnace can have more than one gas coil. In an embodiment or in combination with any of the embodiments herein, at least 25% of the coils in the convection section, or at least 50% of the coils, or at least 60% of the coils, or all of the coils in the convection section or the convection box of the furnace are gas coils. The gas coil receives a gas phase feed at the coil inlet at the inlet of the convection section in which at least 60 wt%, or at least 70 wt%, or at least 80 wt%, or at least 90 wt%, or at least 95 wt%, or at least 97 wt%, or at least 98 wt%, or at least 99 wt%, or at least 99.5 wt%, or at least 99.9 wt% of the feed is vapor.

[0364] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream can be cracked in a cracking furnace. A cracking furnace is a gas furnace. The cracking furnace includes at least one gas coil and at least one liquid coil within the same furnace, or within the same convection zone, or within the same convection box. The liquid coil is a coil (“liquid coil”) that receives a feed that is primarily liquid (more than 50 wt% of the feed is liquid) at its coil inlet at the convection zone inlet.

[0365] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream 119 can be cracked in a thermal gas cracker.

[0366] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream 119 can be cracked in a thermal steam gas cracker in the presence of steam. Steam cracking refers to the high-temperature cracking (decomposition) of hydrocarbons in the presence of steam. When present, steam can be introduced via line 121 shown in FIG. 8b.

[0367] In one embodiment or in combination with any of the embodiments mentioned herein, when from Figure 9 When two or more streams from the chemical recovery facility 10 are combined with another stream from facility 10 to form cracker feed stream 119, this combination can occur upstream of or within the cracker furnace 720. Alternatively, different feed streams can be introduced into furnace 720 individually and can pass through part or all of furnace 720 simultaneously, while being isolated from each other by feeding into separate pipes within the same furnace 720 (e.g., a cracking furnace). Alternatively, at least a portion of one or more streams from the chemical recovery facility can be introduced into the cracker facility downstream of the cracker furnace but upstream of one or more units in the separation facility.

[0368] The heated cracker stream 119 then passes through a cracking furnace 720, where the hydrocarbon components are thermally cracked to form lighter hydrocarbons, including olefins such as ethylene, propylene, and / or butadiene. The residence time of the cracker stream in the cracking furnace 720 can be at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45 seconds in each case, and / or no more than 2, or no more than 1.75, or no more than 1.5, or no more than 1.25, or no more than 1, or no more than 0.9, or no more than 0.8, or no more than 0.75, or no more than 0.7, or no more than 0.65, or no more than 0.6, or no more than 0.5 seconds in each case, or in the range of 0.15 to 2 seconds, 0.20 to 1.75 seconds, or 0.25 to 1.5 seconds.

[0369] The temperature of the cracked olefin-containing effluent 125 removed from the outlet of the furnace can be at least 640, or at least 650, or at least 660, or at least 670, or at least 680, or at least 690, or at least 700, or at least 720, or at least 730, or at least 740, or at least 750, or at least 760, or at least 770, or at least 780, or at least 790, or at least 800, or at least 810, or at least 820, in each case °C, and / or no more than 1000, or no more than 990, or no more than 980, or no more than 970, or no more than 960, or no more than 950, or no more than 940, or no more than 930, or no more than 920, or no more than 910, or no more than 900, or no more than 890, or no more than 880, or no more than 875, or no more than 870, or no more than 860, or no more than 850, or no more than 840, or no more than 830, in each case °C, in the range of 730 to 900 °C, 750 to 875 °C, or 750 to 850 °C.

[0370] In one embodiment or in combination with any of the embodiments mentioned herein, the yield of olefins, ethylene, propylene, butadiene, or combinations thereof, can be at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, in each case percent. As used herein, the term “yield” refers to the mass of product produced from the mass of feedstock / mass of feedstock x 100%. The olefin-containing effluent stream comprises at least 30, or at least 40, or at least 50, or at least 60, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99 (in each case weight percent) of ethylene, propylene, or ethylene and propylene, based on the total weight of the effluent stream.

