Chemical recycling of waste plastic materials with improved solvolysis catalyst chemistry

Abstract

Provided herein are chemical recycling facilities for processing mixed waste plastics. Such facilities have the ability to process mixed plastic waste streams and utilize various recycling facilities, such as solvent decomposition facilities, pyrolysis facilities, cracker facilities, partial oxidation gasification facilities, energy recovery facilities, and solidification facilities. Streams from one or more of these individual facilities can be used as feed to one or more other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.

Description

Background Technology

[0001] When waste is disposed of in landfills after a single use, especially non-biodegradable waste, it can negatively impact the environment. Therefore, from an environmental perspective, it is desirable to recycle as much waste as possible. However, there remain low-value waste streams that are virtually impossible or economically unrecoverable using conventional recycling techniques. Furthermore, some conventional recycling methods generate waste streams that are themselves economically unrecoverable or unrecyclable, resulting in additional waste streams that must be treated or otherwise disposed of.

[0002] Solvent decomposition can be used to break down plastics, such as polyethylene terephthalate (PET), into their component monomers. This can be done with a variety of solvents, including water or various glycols, amines, or alcohols. While this method provides streams of recovered components ethylene glycol and dimethyl terephthalate, it also provides several byproduct streams, which include mixtures of valuable organic compounds as well as byproducts that are difficult to remove. This makes the recovery and / or extraction of certain components from these streams difficult and expensive.

[0003] Several catalysts are known for solvent decomposition (and particularly methanol decomposition) reactions. However, when processing waste plastics, these conventional catalysts may not be as effective as those used for processing purer feed streams. Therefore, using conventional catalysts when processing mixed waste plastics results in a variety of impurities and lower overall reaction efficiency, especially for the amount of solvent required to produce one pound (or one kilogram) of terephthalate product. Higher impurity levels lead to more expensive processes because many impurities from solvent reactions end up in the difficult-to-remove byproduct stream. Summary of the Invention

[0004] In one aspect, the present technology relates to a method for treating waste plastics, the method comprising: (a) combining a waste plastic stream comprising polyethylene terephthalate (PET) and at least one non-PET plastic with a solvent in a solvent decomposition tank to provide a predominantly liquid stream; (b) adding a catalyst to the predominantly liquid stream, wherein the catalyst comprises lithium, manganese, or a combination thereof; and (c) depolymerizing at least a portion of the PET in a solvent decomposition reactor to form a predominantly terephthaloyl group, a predominantly glycol, and at least one byproduct stream.

[0005] In one aspect, the present technology relates to a method for treating waste plastics, the method comprising: (a) combining a waste plastic stream comprising polyethylene terephthalate (PET) and at least one non-PET plastic with a solvent in a solvent decomposition tank to provide a predominantly liquid stream; (b) transferring a portion of the predominantly liquid stream to a solvent decomposition reactor; (c) adding a catalyst to at least one of the waste plastics, solvent, or predominantly liquid stream, wherein the catalyst comprises lithium, manganese, sodium, potassium, or a combination thereof; and (d) depolymerizing at least a portion of the PET in the solvent decomposition reactor to form a predominantly terephthaloyl, predominantly diol, and at least one byproduct stream.

[0006] In one aspect, the present technology relates to a method for treating waste plastics, the method comprising: (a) subjecting a waste plastic stream containing polyethylene terephthalate (PET) to solvent decomposition in a solvent decomposition facility to form a major diol, a major terephthaloyl group, and at least one solvent decomposition byproduct, wherein at least a portion of said treatment is carried out in the presence of at least one solvent decomposition catalyst comprising manganese, lithium, or a combination thereof; and (b) introducing at least a portion of the solvent decomposition byproduct into at least one of: (i) a pyrolysis facility; (ii) a cracking facility; (iii) a partial oxidation (POX) gasifier facility; (iv) an energy recovery facility; and (v) a liquefaction zone.

[0007] In one aspect, the present technology relates to a solvent decomposition method composition comprising: polyethylene terephthalate (PET) and / or its decomposition products; at least one type of non-PET plastic and / or its decomposition products; a primary solvent; and a catalyst comprising manganese and / or lithium. Attached Figure Description

[0008] Figure 1a is a block flowchart illustrating the main steps of a method and facility for chemically recycling waste plastics according to an embodiment of the present technology;

[0009] Figure 1b is a block flowchart illustrating the main steps of the method and equipment for chemical recycling of waste plastics, and in particular showing additional aspects of the method / facility shown in Figure 1a;

[0010] Figure 2 This is a block flowchart illustrating a separation process and zones for separating mixed plastic waste according to an embodiment of the present technology;

[0011] Figure 3 This is a block flowchart illustrating the main steps of a method and facility for solvent decomposition of PET according to an embodiment of the present technology;

[0012] Figure 4 It shows from Figure 3 The diagram shown is a block flow chart illustrating the separation of light organic streams in a PET solvent decomposition facility.

[0013] Figure 5 This is a block flowchart showing a portion of the chemical recovery facility shown in Figure 1a, with particular emphasis on the liquefaction zone and its relationship to other facilities and processes according to embodiments of the present technology;

[0014] Figure 6 This illustrates an embodiment according to the present technology. Figure 5 A block flowchart of an exemplary liquefaction zone;

[0015] Figure 7 This is a block flowchart illustrating the main steps of a pyrolysis method and facility for converting waste plastics into a pyrolysis product stream according to an embodiment of the present technology;

[0016] Figure 8A This is a block flowchart illustrating the main steps of an integrated pyrolysis method and facility and a cracking method and facility according to embodiments of the present technology;

[0017] Figure 8B This is a schematic diagram of a cracking furnace according to an embodiment of the present technology;

[0018] Figure 9 This is a schematic diagram of a POx reactor according to an embodiment of the present technology;

[0019] Figure 10 This is a schematic diagram illustrating various definitions of the term "separation efficiency" as used herein;

[0020] Figure 11 This is a graph showing the results of the methanol decomposition reaction of waste plastic materials, which uses several different types of catalysts described in the examples, and specifically shows the impurities and the ratio of methanol to terephthalate for each test;

[0021] Figure 12 This is a graph showing the results of the methanol decomposition reaction of waste plastic materials, using several different concentrations of manganese catalyst described in the examples. Specifically, it shows the impurities and the methanol to terephthalate ratio for each test; and...

[0022] Figure 13 This is a graph showing the results of the methanol decomposition reaction of waste plastic materials using several different concentrations of sodium hydroxide and manganese catalysts described in the examples. The impurities and the ratio of methanol to terephthalate are shown in particular for each test. Detailed Implementation

[0023] We have discovered a catalyst system that produces fewer impurities while being more efficient (determined by a lower methanol to terephthalate ratio). In particular, we have found that a catalyst system including a catalyst containing manganese and / or lithium compounds (alone or in combination with a base) promotes reactions with fewer impurities and requires less methanol to produce one pound of terephthalate compared to conventional catalysts.

[0024] When indicating a sequence of numbers, it should be understood that each number is modified to be the same as the first or last number in the sequence or sentence, for example, each number is "at least", "at most", or "no more than" depending on the context; and each number is in an "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%", etc.; and "not exceeding 90 wt%, 85, 70, 60..." means the same as "not exceeding 90 wt%, or not exceeding 85 wt%, or not exceeding 70 wt%..." etc.; and "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%..." etc.; and "at least 5, 10, 15, 20 and / or not exceeding 99, 95, 90 wt% by weight" 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 not exceeding 99 wt%, or not exceeding 95 wt%, or not exceeding 90 wt% by weight..." etc.

[0025] Unless otherwise stated, all concentrations or amounts are by weight.

[0026] Integrated chemical recycling facility

[0027] Turning now to Figures 1a and 1b, the main steps of a method for chemically recycling waste plastics for a chemical recycling facility 10 are shown. It should be understood that Figures 1a and 1b depict an exemplary embodiment of the present technology. Certain features depicted in Figures 1a and 1b may be omitted and / or additional features described elsewhere herein may be added to the system depicted in Figures 1a and 1b.

[0028] As shown in Figures 1a and 1b, these steps typically include a pretreatment step / facility 20, and at least one (or at least two or more) of the following: a solvent decomposition 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 may also include one or more other steps, such as direct sale or use, landfill, separation, and solidification, one or more of which are indicated by box 90 in Figures 1a and 1b. Although shown as including all of these steps or facilities, it should be understood that chemical recycling methods and facilities according to one or more embodiments of the present technology may include at least two, three, four, five, or all of these facilities in various combinations for the chemical recycling of plastic waste, and particularly mixed plastic waste. The chemical recycling methods and facilities described herein can be used to convert plastic waste into recycled component products or chemical intermediates for the formation of various end-use materials. The waste plastics fed into the chemical recycling facility / method may be mixed plastic waste (MPW), pre-sorted waste plastics, and / or pre-treated waste plastics.