[0371] In one embodiment or in combination with any of the embodiments mentioned herein, the olefin-containing effluent stream 125 can include at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 wt% C2-C4 olefins. Stream 125 can include primarily ethylene, primarily propylene, or primarily ethylene and propylene, based on the total weight of the olefin-containing effluent stream 125. The weight ratio of ethylene to propylene in the olefin-containing effluent stream 125 can be at least 0.2: 1, at least 0.3: 1, at least 0.4: 1, at least 0.5: 1, at least 0.6: 1, at least 0.7: 1, at least 0.8: 1, at least 0.9: 1, at least 1: 1, at least 1.1: 1, at least 1.2: 1, at least 1.3: 1, at least 1.4: 1, at least 1.5: 1, at least 1.6: 1, at least 1.7: 1, at least 1.8: 1, at least 1.9: 1, or at least 2: 1 and / or no more than 3: 1, no more than 2.9: 1, no more than 2.8: 1, no more than 2.7: 1, no more than 2.5: 1, no more than 2.3: 1, no more than 2.2: 1, no more than 2.1: 1, no more than 2: 1, no more than 1.7: 1, no more than 1.5: 1, or no more than 1.25: 1.

[0372] Turning again to FIG. 8a, in one embodiment or in combination with any of the embodiments mentioned herein, pyrolysis gas 172 can be introduced into the inlet of the cracker furnace 720, or all or a portion of the pyrolysis gas can be introduced downstream of the furnace outlet, at a location upstream or within the separation zone 740 of the cracker facility 70, when introduced into the cracker facility 70. When introduced into or upstream of the separation zone 740, the pyrolysis gas can be introduced upstream of the last stage of compression, or prior to the inlet of at least one of the fractionation columns in the fractionation section of the separation zone 740.

[0373] Prior to entering the cracker facility 70, in one embodiment or in combination with any of the embodiments mentioned herein, the raw pyrolysis gas stream from the pyrolysis facility can undergo one or more separation steps to remove one or more components from the stream. Examples of these components can include, but are not limited to, halogens, aldehydes, oxygenates, nitrogen-containing compounds, sulfur-containing compounds, carbon dioxide, water, vaporized metals, and combinations thereof. The pyrolysis gas stream 172 introduced into the cracker facility 70 includes at least 0.1, at least 0.5, at least 1, at least 1.5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, or at least 5 and / or no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 3, no more than 2, or no more than 1 wt% of one or more aldehyde components, based on the total weight of the pyrolysis gas stream 172.

[0374] In one embodiment or in combination with any of the embodiments mentioned herein, the total ethylene content of pyrolysis gas stream 172 can be at least 1, at least 2, at least 5, at least 7, at least 10, at least 15, at least 20, at least 25, or at least 30 wt% and / or not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 wt% based on the total weight of stream 172. Alternatively, or additionally, the total propylene content of pyrolysis gas stream 172 can be at least 1, at least 2, at least 5, at least 7, at least 10, at least 15, at least 20, at least 25, or at least 30 wt% and / or not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 wt% based on the total weight of stream 172. The combined amount of ethylene and propylene in pyrolysis gas stream 172 can be at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, or at least 45 wt% and / or not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, or not more than 45 wt% based on the total weight of the stream.

[0375] Upon exiting the cracker furnace outlet, the olefin-containing effluent stream 125 can be rapidly cooled (e.g., quenched) in order to prevent the production of large amounts of undesirable byproducts and to minimize fouling in downstream equipment. In one embodiment or in combination with any of the embodiments mentioned herein, the temperature of the olefin-containing effluent from the furnace can be reduced by 35 to 485 °C, 35 to 375 °C, or 90 to 550 °C during the quenching or cooling step to achieve a temperature of 500 to 760 °C.

[0376] The resulting cooled effluent stream can then be separated in a gas-liquid separator, and the vapor can be compressed in a gas compressor with, for example, 1-5 compression stages with optional inter-stage cooling and liquid removal. The gas stream pressure at the outlet of the first set of compression stages is in the range of 7 to 20 bar gauge (barg), 8.5 to 18 barg, or 9.5 to 14 barg. The resulting compressed stream is then treated to remove acid gases, including halogens, CO2, and H2S, by contact with an acid gas removal agent. Examples of acid gas removal agents can include, but are not limited to, caustic and various types of amines. In one embodiment or in combination with any of the embodiments mentioned herein, a single contactor can be used, while in other embodiments, a two-tower absorption-stripping tower configuration can be employed.

[0377] The treated compressed olefin-containing stream can then be further compressed in another compressor, optionally with interstage cooling and liquid separation. The resulting compressed stream has a pressure in the range of 20-50 barg, 25-45 barg, or 30-40 barg. Any suitable water removal method can be used, including, for example, molecular sieves or other similar methods. The resulting stream can then be passed to a fractionation section, where the olefins and other components can be separated into various high purity products or intermediate streams. In some embodiments, all or a portion of the pyrolysis gas can be introduced before and / or after one or more stages of the second compressor. Similarly, the pressure of the pyrolysis gas is within 20 psi, within 50 psi, within 100 psi, or within 150 psi of the pressure of the stream with which it is combined.

[0378] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream from the quench zone can be introduced into at least one column within a fractionation section of the separation zone. As used herein, the term “fractionation” refers to the general process of separating two or more materials having different boiling points. Examples of equipment and methods that utilize fractionation include, but are not limited to, distillation, rectification, stripping, and vapor-liquid separation (single stage).

[0379] In one embodiment or in combination with any of the embodiments mentioned herein, the fractionation section of the cracker facility can include one or more of a demethanizer column, a deethanizer column, a depropanizer column, an ethylene separator, a propylene separator, a debutanizer column, and combinations thereof. As used herein, the term “demethanizer column” refers to a column whose light key component is methane. Similarly, “deethanizer column” and “depropanizer column” refer to columns having ethane and propane as the light key components, respectively.

[0380] Any suitable column arrangement can be used such that the fractionation section provides at least one olefin product stream and at least one paraffin stream. In one embodiment or in combination with any of the embodiments mentioned herein, the fractionation section can provide: at least two olefin streams, such as ethylene and propylene; and at least two paraffin streams, such as ethane and propane; and additional streams, including, for example, methane and lighter components and butane and heavier components.

[0381] In one embodiment or in combination with any of the embodiments herein, the olefin stream removed from the fractionation section can comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% and / or not more than 100, not more than 99, not more than 97, not more than 95, not more than 90, not more than 85, or not more than 80 wt% olefins, based on the total weight of the olefin stream. The olefins can be predominantly ethylene or predominantly propylene. The olefin stream can comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% and / or not more than 99, not more than 97, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, or not more than 65 wt% ethylene, based on the total weight of the olefins in the olefin stream. The olefin stream can comprise at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, or at least 60 wt% and / or not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, or not more than 45 wt% ethylene, based on the total weight of the olefin stream, or it can be present in an amount of 20-80 wt%, 25-75 wt%, or 30-70 wt%, based on the total weight of the olefin stream.

[0382] Alternatively, or additionally, the olefin stream can comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% and / or not more than 99, not more than 97, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, or not more than 65 wt% propylene, based on the total weight of the olefins in the olefin stream. In one embodiment or in combination with any of the embodiments herein, the olefin stream can comprise at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, or at least 60 wt% and / or not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, or not more than 45 wt% propylene, based on the total weight of the olefin stream, or it can be present in an amount of 20-80 wt%, 25-75 wt%, or 30-70 wt%, based on the total weight of the olefin stream.

[0383] When the compressed stream passes through the fractionation section, it passes through a demethanizer, in which methane and lighter (CO, CO2, H2) components are separated from ethane and heavier components. The demethanizer can be operated at a temperature of at least -145, or at least -142, or at least -140, or at least -135, in each case °C, and / or, not more than -120, not more than -125, not more than -130, not more than -135 °C. The bottoms stream from the demethanizer includes at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 99, in each case percent of the total, of ethane and heavier components.