[0029] As used herein, the term "chemical recycling" refers to a waste plastic recycling process that includes steps of chemically converting waste plastic polymers into lower molecular weight polymers, oligomers, monomers, and / or non-polymer molecules (e.g., hydrogen and carbon monoxide), which are useful in themselves and / or can be used as feedstocks for one or more other chemical production processes. A "chemical recycling facility" is a facility that produces recycled component products through the chemical recycling of waste plastics. As used herein, the terms "recycled component" and "r-component" refer to or contain compositions that are directly and / or indirectly derived from waste plastics.

[0030] As used herein, the term “directly derived” means having at least one physical component derived from waste plastics, while “indirectly derived” means having a specified recycled component that i) is attributable to waste plastics, but ii) is not based on having a physical component derived from waste plastics.

[0031] Chemical recycling facilities are not mechanical recycling facilities. As used herein, the terms “mechanical recycling” and “physical recycling” refer to recycling processes that include steps of melting waste plastics and forming the molten plastics into new intermediate products (e.g., pellets or sheets) and / or new final products (e.g., bottles). Typically, mechanical recycling does not significantly alter the chemical structure of the recycled plastics. In one embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility described herein can be configured to receive and process waste streams from mechanical recycling facilities and / or those that are typically not handled by mechanical recycling facilities.

[0032] Although described herein as part of a single chemical recovery facility, it should be understood that one or more of the pretreatment 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, may be located in different geographical locations and / or operated by different commercial entities. Each of the pretreatment 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 may be operated by the same entity, while in other cases, one or more of the pretreatment 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 (e.g., separation or solidification) may be operated by different commercial entities.

[0033] In one embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility 10 may be a commercial-scale facility capable of processing large quantities of mixed plastic waste. As used herein, the term "commercial-scale facility" means a facility with an average annual feed rate of at least 500 lb / h over a year. The average feed rate to the chemical recycling facility (or to any one of the pretreatment 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) may 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, or 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 lbs / 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 lbs / hour. When the facility comprises two or more feed streams, the average annual feed rate is determined based on the combined weight of the feed streams.

[0034] Furthermore, it should be understood that each of the pretreatment 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 may include multiple units operating in series or in parallel. For example, pyrolysis facility 60 may include multiple pyrolysis reactors / units operating in parallel, each receiving a feed containing waste plastics. When a facility consists of multiple individual units, the average annual feed rate of the facility is calculated as the sum of the average annual feed rates of all common types of units within the facility.

[0035] Furthermore, in one embodiment or in combination with any of the embodiments mentioned herein, the chemical recovery facility 10 (or any one of the pretreatment 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) may operate in a continuous manner. Additionally, or alternatively, at least a portion of the chemical recovery facility 10 (or any one of the pretreatment 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) may operate in an intermittent or semi-intermittent manner. In some cases, the facility may include multiple tanks between sections of a single facility or between two or more different facilities to manage inventory and ensure a consistent flow rate into each facility or its sections.

[0036] Additionally, the two or more facilities shown in Figures 1a and 1b may 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 facilities may co-locate. As used herein, the term “co-located” refers to facilities in which at least a portion of process flows and / or support equipment or services are shared between two facilities. When the two or more facilities shown in Figures 1a and 1b co-locate, the facilities may meet at least one of the following criteria (i) to (v): (i) the facilities share at least one non-residential utility; (ii) the facilities share at least one service group; (iii) the facilities are owned and / or operated by parties sharing at least one boundary; (iv) the facilities are connected by at least one conduit; 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 center. At least one, at least two, at least three, at least four, or all of the above statements (i) to (v) may be true.

[0037] Regarding (i), examples of suitable public utility services include, but are not limited to, steam systems (combined heat and power 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 / sewage systems, storage facilities, pipelines, flare systems, and combinations thereof.

[0038] Regarding (ii), examples of service groups and facilities include, but are not limited to, emergency service personnel (fire and / or medical), third-party suppliers, state or local government oversight groups, and combinations thereof. Government oversight groups may include, for example, regulatory or environmental agencies at the city, county, and state levels, as well as municipal and tax agencies.

[0039] Regarding (iii), the boundary may be, for example, a fence line, a land boundary line, a gate, or a shared boundary with at least one boundary of land or facilities owned by a third party.

[0040] Regarding (iv), the conduit can be a fluid conduit carrying a gas, liquid, solid / liquid mixture (e.g., slurry), solid / gas mixture (e.g., pneumatic conveying), solid / liquid / gas mixture, or solid (e.g., belt conveying). In some cases, two units may share one or more conduits selected from the above list. Fluid conduits can be used to transport process flows or utilities between two units. For example, the outlet of one facility (e.g., solvent decomposition facility 30) may be fluidly connected to the inlet of another facility (e.g., POX vaporization facility 50) via a conduit. In some cases, a temporary storage system may be provided for materials transported within conduits between the outlet of one facility and the inlet of another facility. The temporary storage system may include, for example, one or more tanks, containers (open or closed), buildings, or containers configured to store materials carried by the conduit. In some cases, temporary storage between the exit of one facility and the entrance of another facility may be for 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.

[0041] Turning back to Figures 1a and 1b, a stream 100 of waste plastics can be introduced into a chemical recycling facility 10. This waste plastic may be mixed plastic waste (MPW). As used herein, the terms “waste plastic” and “plastic waste” refer to used, discarded, and / or discarded plastic materials, such as plastic materials typically sent to landfills. Other examples of waste plastics (or plastic waste) include used, discarded, and / or discarded plastic materials that are typically sent to incinerators. The stream 100 of waste plastics fed into the chemical recycling facility 10 may include untreated or partially treated waste plastics. As used herein, the term “untreated waste plastic” refers to waste plastics that have not undergone 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 containers. As used herein, the term “partially treated waste plastic” refers to waste plastics that have undergone at least one automated or mechanized sorting, washing, or shredding step or process. Partially treated waste plastics may originate from, for example, municipal recycling facilities (MRFs) or recycling plants. When partially treated waste plastics are supplied to the chemical recycling facility 10, one or more pretreatment steps may be skipped. Waste plastics may include at least one of post-industrial (or pre-consumer) plastics and / or post-consumer plastics.

[0042] 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 (PO), and polyvinyl chloride (PVC). In one embodiment or in combination with any of the embodiments mentioned herein, MPW comprises at least two different types of plastics, each type of plastic being 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 the plastics in the MPW.

[0043] In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of the plastic in the MPW, 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. In one or more embodiments, the MPW may also comprise 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 the plastic in the MPW.

[0044] In one embodiment or in combination with any embodiment mentioned herein, the MPW contains 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, based on the total weight of the stream. Alternatively, or additionally, the MPW contains 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% PET, based on the total weight of the stream.

[0045] Based on the total weight of the stream, the MPW stream may contain non-PET components in the following amounts: 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 may be present in amounts of 0.1 wt%-50 wt%, 1 wt%-20 wt%, or 2 wt%-10 wt%. Examples of such non-PET components may include, but are not limited to, ferrous and nonferrous metals, inert materials (e.g., rock, glass, sand, etc.), plastic inert materials (e.g., titanium dioxide, silicon dioxide, etc.), olefins, binders, compatibilizers, biosludge, cellulose materials (e.g., paperboard, paper, etc.), and combinations thereof.

[0046] In one embodiment or in combination with any of the embodiments mentioned herein, all or part of the MPW may be derived from or include municipal waste. The municipal waste portion of the MPW may include, for example, PET, in amounts of 45wt%-95wt%, 50wt%-90wt%, or 55wt%-85wt% based on the total weight of the municipal waste stream (or a portion thereof).