[0384] In one embodiment or in combination with any of the embodiments mentioned herein, all or a portion of the stream introduced into the fractionation section can be introduced into a deethanizer, in which C2and lighter components are separated from C3and heavier components by fractionation. The deethanizer can be operated at a top temperature of at least -35, or at least -30, or at least -25, or at least -20, in each case °C, and / or, not more than -5, not more than -10, not more than -15, not more than -20 °C; and a top pressure of at least 3, or at least 5, or at least 7, or at least 8, or at least 10, in each case barg, and / or, not more than 20, or not more than 18, or not more than 17, or not more than 15, or not more than 14, or not more than 13, in each case barg. The deethanizer withdraws at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99, in each case percent of the total, of C2and lighter components introduced into the column in the top stream. The top stream removed from the deethanizer includes at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case weight percent, of ethane and ethylene, based on the total weight of the top stream.

[0385] In one embodiment or in combination with any of the embodiments herein, the C2and lighter overhead stream from the deethanizer can be further separated in an ethane-ethylene fractionator column (ethylene fractionator or ethylene splitter). In the ethane-ethylene fractionator column, an ethylene and lighter components stream can be removed from the top of the column or as a side stream from the upper half of the column, while ethane and any residual heavier components are removed in a bottoms stream. The ethylene fractionator column can be operated at a top temperature of at least -45, or at least -40, or at least -35, or at least -30, or at least -25, or at least -20, in each case °C, and / or not more than -15, or not more than -20, or not more than -25, in each case °C; and a top pressure of at least 10, or at least 12, or at least 15, in each case barg, and / or not more than 25, not more than 22, not more than 20 barg. The overhead stream, which can be rich in ethylene, can include at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 98, or at least 99, in each case wt%, of ethylene, based on the total weight of the stream, and can be sent to a downstream processing unit for further processing, storage, or sale.

[0386] The bottoms stream of the ethane-ethylene fractionator can include at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98, in each case wt%, of ethane, based on the total weight of the bottoms stream. As previously described, all or a portion of the extracted ethane can be recovered to the inlet of the cracker furnace as an additional feedstock, either alone or in combination with pyrolysis oil and / or pyrolysis gas.

[0387] In some embodiments, at least a portion of the compressed stream can be separated in a depropanizer column, where C3and lighter components are removed as an overhead vapor stream, and C4and heavier components leave the column in a liquid bottoms. The depropanizer column can be operated at an overhead temperature of at least 20, or at least 35, or at least 40, in each case °C and / or an overhead pressure of at least 10, or at least 12, or at least 15, in each case barg and / or not more than 20, or not more than 17, or not more than 15, in each case barg. The depropanizer column strips at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99, in each case as a percentage of the total amount of C3and lighter components introduced into the column in the overhead stream. In one embodiment or in combination with any of the embodiments mentioned herein, the overhead stream removed from the depropanizer column comprises at least or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98 wt% of propane and propylene, in each case based on the total weight of the overhead stream.

[0388] In one embodiment or in combination with any of the embodiments mentioned herein, the overhead stream from the depropanizer column can be introduced into a propane-propylene fractionator (propylene fractionator or propylene splitter), where propylene and any lighter components are removed in the overhead stream, and propane and any heavier components leave the column in a bottoms stream. The propylene fractionation column can be operated at an overhead temperature of at least 20, or at least 25, or at least 30, or at least 35, in each case °C and / or not more than 55, not more than 50, not more than 45, not more than 40 °C; and an overhead pressure of at least 12, or at least 15, or at least 17, or at least 20, in each case barg and / or not more than 20, or not more than 17, or not more than 15, or not more than 12, in each case barg. The overhead stream, which can be enriched in propylene, can comprise at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 98, or at least 99, in each case weight percent propylene, based on the total weight of the stream, and can be sent to a downstream processing unit for further processing, storage, or sale.

[0389] The bottoms stream from the propane-propylene fractionator can include at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98, in each case weight percent, propane based on the total weight of the bottoms stream. As discussed previously, all or a portion of the extracted propane can be recovered to the cracker furnace as an additional feed, either alone or in combination with pyrolysis oil and / or pyrolysis gas.

[0390] In one embodiment or in combination with any of the embodiments referred to herein, at least a portion of the compressed stream can be sent to a debutanizer column to separate C4and lighter components, including butenes, butanes, and butadiene, from C5and heavier (C5+) components. The debutanizer column can be operated at a column top temperature of at least 20, or at least 25, or at least 30, or at least 35, or at least 40, in each case °C, and / or not more than 60, or not more than 65, or not more than 60, or not more than 55, or not more than 50, in each case °C, and a column top pressure of at least 2, or at least 3, or at least 4, or at least 5, in each case barg, and / or not more than 8, or not more than 6, or not more than 4, or not more than 2, in each case barg. The debutanizer column extracts at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99, in each case percent, of the total amount of C4and lighter components introduced into the column in the column top stream.

[0391] In one embodiment or in combination with any of the embodiments referred to herein, the column top stream removed from the debutanizer column includes at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, butadiene, in each case weight percent, based on the total weight of the column top stream. The bottoms stream from the debutanizer column includes primarily C5and heavier components, the amount of which is at least 50, or at least 60, or at least 70, or at least 80, or at least 90, or at least 95, wt%, based on the total weight of the stream. The debutanizer bottoms stream can be sent to further separation, treatment, storage, sale, or use. In one embodiment or in combination with any of the embodiments described herein, the column top stream or C4from the debutanizer column can be subjected to any conventional separation process, such as an extraction or distillation process, to extract a more concentrated butadiene stream.

[0392] In one embodiment or in combination with any of the embodiments referred to herein, at least a portion of one or more of the above streams can be introduced into Figure 9one or more of the illustrated facilities, while in other embodiments, all or a portion of the stream withdrawn from the separation zone of the cracking facility can be sent to further separation and / or storage, transportation, sale, and / or use.

[0393] Partial Oxidation (POX) Gasification

[0394] In an embodiment or in combination with any of the embodiments described herein, the chemical recycling facility can further include a partial oxidation (POX) gasification facility. As used herein, the term "partial oxidation" refers to the high temperature conversion of a carbon-containing feed to syngas (carbon monoxide, hydrogen, and carbon dioxide) where the conversion is carried out in the presence of a sub-stoichiometric amount of oxygen. The conversion can be a conversion of a hydrocarbon-containing feed and can be carried out using a sub-stoichiometric amount of oxygen than is required for complete oxidation of the feed (i.e., all carbon is oxidized to carbon dioxide and all hydrogen is oxidized to water). Reactions that occur within a partial oxidation (POX) gasifier include the conversion of a carbon-containing feed to syngas, specific examples of which include, but are not limited to: partial oxidation, water gas shift, water gas - primary reactions, Boudouard, oxidation, methanation, hydrogen reforming, steam reforming, and carbon dioxide reforming. The feed to the POX gasification can include solids, liquids, and / or gases. A "partial oxidation facility" or "POX gasification facility" is a facility that includes all equipment, piping, and controls necessary to carry out POX gasification of waste plastics and feedstocks derived therefrom.

[0395] In the POX gasification facility, the feed stream can be converted to syngas in the presence of a sub-stoichiometric amount of oxygen. In an embodiment or in combination with any of the embodiments mentioned herein, the feed stream to the POX gasification facility can comprise one or more PO-enriched waste plastics, at least one solventysis byproduct stream, a pyrolysis stream (including pyrolysis gas, pyrolysis oil, and / or pyrolysis residue), and at least one stream from the cracking facility. One or more of these streams can be introduced continuously into the POX gasification facility, or one or more of these streams can be introduced intermittently. When multiple types of feed streams are present, each can be introduced separately, or all or a portion of the streams can be combined so that the combined stream is introduced into the POX gasification facility. When present, the combination can be carried out in a continuous or intermittent manner. The feed stream can be in the form of a gas, a liquid or liquefied plastic, a solid (typically comminuted), or a slurry.

[0396] The POX gasification facility includes at least one POX gasification reactor. An exemplary POX gasification reactor 52 is shown in Figure 1POX gasification unit can include a gas-fed, liquid-fed, or solid-fed reactor (or gasifier). In one embodiment or in combination with any of the embodiments mentioned herein, the POX gasification facility can perform liquid-fed POX gasification. As used herein, "liquid-fed POX gasification" refers to a POX gasification process in which the feed to the process contains, primarily (by weight), components that are liquid at 25°C and 1 atm. Additionally, or alternatively, the POX gasification unit can perform gas-fed POX gasification. As used herein, "gas-fed POX gasification" refers to a POX gasification process in which the feed to the process contains, primarily (by weight), components that are gaseous at 25°C and 1 atm.