[0047] In one embodiment or in combination with any of the embodiments mentioned herein, all or part of the MPW may be derived from a municipal recycling facility (MRF) and may include, for example, PET in an amount of 65wt%-99.9wt%, 70wt%-99wt%, or 80wt%-97wt% based on the total weight of the stream. Non-PET components in such a stream may include, for example, other plastics in an amount of at least 1, at least 2, at least 5, at least 7, or at least 10wt% and / or no more than 25, no more than 22, no more than 20, no more than 15, no more than 12, or no more than 10wt% based on the total weight of the stream, or may be present in an amount of 1wt%-22wt%, 2wt%-15wt%, or 5wt%-12wt% based on the total weight of the stream. In one embodiment or in combination with any of the embodiments mentioned herein, non-PET components may include other plastics in an amount ranging from 2wt%-35wt%, 5wt%-30wt%, or 10wt%-25wt% based on the total weight of the stream, particularly when, for example, the MPW includes colored sorting plastics.

[0048] In one embodiment or in combination with any of the embodiments mentioned herein, all or part of the MPW may be derived from a recycling facility and may include, for example, PET, in amounts of 85wt%-99.9wt%, 90wt%-99.9wt%, or 95wt%-99wt% based on the total weight of the stream. Non-PET components in such a stream may include, for example, other plastics, in amounts of at least 1, at least 2, at least 5, at least 7, or at least 10wt% and / or no more than 25, no more than 22, no more than 20, no more than 15, no more than 12, or no more than 10wt% based on the total weight of the stream, or may be present in amounts of 1wt%-22wt%, 2wt%-15wt%, or 5wt%-12wt% based on the total weight of the stream.

[0049] As used herein, the term "plastic" can include any organic synthetic polymer that is solid at 25°C and 1 atmosphere. In one embodiment or in combination with any embodiment mentioned herein, 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 1000, 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 may be at least 300, or at least 500, or at least 1000, 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.

[0050] Suitable examples of plastics may include, but are not limited to, aromatic and aliphatic polyesters, polyolefins, polyvinyl chloride (PVC), polystyrene, polytetrafluoroethylene, acrylonitrile butadiene styrene (ABS), cellulose products, epoxides, polyamides, phenolic resins, polyacetals, polycarbonates, polyphenylene alloys, poly(methyl methacrylate), styrene-containing polymers, polyurethanes, vinyl polymers, styrene-acrylonitrile, thermoplastic elastomers other than tires, urea-containing polymers, and melamine.

[0051] Examples of polyesters may include those having repeating aromatic or cyclic units, such as those containing repeating terephthalate, isophthalate, or naphthalene ester units, such as PET, modified PET, and PEN, or those containing repeating furanyl ester units. Polyethylene terephthalate (PET) is also an example of a suitable polyester. As used herein, “PET” or “polyethylene terephthalate” refers to a homopolymer of polyethylene terephthalate, or to polyethylene terephthalate modified with one or more acids and / or glycol modifiers and / or containing residues or portions other than ethylene glycol and terephthalic acid, such residues or portions as isophthalic acid, 1,4-cyclohexanedicarboxylic acid, diethylene glycol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol (TMCD), cyclohexanediethanol (CHDM), propylene glycol, isosorbide, 1,4-butanediol, 1,3-propanediol and / or neopentyl glycol (NPG).

[0052] The definitions of the terms "PET" and "polyethylene terephthalate" also include polyesters having repeating terephthalate units (whether or not they contain repeating glycol-based units) and one or more diol residues or portions, 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 may include, but are not limited to, polypropylene terephthalate, polybutylene terephthalate and their copolyesters. Examples of aliphatic polyesters may include, but are not limited to, polylactic acid (PLA), polyglycolic acid, polycaprolactone and polyethylene adipate. Polymers may include mixed aliphatic-aromatic copolyesters, including, for example, mixed terephthalate / adipate esters.

[0053] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic may comprise at least one type of plastic having repeating terephthalate units, wherein, based on the total weight of the stream, such plastic is present in amounts 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 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%, or, based on the total weight of the stream, it may be present in amounts ranging from 1 wt% to 45 wt%, 2 wt% to 40 wt%, or 5 wt% to 40 wt%. A similar amount of copolyester having multiple cyclohexanediol moieties, 2,2,4,4-tetramethyl-1,3-cyclobutanediol moieties, or combinations thereof, may also be present.

[0054] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic may comprise at least one type of plastic having repeating terephthalate units, wherein, based on the total weight of the stream, such plastic is present in amounts 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 no more than 99.9, no more than 99, no more than 97, no more than 95, no more than 90, or no more than 85 wt%, or, based on the total weight of the stream, it may be present in amounts ranging from 30 wt% to 99.9 wt%, 50 wt% to 99.9 wt%, or 75 wt% to 99 wt%.

[0055] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic may contain repeating terephthalate 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 no more than 75, no more than 72, no more than 70, no more than 60 or no more than 65 wt% based on the total weight of the waste plastic stream, or may contain repeating terephthalate 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.

[0056] Specific examples of polyolefins may 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 above polyolefins. Waste plastics may include polymers, including linear low-density polyethylene (LLDPE), polymethylpentene, polybutene-1, and their copolymers. Waste plastics may include flash-spun high-density polyethylene.

[0057] Waste plastics may include thermoplastic polymers, thermosetting polymers, or combinations thereof. In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of the stream, the waste plastics may contain 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% of one or more thermosetting polymers, or based on the total weight of the stream, the thermosetting polymers may be present in amounts of 0.1 wt%-45 wt%, 1 wt%-40 wt%, 2 wt%-35 wt%, or 2 wt%-20 wt%.

[0058] Alternatively, or additionally, based on the total weight of the stream, waste plastics may contain 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% of cellulose material, or based on the total weight of the stream, cellulose material may be present in amounts ranging from 0.1 wt% to 45 wt%, 1 wt% to 40 wt%, or 2 wt% to 15 wt%. Examples of cellulose material may include cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, cellulose acetate butyrate, and regenerated cellulose such as viscose. Additionally, the cellulose material may include cellulose derivatives having an acyl substitution degree of less than 3, not exceeding 2.9, not exceeding 2.8, not exceeding 2.7 or not exceeding 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.

[0059] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic may contain STYROFOAM or expanded polystyrene.

[0060] Waste plastics can originate from one or more of a variety of sources. In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics can originate from plastic bottles, diapers, eyeglass frames, films, packaging materials, carpets (residential, commercial and / or automotive), textiles (clothing and other fabrics), and combinations thereof.

[0061] In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics (e.g., MPW) fed to a chemical recycling facility may include one or more plastics having or derived from the following: having resin ID codes 1-7 with a chasing arrow triangle established by SPI. Waste plastics may include one or more plastics that are not typically mechanically recycled. Such plastics may include, but are not limited to, plastics having resin ID codes 3 (polyvinyl chloride), 5 (polypropylene), 6 (polystyrene), and / or 7 (others). In one embodiment or in combination with any embodiment mentioned herein, the plastic has at least 1, at least 2, at least 3, at least 4, or at least 5 resin ID codes 3-7 or 3, 5, 6, 7, or combinations thereof, and based on the total weight of all the plastic, it may be present in the waste plastic in the following amounts: 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 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, or no more than 35 wt%, or based on the total weight of the plastic, the amount may be 0.1 wt%-90 wt%, 1 wt%-75 wt%, 2 wt%-50 wt%, or no more than 50 wt%.

[0062] In one embodiment or in combination with any of the embodiments mentioned herein, the following amounts of total plastic components in waste plastics fed to a chemical recycling facility may include plastics that do not have resin ID codes 3, 5, 6 and / or 7 (e.g., in the case of unclassified plastics): at least 5, at least 10, at least 15, at least 20, at least 25, at least 30 or at least 35 and / or 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%. The total plastic composition of the waste plastics fed into the chemical recycling facility 10 may contain plastics without resin ID codes 4-7 in the following amounts: 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 based on the total weight of the plastic composition, it may be in the range of 0.1 wt%-60 wt%, 1 wt%-55 wt%, or 2 wt%-45 wt%.

[0063] In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics (e.g., MPW) fed to a chemical recycling facility may contain plastics not classified as resin ID codes 3-7 or ID codes 3, 5, 6, or 7. Based on the total weight of plastics in the waste plastic stream, the total amount of plastics not classified as resin ID codes 3-7 or ID codes 3, 5, 6 or 7 in the waste plastics may 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 exceeding 95, not exceeding 90, not exceeding 85, not exceeding 80, not exceeding 75, not exceeding 70, not exceeding 65, not exceeding 60, not exceeding 55, not exceeding 50, not exceeding 45, not exceeding 40, not exceeding 35wt%, or based on the total weight of plastics in the waste plastic stream, it may be in the range of 0.1wt%-95wt%, 0.5wt%-90wt%, or 1wt%-80wt%.