[0397] Additionally, or alternatively, the POX gasification unit can perform solid-fed POX gasification. As used herein, "solid-fed POX gasification" refers to a POX gasification process in which the feed to the process contains, primarily (by weight), components that are solid at 25°C and 1 atm.

[0398] Gas-fed, liquid-fed, and solid-fed POX gasification processes can be co-fed with lesser amounts of other components having different phases at 25°C and 1 atm. Thus, a gas-fed POX gasifier can be co-fed with liquids and / or solids, but the liquids and / or solids are only in amounts less than the amount of gas fed to the gas-phase POX gasifier (by weight); a liquid-fed POX gasifier can be co-fed with gas and / or solids, but the gas and / or solids are only in amounts less than the amount of liquid fed to the liquid-fed POX gasifier (by weight); a solid-fed POX gasifier can be co-fed with gas and / or liquids, but the gas and / or liquids are only in amounts less than the amount of solids fed to the solid-fed POX gasifier (by weight).

[0399] In one embodiment or in combination with any of the embodiments mentioned herein, the total feed to a gas-fed POX gasifier can contain at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of components that are gaseous at 25°C and 1 atm; the total feed to a liquid-fed POX gasifier can contain at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of components that are liquid at 25°C and 1 atm; the total feed to a solid-fed POX gasifier can contain at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of components that are solid at 25°C and 1 atm.

[0400] As Figure 1As generally shown, the gasification feed stream 116 can be introduced into the gasification reactor with an oxidant stream 180. The feedstock stream 116 and the oxidant stream 180 can be injected through an injector assembly into a pressurized gasification zone having a pressure of, for example, typically at least 500, at least 600, at least 800, or at least 1,000 psig (or at least 35, at least 40, at least 55, or at least 70 barg).

[0401] In one embodiment or in combination with any embodiment mentioned herein, the oxidant in stream 180 comprises an oxidizing gas, which can include air, oxygen-enriched air, or molecular oxygen (O2). The oxidant comprises at least 25, at least 35, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, at least 95, at least 97, at least 99, or at least 99.5 mole percent (mol%) of molecular oxygen, based on moles of all components in the oxidant stream 180 injected into the reaction (combustion) zone of the gasification reactor 52. The particular amount of oxygen supplied to the reaction zone relative to the components in the feed stream 116 can be sufficient to obtain maximum yield or near maximum yield of carbon monoxide and hydrogen from the gasification reaction, taking into account the amount of feedstock stream, and the amount of charge to the feed, processing conditions, and reactor design.

[0402] The oxidant can include or be instead of air, oxygen-enriched air, and molecular oxygen other oxidizing gases or liquids. Examples of such oxidizing liquids suitable for use as the oxidant include water (which can be added as a liquid or as steam) and ammonia. Examples of such oxidizing gases suitable for use as the oxidant include carbon monoxide, carbon dioxide, and sulfur dioxide.

[0403] In one embodiment or in combination with any embodiment mentioned herein, an atomization-enhancing fluid is fed to the gasification zone along with the feedstock and the oxidant. As used herein, the term “atomization-enhancing fluid” refers to a liquid or gas that is operable to reduce the viscosity to reduce the energy of dispersion, or to increase the energy available to aid in dispersion. The atomization-enhancing fluid can be mixed with the plastic-containing feedstock before the feedstock is fed to the gasification zone, or added separately to the gasification zone, for example to an injection assembly connected to the gasification reactor. In one embodiment or in combination with any embodiment mentioned herein, the atomization-enhancing fluid is water and / or steam. However, in one embodiment or in combination with any embodiment mentioned herein, steam and / or water is not supplied to the gasification zone.