[0064] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises plastic having or derived from plastic 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.

[0065] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises a multicomponent polymer. As used herein, the term "multicomponent polymer" refers to an article and / or granules comprising at least one synthetic or natural polymer that is combined, attached, or otherwise physically and / or chemically associated with at least one other polymer and / or nonpolymer solid. The polymer may be a synthetic polymer or plastic, such as PET, olefins, and / or nylon. The nonpolymer solid may be a metal, such as aluminum, or other nonplastic solid as described herein. Multicomponent polymers may include metallized plastics.

[0066] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises a multi-component plastic in the form of a multilayer polymer. As used herein, the term "multilayer polymer" refers to a multi-component polymer comprising PET and at least one other polymer and / or non-polymer solid, which are physically and / or chemically bonded together in the form of two or more physically distinct layers. A polymer or plastic is considered a multilayer polymer even if a transition region may exist between two layers, for example, in the form of an adhesively bonded layer or a co-extruded layer. An adhesive between two layers is not considered a single layer. A multilayer polymer may include: a layer comprising PET and one or more additional layers, wherein at least one additional layer is a synthetic or natural polymer other than PET, or a polymer without repeating ethylene terephthalate units, or a polymer without repeating alkylene terephthalate units ("non-PET polymer layer"), or other non-polymer solids.

[0067] Examples of non-PET polymer layers include nylon, polylactic acid, polyolefins, polycarbonate, ethylene-vinyl alcohol, polyvinyl alcohol, and / or other plastics or plastic films associated with PET-containing articles and / or granules, as well as natural polymers such as whey protein. Multilayer polymers may include a metal layer, such as aluminum, provided that at least one additional polymer layer other than the PET layer is present. These layers may be adhered by adhesive bonding or other methods, physically adjacent (i.e., the article is pressed onto the film), tackified (i.e., the plastics are heated and bonded together), co-extruded plastic film, or otherwise attached to PET-containing articles. Multilayer polymers may include PET films associated with articles containing other plastics in the same or similar manner. MPWs may comprise multicomponent polymers in the form of PET and at least one other plastic, such as polyolefins (e.g., polypropylene) and / or other synthetic or natural polymers, combined in a single physical phase. For example, MPWs may comprise heterogeneous mixtures containing a compatibilizer, PET, and at least one other synthetic or natural polymer plastic (e.g., a non-PET plastic) combined in a single physical phase. As used herein, the term "compensator" refers to an agent that can combine at least two otherwise immiscible polymers in a physical mixture (i.e., a blend).

[0068] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains no more than 20, 10, 5, 2, 1, or 0.1 wt% nylon on a dry plastic basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW contains 0.01 wt%-20 wt%, 0.05 wt%-10 wt%, 0.1 wt%-5 wt%, or 1 wt%-2 wt% nylon on a dry plastic basis.

[0069] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises, on a dry plastic basis, 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 multicomponent plastic. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises, on a dry plastic basis, 0.1 wt%-40 wt%, 1 wt%-20 wt%, or 2 wt%-10 wt% of multicomponent plastic. In one embodiment or in combination with any of the mentioned embodiments, on a dry plastic basis, 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 multilayer plastic. In one embodiment or in combination with any of the mentioned embodiments, on a dry plastic basis, the MPW comprises, no more than 0.1 wt%-40 wt%, 1 wt%-20 wt%, or 2 wt%-10 wt% of multilayer plastic.

[0070] In one embodiment or in combination with any of the mentioned embodiments, the MPW feedstock in stream 100 to chemical recycling facility 10 comprises no more than 20, 15, 12, 10, 8, 6, 5, 4, 3, 2, or 1 wt% of biowaste material, the total weight of the MPW feedstock being taken as 100 wt% on a dry basis. Alternatively, the MPW feedstock may comprise 0.01 wt%-20 wt%, 0.1 wt%-10 wt%, 0.2 wt%-5 wt%, or 0.5 wt%-1 wt% of biowaste material, the total weight of the MPW feedstock being taken as 100 wt% on a dry basis. As used herein, the term "biowaste" refers to material derived from living organisms or organic sources. Exemplary biowaste materials include, but are not limited to, cotton, wood, sawdust, food scraps, animals and animal parts, plants and plant parts, and fertilizers.

[0071] In one embodiment or in combination with any of the mentioned embodiments, the MPW feedstock comprises no more than 20, 15, 12, 10, 8, 6, 5, 4, 3, 2, or 1 wt% of manufactured cellulose products, the total weight of the MPW feedstock being taken as 100 wt% on a dry basis. The MPW feedstock may also comprise 0.01 wt%-20 wt%, 0.1 wt%-10 wt%, 0.2 wt%-5 wt%, or 0.5 wt%-1 wt% of manufactured cellulose products, the total weight of the MPW feedstock being taken as 100 wt% on a dry basis. As used herein, the term "manufactured cellulose product" refers to non-natural (i.e., man-made or machine-made) articles and their waste, including cellulose fibers. Exemplary manufactured cellulose products include, but are not limited to, paper and paperboard.

[0072] In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of plastics in the waste plastic feed, the waste plastics (e.g., MPW) fed to the chemical recycling facility may 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).

[0073] Additionally, or alternatively, waste plastics (e.g., MPW) fed to the chemical recycling facility may 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. Non-plastic solids may include inert fillers (e.g., calcium carbonate, hydrated aluminum silicate, alumina trihydrate, calcium sulfate), rocks, glass, and / or additives (e.g., thixotropic adhesives, pigments and colorants, flame retardants, explosion suppressants, UV inhibitors and stabilizers, conductive metals or carbon, mold release agents such as zinc stearate, waxes, and silicones).

[0074] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the MPW stream or composition, the MPW may contain 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 liquid. Based on the total weight of the MPW stream 100, the amount of liquid in the MPW may range from 0.01 wt% to 25 wt%, 0.5 wt% to 10 wt%, or 1 wt% to 5 wt%.

[0075] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the waste plastics, the MPW may contain 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 liquid. Based on the total weight of the waste plastics, the liquid in the waste plastics may be in the range of 35wt%-65wt%, 40wt%-60wt%, or 45wt%-55wt%.

[0076] In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the MPW, the amount of textiles (including textile fibers) in the MPW flow in pipeline 100 may 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 material, which is derived from textiles or textile fibers. Based on the total weight of MPW flow 100, the amount of textiles (including textile fibers) in the MPW in flow 100 may 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 MPW flow 100, the amount of textiles in MPW flow 100 may be in the range of 0.1 wt%-50 wt%, 5 wt%-40 wt%, or 10 wt%-30 wt%.

[0077] The MPW introducing chemical recycling facility 10 may contain recycled textiles. Textiles may contain natural and / or synthetic fibers, rovings, yarns, nonwoven webs, fabrics, textiles, and products made from or containing any of the aforementioned items. Textiles may be woven, knitted, knotted, sewn, tufted, and may include pressed fibers, such as felted, embroidered, lace, crocheted, or woven, or may include nonwoven webs and materials. Textiles may include: fabrics, and fibers separated from textiles or other fiber-containing products, waste or substandard fibers or yarns or fabrics, or any other source of loose fibers and yarns. Textiles may also include staple fibers, continuous fibers, threads, yarn bundles, twisted yarns and / or spun yarns, greige fabrics made from yarns, finished fabrics produced by wet processing of greige fabrics, and apparel made from finished fabrics or any other fabrics. Textiles include clothing, interior decoration, and industrial textiles. Textiles may include post-industrial textiles (pre-consumer) or post-consumer textiles or both.

[0078] In one embodiment or in combination with any of the mentioned embodiments, textiles may include clothing, which can generally be defined as articles worn by or made for the human body. Such textiles may include sports jackets, suits, trousers and casual or work pants, shirts, socks, sportswear, dresses, close-fitting garments, outerwear such as raincoats, low-temperature jackets and coats, sweaters, protective clothing, uniforms, and accessories such as scarves, hats, and gloves. Examples of textiles in the interior furnishing category include furniture upholstery and covers, carpets and mats, curtains, bedding such as sheets, pillowcases, comforters, quilts, mattress covers; linen products, tablecloths, towels, and blankets. Examples of industrial textiles include: transportation (car, airplane, train, bus) seats, floor mats, trunk liners, and roof liners; outdoor furniture and mats, tents, backpacks, luggage, ropes, conveyor belts, calendered felt, polishing cloths, rags, soil erosion fabrics and geotextiles, agricultural mats and screens, personal protective equipment, bulletproof vests, medical bandages, stitching, tape, etc.

[0079] The category of nonwoven webs classified as textiles does not include wet-laid nonwoven webs and articles made from them. While various articles with the same function can be made by either dry-laid or wet-laid methods, 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 may 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, underwear, and pet training pads. Other examples include various dry or wet wipes, including those for consumer (e.g., personal care or household) and industrial (e.g., food service, healthcare, or professional) uses. Nonwoven webs can also be used as stuffing for pillows, mattresses, and upholstery, as well as for quilts and comforters. In the medical and industrial fields, the nonwoven mesh of the present invention can be used for consumer face shields, medical face shields and industrial face shields, protective clothing, hats and shoe covers, disposable sheets, surgical gowns, curtains, bandages and medical dressings.

[0080] Additionally, the nonwoven nets described herein can be used in environmental fabrics such as geotextiles and tarpaulins, oil-absorbing mats and chemical-absorbing mats, as well as building materials such as sound or heat insulation, tents, timber and soil coverings, and sheets. Nonwoven nets can also be used for other consumer end-uses, such as for carpet backing, packaging of consumer, industrial, and agricultural products, heat or sound insulation, and various types of clothing.

[0081] Dry-laid nonwoven webs as described herein can also be used in a variety of filtration applications, including transportation (e.g., automotive or aerospace), commercial, residential, industrial, or other specialized applications. Examples may include filter elements for consumer or industrial air or liquid filters (e.g., gasoline, oil, water), including nanofiber webs for microfiltration, and end-use applications such as tea bags, coffee filters, and drying paper. Furthermore, nonwoven webs as described herein can be used to form various components for automotive applications, including but not limited to brake pads, trunk liners, carpet tufting, and floor mats.

[0082] Textiles may include one or more types of natural fibers and / or one or more 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.

[0083] Natural fibers include those of plant or animal origin. Natural fibers can be cellulose, hemicellulose, and lignin. Examples of plant-derived natural fibers include: hardwood pulp, softwood pulp, and wood flour; and other plant fibers, including those found in wheat straw, rice straw, Manila hemp, coconut fiber, cotton, flax, hemp, jute, bagasse, kapok, papyrus, ramie, rattan, grapevine, kenaf, Manila hemp, hena lamina, sisal, soybean, cereal straw, bamboo, reeds, fine-stemmed needlegrass, bagasse, Indian grass, milkweed fiber, pineapple leaf fiber, switchgrass, and lignin-containing plants. Examples of animal-derived fibers include wool, silk, mohair, cashmere, goat hair, horsehair, poultry fiber, camel hair, Angora wool, and alpaca wool.

[0084] Synthetic fibers are those fibers that are synthesized or derived, or regenerated, at least in part, through chemical reactions, including but not limited to: rayon, viscose, mercerized fiber, or other types of regenerated cellulose (natural cellulose is converted into soluble cellulose derivatives and subsequently regenerated), such as lyocell (also known as TENCEL™), cupro (CuPro), Modal, acetates such as polyvinyl acetate, polyamides including nylon, polyesters such as PET, olefin polymers such as polypropylene and polyethylene, polycarbonate, polysulfone, polyethers such as polyether-urea called spandex or elastic fiber, polyacrylates, acrylonitrile copolymers, polyvinyl chloride (PVC), polylactic acid, polyglycolic acid, sulfonated polyester fibers, and combinations thereof.

[0085] Before entering the 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., granulated) 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 in any form mentioned herein and can undergo one or more of the aforementioned steps in pretreatment facility 20 prior to processing in the remaining facilities of the chemical recycling facility 10 shown in Figures 1a and 1b.

[0086] In one embodiment or in combination with any of the embodiments mentioned herein, a combination of polyethylene terephthalate (PET) and one or more polyolefins (PO) comprises 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 waste plastics (e.g., MPW) fed into the chemical recycling facility in stream 100 of Figures 1a and 1b. Based on the total weight of plastics in the waste plastics introduced into the chemical recycling facility 10, polyvinyl chloride (PVC) may comprise 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.

[0087] 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.

[0088] In one embodiment or in combination with any embodiment mentioned herein, 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 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 or no more than 35 wt% of PO, or based on the total weight of the waste plastic introduced into the chemical recycling facility 10, PO may be present in amounts ranging from 5 wt% to 75 wt%, 10 wt% to 60 wt%, or 20 wt% to 35 wt%.

[0089] Waste plastics (e.g., MPW) introduced into chemical recycling facilities can be supplied from a variety of sources, including, but not limited to, municipal recycling facilities (MRFs) or recycling facilities, other mechanical or chemical sorting or separation facilities, manufacturers or plants or commercial production facilities, or retailers or distributors or wholesalers with post-industrial and pre-consumer recyclables, directly from households / businesses (i.e., untreated recyclables), landfills, collection centers, convenience centers, or warehouses at docks or on ships or on board. In one embodiment or in combination with any of the embodiments mentioned herein, the source of waste plastics (e.g., MPW) does not include a storage state return facility, whereby consumers can store specific recyclable items (e.g., plastic containers, bottles, etc.) to receive a monetary refund from that state. In one embodiment or in combination with any of the embodiments mentioned herein, the source of waste plastics (e.g., MPW) does include a storage state return facility, whereby consumers can store specific recyclable items (e.g., plastic containers, bottles, etc.) to receive a monetary refund from that state. For example, such return facilities are typically found in grocery stores.

[0090] In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics may be provided as a waste stream from another processing facility (such as a municipal recycling facility (MRF) or a recycling facility) or as a plastic-containing mixture comprising waste plastics that have been sorted by consumers and left on the curb or collected at central convenience stations. In one or more such embodiments, the waste plastic comprises one or more MRF products or byproducts, recycled byproducts, sorted plastic-containing mixtures, and / or PET-containing waste plastic from a plastics manufacturing facility, wherein, on a dry plastic basis, the one or more MRF products or byproducts, recycled byproducts, sorted plastic-containing mixtures, and / or PET-containing waste plastic comprises 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 may be in the range of 10 wt%-99.9 wt%, 20 wt%-99 wt%, 30 wt%-95 wt%, or 40 wt%-90 wt% PET.

[0091] In one or more such embodiments, the waste plastic comprises a quantity of PET-containing recycled by-products or plastic mixtures, which, on a dry plastic basis, contain 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% of PET, or on a dry plastic basis, may range from 1 wt% to 99.9 wt%, 1 wt% to 99 wt%, or 10 wt% to 90 wt% of PET. The recycling facility may also include a process for producing high-purity PET (at least 99 wt% or at least 99.9 wt%) recycled by-products, but in a form undesirable for mechanical recycling facilities. As used herein, the term "recycled by-product" refers to any material separated or extracted by the recycling facility that is not extracted as a transparent rPET product, including colored rPET. The recycled by-products described above and below are generally considered waste products and may be sent to landfills.

[0092] In one or more of these embodiments, the waste plastic comprises a quantity of recycled wet fines, on a dry plastic basis, comprising at least 20, at least 40, at least 60, at least 80, at least 90, at least 95, or at least 99 wt% and / or no more than 99.9 wt% PET. In one or more of these embodiments, the waste plastic comprises a quantity of a mixture of colored plastics, on a dry plastic basis, comprising at least 1, at least 10, at least 20, at least 40, at least 60, at least 80, or at least 90 and / or no more than 99.9 or no more than 99 wt% PET. In one or more of these embodiments, the waste plastic comprises a quantity of eddy waste stream, on a dry plastic basis, comprising metal and at least 0.1, at least 1, at least 10, at least 20, at least 40, at least 60, or at least 80 wt% and / or no more than 99.9, no more than 99, or no more than 98 wt% PET. In one or more of these embodiments, the waste plastic comprises a certain amount of recycled sheet waste, which, on a dry plastic basis, 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% and / or no more than 99.9, no more than 99, or no more than 98 wt% of PET, or, on a dry plastic basis, may be in the range of 0.1 wt%-99.9 wt%, 1 wt%-99 wt%, or 10 wt%-98 wt% of PET. In one or more of these embodiments, the waste plastic comprises a certain amount of dry fines, which, on a dry plastic basis, comprises at least 50, at least 60, at least 70, at least 80, at least 90, at least 95, at least 99, or at least 99.9 wt% of PET.