[0404] In one embodiment or in combination with any of the embodiments mentioned herein, a gas stream enriched in carbon dioxide or nitrogen (e.g., greater than the molar amount present in air, or at least 2, at least 5, at least 10, or at least 40 mol%) is charged to the gasifier. These gases can be used as a carrier gas to propel the feedstock to the gasification zone. Due to the pressure within the gasification zone, these carrier gases can be compressed to provide the motive force for introduction into the gasification zone. The gas stream can be the same or different in composition from the atomization-enhancing fluid. In one or more embodiments, the gas stream also functions as the atomization-enhancing fluid.

[0405] In one embodiment or in combination with any of the embodiments mentioned herein, a gas stream enriched in hydrogen (H2) (e.g., at least 1, at least 2, at least 5, at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, or at least 90 mol%) is charged to the gasifier. Hydrogen can be added to influence the partial oxidation reactions, thereby controlling the resulting syngas composition.

[0406] In one embodiment or in combination with any of the embodiments mentioned herein, no gas stream containing greater than 0.01 mol% or greater than 0.02 mol% carbon dioxide is charged to the gasifier or gasification zone. Alternatively, no gas stream containing more than 77, more than 70, more than 50, more than 30, more than 10, more than 5, or more than 3 mol% nitrogen is charged to the gasifier or gasification zone. Further, no gaseous hydrogen stream having more than 0.1, more than 0.5, more than 1, or more than 5 mol% hydrogen is charged to the gasifier or gasification zone. Further, no methane stream containing more than 0.1, more than 0.5, more than 1, or more than 5 mol% methane is charged to the gasifier or gasification zone. In certain embodiments, the only gaseous stream introduced to the gasification zone is the oxidant.

[0407] As previously described, the gasification process can be a partial oxidation (POX) gasification reaction. Generally, to increase the production of hydrogen and carbon monoxide, the oxidation process involves the partial rather than complete oxidation of the gasification feedstock, and thus, can be operated in an oxygen-lean environment relative to the amount required to completely oxidize 100% of the carbon and hydrogen bonds. In one embodiment or in combination with any of the embodiments mentioned herein, the total oxygen demand of the gasifier can exceed the amount theoretically required to convert the carbon content of the gasification feedstock to carbon monoxide by at least 5%, at least 10%, at least 15%, or at least 20%. Generally, satisfactory operation can be obtained when the total oxygen supply exceeds the theoretical demand by 10% to 80%. For example, examples of suitable amounts of oxygen per pound of carbon can be in the following ranges: 0.4 to 3.0, 0.6 to 2.5, 0.9 to 2.5, or 1.2 to 2.5 pounds of free oxygen per pound of carbon.

[0408] By introducing separate streams of feedstock and oxidant and causing them to impinge on each other within the reaction zone, mixing of the feedstock and oxidant streams can be accomplished entirely within the reaction zone. In one embodiment or in combination with any embodiment mentioned herein, the oxidant stream is introduced into the reaction zone of the gasifier at a high velocity to both exceed the flame propagation velocity and improve mixing with the feedstock stream. In one embodiment or in combination with any embodiment mentioned herein, the oxidant can be injected into the gasification zone at a velocity in the range of 25 to 500, 50 to 400, or 100 to 400 feet per second. These values would be the velocity of the gaseous oxidant stream at the injector-gasification zone interface, or the injector tip velocity. Mixing of the feedstock stream and oxidant can also be accomplished outside of the reaction zone. For example, in one embodiment or in combination with any embodiment mentioned herein, the feedstock, oxidant, and / or atomization-enhancing fluid can be combined in a conduit upstream of the gasification zone or in a sparging assembly connected to the gasification reactor.

[0409] In one embodiment or in combination with any embodiment mentioned herein, the gasification feedstock stream, oxidant, and / or atomization-enhancing fluid can optionally be preheated to a temperature of at least 200°C, at least 300°C, or at least 400°C. However, the gasification process employed need not preheat the feedstock stream to effectively gasify the feedstock, and the preheating step can result in a decrease in energy efficiency of the process.