[0093] Chemical recycling facility 10 may also include infrastructure for receiving waste plastics (e.g., MPW) as described herein, to facilitate the delivery of waste plastics by any suitable type of vehicle, including, for example, trains, trucks, and / or ships. This infrastructure may include facilities to assist in unloading waste plastics from vehicles, and one or more conveying systems for storage facilities and for transporting waste plastics from the unloading area to downstream processing areas. Such conveying systems may include, for example, pneumatic conveyors, belt conveyors, bucket conveyors, vibrating conveyors, screw conveyors, cart-on-track conveyors, trailer conveyors, overhead conveyors, front-end loaders, trucks, and chain conveyors.

[0094] Waste (e.g., MPW) introduced into the chemical recycling facility 10 can be in several forms, including but not limited to: whole articles, granules (e.g., crushed, granulated, fibrous plastic granules), bundled packages (e.g., compressed and bundled whole articles), unbundled items (i.e., not bundled or unpackaged), containers (e.g., boxes, sacks, trailers, railcars, loader buckets), stockpiles (e.g., on concrete slabs of buildings), solid / liquid slurries (e.g., pumped slurries of plastics in water), and / or physically conveyed loose materials (e.g., granules on a conveyor belt) or pneumatically conveyed loose materials (e.g., granules mixed with air and / or inert gases in a conveyor pipe).

[0095] As used herein, the term "waste plastic pellets" refers to waste plastic with a D90 of less than 1 inch. In one embodiment or in combination with any embodiment mentioned herein, waste plastic pellets may be MPW pellets. Waste plastic or MPW pellets may include, for example, shredded or minced plastic pellets, or plastic granules. When all or substantially all of the articles are introduced into the chemical recycling facility 10 (or pretreatment facility 20), one or more shredding or granulation steps may be used therein to form waste plastic pellets (e.g., MPW pellets). Alternatively, or additionally, at least a portion of the waste plastic introduced into the chemical recycling facility 10 (or pretreatment facility 20) may already be in pellet form.

[0096] The general configuration and operation of each facility that may exist in the chemical recycling facilities shown in Figures 1a and 1b will now be described in further detail below, starting with the pretreatment facility. Optionally, although not shown in Figures 1a and 1b, at least one stream from the chemical recycling facility may be sent to an industrial landfill or other similar type of treatment or disposal facility.

[0097] Preprocessing

[0098] As shown in Figures 1a and 1b, untreated and / or partially treated waste plastics, such as mixed plastic waste (MPW), may first be introduced into pretreatment facility 20 via stream 100. In pretreatment facility 20, the stream may undergo one or more treatment steps to prepare it for chemical recycling. As used herein, the term “pretreatment” refers to the preparation of waste plastics for chemical recycling using one or more of the following steps: (i) crushing, (ii) granulation, (iii) washing, (iv) drying, and / or (v) separation. As used herein, the term “pretreatment facility” refers to a facility that includes all the equipment, piping, and control devices required to perform waste plastic pretreatment. Pretreatment facilities as described herein can employ any suitable method to prepare waste plastics for chemical recycling using one or more of these steps, which will be described in further detail below.

[0099] Crushing and granulation

[0100] In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics (e.g., MPW) may be provided as unsorted or pre-sorted plastic bales or in other large aggregate forms. The bales or aggregates of plastic undergo an initial process in which they are broken up. The plastic bales may be fed to a bale opener, which includes, for example, one or more rotating shafts equipped with teeth or blades configured to separate the bales and, in some cases, shred the plastic constituting the bales. In one or more other embodiments, the bales or aggregates of plastic may be fed to a chaff cutter, where they are cut into smaller plastic sheets. The unpacked and / or chaff-cut plastic solids may then undergo a sorting process in which various non-plastic heavy materials, such as glass, metal, and rock, are removed. This sorting process may be performed manually or by machine. The sorting machine may rely on optical sensors, magnets, eddy currents, pneumatic lifts or conveyors based on drag coefficient separation, or sieves to identify and remove heavy materials.

[0101] 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, 0.75 inches, or 0.5 inches, such as used containers. Alternatively, or additionally, the waste plastic feedstock may also comprise multiple plastic solids that at some point had a size greater than one inch, but these solids may have been compacted, compressed, or otherwise aggregated into larger units, such as bales. In embodiments where at least some or all of the plastic solids have a size greater than one inch, 0.75 inches, or 0.5 inches, the feedstock may undergo mechanical size reduction operations, such as grinding / granulation, shredding, chopping, cutting, or other pulverizing processes, to provide MPW pellets with reduced dimensions. Such mechanical size reduction operations may include size reduction steps rather than crushing, compacting, or forming bales of the plastic.

[0102] In one or more other embodiments, the waste plastics may have already undergone some initial separation and / or size reduction processes. In particular, the waste plastics may be in the form of granules or flakes and provided in some kind of container, such as sacks or boxes. Depending on the composition of these plastic solids and what pretreatment they may have undergone, the plastic raw material may bypass unpacking machines, chaff cutters, and / or heavy removal stations and proceed directly to granulation equipment for further size reduction.

[0103] In one embodiment or in combination with any of the embodiments mentioned herein, unpacked or crushed plastic solids may be fed to a crushing or granulating apparatus, in which the plastic solids are ground, shredded, or otherwise reduced in size. The plastic material may be formed into granules having a D90 particle size of less than 1 inch, less than ¾ inch, or less than ½ inch. In one or more other embodiments, the D90 particle size of the plastic material exiting the granulating apparatus is 1 / 16 inch to 1 inch, 1 / 8 inch to ¾ inch, ¼ inch to 5 / 8 inch, or 3 / 8 inch to ½ inch.

[0104] Washing and drying

[0105] In one embodiment or in combination with any of the embodiments mentioned herein, untreated or partially treated waste plastics provided to a chemical recycling facility may contain a variety of organic contaminants or residues that may be associated with the previous use of the waste plastics. For example, waste plastics may contain food or beverage contaminants, particularly if the plastic material was used for food or beverage packaging. Therefore, waste plastics may also contain microbial contaminants and / or compounds produced by microorganisms. Exemplary microorganisms that may be present on the plastic solid surfaces constituting waste plastics include Escherichia coli, Salmonella, Clostridium difficile, Staphylococcus aureus, Listeria monocytogenes, Staphylococcus epidermidis, Pseudomonas aeruginosa, and Pseudomonas fluorescens.

[0106] Various microorganisms can produce compounds that cause foul odors. Exemplary odor-causing compounds include hydrogen sulfide, dimethyl sulfide, methanethiol, putrescine, cadaverine, trimethylamine, ammonia, acetaldehyde, acetic acid, propionic acid, and / or butyric acid. Therefore, it is understood that waste plastics may pose an odor nuisance problem. Consequently, waste plastics can be stored in enclosed spaces, such as shipping containers, enclosed railcars, or enclosed trailers, until they can be further processed. In some embodiments, untreated or partially treated waste plastics, once they arrive at the location where they are to be processed (e.g., shredding, washing, and sorting), can be stored in enclosed spaces for no more than one week, no more than five days, no more than three days, no more than two days, or no more than one day.

[0107] In one embodiment or in combination with any of the embodiments mentioned herein, pretreatment facility 20 may also include equipment or steps for treating waste plastics with a chemical composition having antimicrobial properties, thereby forming treated granular plastic solids. In some embodiments, this may include treating the waste plastics with sodium hydroxide, a high-pH saline solution (e.g., potassium carbonate), or other antimicrobial compositions.

[0108] Additionally, in one embodiment or in combination with any of the embodiments mentioned herein, waste plastics (e.g., MPW) may optionally be washed to remove inorganic non-plastic solids, such as soil, glass, fillers, and other non-plastic solid materials, and / or to remove biological components such as bacteria and / or food. Based on the total weight of the waste plastics, the resulting washed waste plastics may also be dried to a moisture content not exceeding 5, 3, 2, 1, 0.5, or 0.25 wt% water (or liquid). Drying may be carried out in any suitable manner, including by heating and / or airflow, mechanical drying (e.g., centrifugation), or by allowing the liquid to evaporate within a specified time.

[0109] Separation

[0110] In one embodiment or in combination with any of the embodiments mentioned herein, the pretreatment facility 20 or the steps of the chemical recycling process or the chemical recycling facility 10 may include at least one separation step or separation zone. The separation step or separation zone may be configured to separate the waste plastic stream into two or more streams enriched with certain types of plastics. This separation is particularly advantageous when the waste plastic fed to the pretreatment facility 20 is MPW (multi-component plastic).