[0410] In one embodiment or in combination with any embodiment mentioned herein, the type of gasification technology employed can be a partial oxidation entrained flow gasifier that produces a syngas. This technology is distinct from fixed bed (or moving bed) gasifiers and fluidized bed gasifiers. An exemplary gasifier that can be used is described in U.S. Patent No. 3,544,291, the entire disclosure of which is incorporated herein by reference to the extent not inconsistent with the present disclosure. However, in one embodiment or in combination with any embodiment mentioned herein, other typ...

Claims

1. A method of recycling plastic waste, the method comprising: (a) feeding an amount of PET-containing dry fines from said plastic waste to a solvolysis facility within a chemical recycling facility, wherein the average particle size of the dry fines is less than 0.32 cm and the moisture content is less than 2 wt%; wherein, the amount of PET-containing dry fines comprises no more than 50 wt% polyolefins on a dry basis; separating the PET-containing dry fines into a PET-rich stream and a polyolefin-rich stream by a pre-treatment facility; the polyolefin-rich stream comprises no more than 5 wt% halogens based on the total weight of plastics in the polyolefin-rich stream; and (b) depolymerizing at least a portion of the PET-rich stream in the chemical recycling facility to provide a recycled-content predominantly glycol stream, a recycled-content predominantly terephthalyl stream, and one or more solvolysis byproduct streams, wherein all or a portion of the one or more solvolysis byproduct streams are combined with at least a portion of the polyolefin-rich stream to form a combined stream, and then the resulting combined stream is introduced into at least one downstream processing facility comprising a pyrolysis facility, a cracking facility, a POX gasification facility, and an energy recovery facility; wherein the polyolefin-rich stream is introduced into a liquefaction zone prior to introduction into the downstream processing facility; all or a portion of the solvolysis byproduct stream is added prior to introduction of the polyolefin-rich stream into the liquefaction zone and / or after removal of a liquefied plastic stream from the liquefaction zone to form the combined stream; the liquefaction zone comprises at least one melt tank, at least one circulating loop pump, at least one external heat exchanger, at least one stripping column, and at least one separation vessel; the circulating loop pump circulates liquefied waste plastic; the external heat exchanger receives a liquefied plastic stream from the melt tank, heats it, and returns at least a portion of the heated liquefied plastic stream to the melt tank; the stripping column and separation vessel are disposed downstream of the external heat exchanger and upstream of the melt tank; the stripping column receives the heated liquefied plastic stream from the external heat exchanger and sparges a stripping gas into the liquefied plastic stream to create a two-phase medium; the two-phase medium flows through the separation vessel, wherein a halogen-enriched gas phase separates from a halogen-depleted liquid phase and is removed from the separation vessel.

2. The method of claim 1, wherein, the amount of PET-containing dry fines comprises at least 90 wt% PET on a dry basis.

3. The method of claim 1, wherein, the amount of PET-containing dry fines comprises at least 0.1 wt% copolyesters on a dry basis.

4. The method of claim 1, wherein, the amount of PET-containing dry fines comprises no more than 20 wt% PVC on a dry basis.

5. The method of claim 1, wherein, the dry fines are extracted from a solids-liquid separator and / or dust collector of a PET recycling facility and / or PET article manufacturer, wherein the dust is generated from conveying, drying, densification, centrifugation processes, and / or grinding PET-containing plastic materials.

6. The method of claim 5, wherein, the dry fines comprise dust formed during densification, extrusion, and / or packaging processes at a PET recycling plant.

7. The method of any one of claims 1-6, wherein, the dry fines are directly fed to the chemical recycling facility by a conveying system, wherein the conveying system interconnects the chemical recycling facility with the PET recycling facility.

8. The method of any one of claims 1-6, further comprising, prior to the depolymerizing (b), densifying the dry fines within the chemical recycling facility to form densified plastic particles having a D90 particle size of 0.32 cm to 2.54 cm.

9. The method of claim 8, further comprising feeding the densified plastic particles to a solvolysis facility within the chemical recycling facility.

10. The method of any one of claims 1-6, further comprising, prior to the separating, screening the dry fines to extract dry fines having a particle size of less than 1000 pm, and densifying at least a portion of the dry fines having a particle size of less than 1000 pm to form densified plastic particles having a D90 particle size of 0.32 cm to 2.54 cm.

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