[0111] In one embodiment or in combination with any of the embodiments mentioned herein, the separation zone 22 of the pretreatment facility 20 (see Figure 2 This can separate waste plastics (such as MPW) into components such as... Figure 2 The PET sorting stream 112 and PET depletion stream 114 are shown. As used herein, the term "enrichment" means having a concentration (on undiluted dry weight) of a particular component that is greater than the concentration of that component in the reference material or stream. As used herein, the term "depletion" means having a concentration (on undiluted dry weight) of a particular component that is less than the concentration of that component in the reference material or stream. Unless otherwise stated, all weight percentages used herein are on undiluted dry weight.

[0112] When the enriched or depleted component is a solid, the concentration is expressed as undiluted solid dry weight; when the enriched or depleted component is a liquid, the concentration is expressed as undiluted liquid dry weight; and when the enriched or depleted component is a gas, the concentration is expressed as undiluted gas dry weight. Furthermore, enrichment and depletion can be expressed in mass balance terms rather than concentration. Therefore, the component mass of a stream rich in a particular component can be greater than the component mass in a reference stream (e.g., feed stream or other product stream), while the component mass of a stream depleted in relation to a particular component can be less than the component mass in a reference stream (e.g., feed stream or other product stream).

[0113] Refer again Figure 2The PET concentration or mass of the PET-enriched stream 112 of waste plastics removed from pretreatment facility 20 (or separation zone 22) can be higher than that of the waste plastic feed stream 100 introduced into pretreatment facility 20 (or separation zone 22). Similarly, the PET-depleted stream 114 removed from pretreatment facility 20 (or separation zone 22) can be PET-depleted and have a lower PET concentration or mass than that of the waste plastics introduced into pretreatment 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 that of the waste plastic (e.g., MPW) stream introduced into pretreatment facility 20 (or separation zone 22).

[0114] In one embodiment or in combination with any of the embodiments mentioned herein, when the MPW stream 100 is fed to the pretreatment facility 20 (or separation zone 22), the PET enriched stream may be rich in PET concentration or mass relative to the MPW stream or the PET-poor stream, or both, on an undiluted solids dry weight basis. For example, if the PET enriched stream is diluted with a liquid or other solid after separation, the enrichment will be based on the concentration in the undiluted PET enriched stream, on a dry basis. In one embodiment or in combination with any of the mentioned embodiments, the PET enrichment percentage of the PET enrichment stream 112, relative to the MPW feed stream (PET enrichment percentage based on feed), the PET depleted product stream 114 (PET enrichment percentage based on product), or both, is determined by the following formula:

[0115]

[0116] and

[0117]

[0118] Where PETe is the concentration of PET in PET enriched product stream 112, based on undiluted dry weight;

[0119] PETM is the concentration of PET in the MPW feed stream 100, on a dry basis; and

[0120] PETd is the concentration of PET in PET-depleted product stream 114, on a dry basis.

[0121] In one embodiment or in combination with any of the embodiments mentioned herein, when a stream containing MPW 100 is fed to pretreatment facility 20 (or separation zone 22), the PET enriched stream is also rich in halogens, such as fluorine (F), chlorine (Cl), 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 lean product stream 114 or both. In one embodiment or in combination with any of the mentioned embodiments, the PVC enrichment percentage of the PET enrichment stream 112 relative to the MPW feed stream (based on the PVC enrichment percentage of the feed), the PET depleted product stream (based on the PVC enrichment percentage of the product), or both, is determined by the following formula:

[0122]

[0123] and

[0124]

[0125] Where PVCe is the concentration of PVC in PET enriched product stream 112, based on undiluted dry weight;

[0126] PVCm is the concentration of PVC in the MPW feed stream 100, based on undiluted dry weight; and

[0127] Wherein PVCd is the concentration of PVC in PET depleted product stream 114, based on undiluted dry weight.

[0128] In one embodiment or in combination with any of the mentioned embodiments, when MPW stream 100 is fed to pretreatment facility 20 (or separation zone 22), PET depleted stream 114 is rich in polyolefins on an undiluted solids dry weight basis, relative to the concentration or mass of polyolefins in MPW feed stream 100, PET enriched product stream 112, or both. In one embodiment or in combination with any of the mentioned embodiments, the percentage of polyolefin enrichment in the PET lean stream 114 relative to the MPW feed stream 100 (based on the PO enrichment percentage of the feed) or relative to the PET enriched product stream 112 (based on the PO enrichment percentage of the product), or both, is determined by the following formula:

[0129]

[0130] and

[0131]

[0132] Where POd is the concentration of polyolefin in PET lean product stream 114, based on undiluted dry weight;

[0133] POm is the concentration of PO in the MPW feed stream 100, on a dry basis; and

[0134] POe is the concentration of PO in PET enriched product stream 112, on a dry basis.

[0135] In one embodiment or in combination with any other embodiment, when the MPW stream 100 is fed to the pretreatment facility 20 (or separation zone 22), the PET depleted stream 114 is also depleted in terms of halogens, such as fluorine (F), chlorine (Cl), 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. In one embodiment or in combination with any of the mentioned embodiments, the PVC depletion percentage of the PET depleted stream 114 relative to the MPW feed stream 100 (based on the PVC depletion percentage of the feed) or the PET enriched product stream 112 (based on the PVC depletion percentage of the product) is determined by the following formula:

[0136]

[0137] and

[0138]

[0139] Where PVCm is the concentration of PVC in the MPW feed stream 100, based on undiluted dry weight;

[0140] PVCd is the concentration of PVC in PET lean product stream 114, on an undiluted dry weight basis; and

[0141] PVCe is the concentration of PVC in PET enriched product stream 112, on an undiluted dry weight basis.

[0142] The PET depletion stream 114 is depleted in terms of PET relative to the concentration or mass of PET in the MPW feed stream 100, the PET enrichment stream 112, or both. In one embodiment or in combination with any of the mentioned embodiments, the percentage of PET depletion in the PET depletion stream 114 relative to the MPW feed stream 100 (PET depletion % based on feed) or the PET enrichment product stream 112 (PET depletion % based on product) is determined by the following formula:

[0143]

[0144] and

[0145]

[0146] Where PETm is the concentration of PET in the MPW feed stream 100, on an undiluted dry basis;

[0147] PETd is the concentration of PET in PET-depleted product stream 114, on an undiluted dry basis; and

[0148] PETe is the concentration of PET in PET enriched product stream 112, based on undiluted dry weight.

[0149] In any of the above embodiments, the percentage of enrichment or depletion can be an average over one week, three days, or one day, and taking into account the residence time of the MPW from the inlet to the outlet, measurements can be taken to reasonably correlate the sample taken at the process outlet with the MPW as a whole containing that MPW sample. For example, if the average residence time of the MPW is 2 minutes, the outlet sample is taken two minutes after the inlet sample, thus correlating the samples with each other.

[0150] In one embodiment or in combination with any embodiment mentioned herein, the PET enrichment stream exiting the separation zone 22 or pretreatment facility 20 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, 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 plastic in the PET enrichment stream. The PET enrichment stream 112 may also be rich in PVC and may 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, or no more than 3 wt% halogens (including PVC), based on the total weight of plastic in the PET enrichment stream, or it may be in the range of 0.1 wt%-10 wt%, 0.5 wt%-8 wt%, or 1 wt%-5 wt%. The PET enrichment stream may 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 pretreatment facility 20 (or separation zone 22).

[0151] PET enrichment stream 112 can also be depleted in terms of PO and / or heavier plastics, such as polytetrafluoroethylene (PTFE), polyamides (PA 12, PA 46, PA 66), polyacrylamide (PARA), polyhydroxybutyrate (PHB), polycarbonate / polybutylene terephthalate blends (PC / PBT), polyvinyl chloride (PVC), polyimide (PI), polycarbonate (PC), polyethersulfone (PESU), polyetheretherketone (PEEK), polyamide-imide (PAI), polyethyleneimine (PEI), polysulfone (PSU), polyoxymethylene (POM), polyglycolic acid (polyglycolic acid, PGA), polyphenylene sulfide (PPS), thermoplastic styrene elastomer (TPS), and amorphous thermoplastics. The materials may include polyimide (TPI), liquid crystal 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 may include carbon, glass, and / or mineral fillers and have a higher density than PET and PVC.

[0152] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the plastic in the PET enrichment stream 112, the PET enrichment stream 112 may contain no more than 45, 40, 35, 30, 25, 20, 15, 10, 5, 2, 1, or 0.5 wt% PO. The PET enrichment stream 112 may contain no more than 10, 8, 5, 3, 2, or 1 wt% of the total PO introduced into the pretreatment facility 20 (or separation zone 22). Based on the total weight of the PET enrichment stream 112, the PET enrichment stream 112 may contain no more than 45, 40, 35, 30, 25, 20, 15, 10, 5, 2, or 1 wt% of components other than PET.

[0153] Additionally, or alternatively, on a dry basis, the PET enrichment stream 112 may contain no more than 2, 1, 0.5, or 0.1 wt% of a binder. Typical binders include carpet adhesives, latex, styrene-butadiene rubber, etc. Furthermore, on a dry basis, the PET enrichment stream 112 may include no more than 4, 3, 2, 1, 0.5, or 0.1 wt% of plastic fillers and solid additives. Exemplary fillers and additives include silicon dioxide, calcium carbonate, talc, silica, glass, glass beads, alumina, and other solid inert substances that do not chemically react with the plastic or other components in the methods described herein.

[0154] In one embodiment or in combination with any of the embodiments mentioned herein, the PET depleted (or PO enriched) stream 114 leaving the separation zone 22 or pretreatment facility 20 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, at least 95, at least 97, at least 99, or at least 99.5 wt% PO, based on the total weight of plastic in the PET depleted (or PO enriched) stream. The PET depleted (or PO enriched) stream may be depleted in terms of PVC, and may 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% halogens, including chlorine in the PVC, based on the total weight of plastic in the PET depleted (or PO enriched) stream. The PET depletion or PO enrichment stream may 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 pretreatment facility 20 or separation facility 22.

[0155] The PO enrichment stream 114 may also be depleted in terms of PET and / or other plastics, including PVC. In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of plastics in the PET depletion or PO enrichment stream, the PET depletion (or PO enrichment stream) may contain no more than 45, 40, 35, 30, 25, 20, 15, 10, 5, 2, 1, or 0.5 wt% PET. The PO enrichment (or PET depletion) stream 114 may contain no more than 10, 8, 5, 3, 2, or 1 wt% of the total amount of PET introduced into the pretreatment facility.

[0156] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the PET-deficient or PO-enriched stream 114, the PET-deficient or PO-enriched stream 114 may contain no more than 45, 40, 35, 30, 25, 20, 15, 10, 5, 2, or 1 wt% of components other than PO. Based on the total weight of the stream, the PET-deficient or PO-enriched stream 114 contains no more than 4, 2, 1, 0.5, or 0.1 wt% of binder.

[0157] In one embodiment or in combination with any of the embodiments mentioned herein, the melt viscosity of the PET depletion or PO enrichment stream 114 can be 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 4,500, at least 5,000, at least 5,500, at least 6,000, at least 6,500, at least 7,000, at least 7,500, at least 8,000, at least 8,500, at least 9,000, at least 9,500, or at least 10,000 poises, measured using a Brookfield R / S rheometer with a V80-40 paddle rotor, operating at a shear rate of 10 rad / s and a temperature of 350°C. Alternatively, or additionally, the melt viscosity of the PET-depleted or PO-enriched flow may be 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 poises (measured at 10 rad / s and 350°C). Alternatively, the melt viscosity of the flow can be in the range of 1 to 25,000 poise, 500 to 22,000 poise, or 1,000 to 17,000 poise (measured at 10 rad / s and 350 °C).

[0158] Waste plastics can be separated into two or more streams rich in certain types of plastics using any suitable type of separation apparatus, system, or facility, such as PET enrichment stream 112 and PO enrichment stream 114. Examples of suitable types of separation include mechanical separation and density separation, which may include flotation-sinking separation and / or centrifugal density separation. As used herein, the term “flotation-sinking 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 force. Generally, the term “density separation process” refers to a process that separates materials into at least a higher density output and a lower density output based at least in part on their respective densities, and includes both flotation-sinking separation and centrifugal density separation.

[0159] When using flotation-sinking separation, the liquid medium may include water. Salts, sugars, and / or other additives may be added to the liquid medium, for example, to increase the density of the liquid medium and adjust the target separation density for the flotation-sinking stage. The liquid medium may 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 acetate, carbonate, citrate, nitrate, nitrite, phosphate, and / or sulfate. The liquid medium may include a concentrated salt solution comprising sodium bromide, sodium dihydrogen phosphate, 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 of the embodiments mentioned herein, the salt is a caustic alkali component. The salt may include sodium hydroxide, potassium hydroxide, and / or potassium carbonate. The pH of the concentrated salt solution may be greater than 7, greater than 8, greater than 9, or greater than 10.

[0160] In one embodiment or in combination with any of the embodiments mentioned herein, the liquid medium may comprise sugars, such as sucrose. The liquid medium may include carbon tetrachloride, chloroform, dichlorobenzene, dimethyl sulfate, and / or trichloroethylene. The specific components and concentration of the liquid medium may be selected based on the desired target separation density for the separation stage. Centrifugal density separation processes may also utilize the liquid medium as described above to improve separation efficiency at the target separation density.

[0161] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic separation method includes at least two density separation stages. In some such embodiments, the method typically includes introducing waste plastic particles into a first density separation stage and feeding the output from the first density separation stage into a second density separation stage. The density separation stage can be any system or unit operation performing a density separation process as defined herein. At least one of the density separation stages includes a centrifugal separation stage or a flotation-sinking separation stage. Each of the first and second density separation stages includes a centrifugal separation stage and / or a flotation-sinking separation stage.

[0162] To produce a PET enriched material stream, one of the density separation stages may include a low-density separation stage, while the other typically includes a high-density separation stage. As defined herein, the target separation density of the low-density separation stage is less than the target separation density of the high-density separation stage. The target separation density of the low-density separation stage is less than the density of PET, and the target separation density of the high-density separation stage is greater than the density of PET.

[0163] As used herein, the term "target separation density" refers to the density at which materials undergoing a density separation process preferentially separate into a higher density output, and at a lower density, the materials separate into a lower density output. The target separation density specifies a density value above which all plastics and other solid materials have a density higher than the target density separation value, and all plastics and other solid materials below the target density separation value have a density lower density separation value. However, during density separation, the actual separation efficiency of materials can depend on various factors, including residence time and the relative proximity of the density of a particular material to the target density separation value, as well as factors related to particle form, such as area-to-mass ratio, sphericity, and porosity.

[0164] In one embodiment or in combination with any embodiment 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 for 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 not exceeding 1.45, not exceeding 1.44, not exceeding 1.43, not exceeding 1.42, or not exceeding 1.41 g / cc. The target separation density for the low-density separation stage is in the range of 1.25 to 1.35 g / cc, and the target separation density for the high-density separation stage is in the range of 1.35 to 1.45 g / cc.

[0165] Referring again to Figures 1a and 1b, the PET enriched stream 112 and the PO enriched stream 114 can be introduced into one or more downstream processing facilities (or undergo one or more downstream processing steps) within the chemical recovery facility 10. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PET enriched stream 112 can be introduced into the solvent decomposition facility 30, while at least a portion of the PO enriched stream 114 can be introduced directly or indirectly into one or more of the pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, energy recovery facility 80, or other facilities 90 (such as solidification or separation facilities). Additional details of each step and facility type according to one or more embodiments of the present technology, as well as the general integration of each of these steps and facilities with one or more of the other steps and facilities, will be discussed in further detail below.

[0166] Solvent decomposition

[0167] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PET enriched stream 112 from pretreatment facility 20 may be introduced into solvent decomposition facility 30. As used herein, the terms “solvent decomposition” or “ester solvent decomposition” refer 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 “solvent decomposition facility” is a facility that includes all the equipment, piping, and control devices required for the solvent decomposition of waste plastics and the raw materials derived therefrom.

[0168] When the ester undergoing solvent decomposition contains PET, the solvent decomposition performed in the solvent decomposition facility can be PET solvent decomposition. As used herein, the term "PET solvent decomposition" refers to the chemical decomposition of a feed containing polyterephthalate 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 critical terephthaloyl product extracted from the solvent decomposition facility. As used herein, the term "major diol" refers to the major diol product extracted from the solvent decomposition facility. As used herein, the term "diol" refers to a component containing two or more -OH functional groups per molecule. As used herein, the term "terephthaloyl" refers to a molecule comprising the following groups:

[0169]

[0170] In one embodiment or in combination with any of the embodiments mentioned herein, the predominant terephthaloyl product comprises a terephthaloyl group, such as terephthalic acid or dimethyl terephthalate (or an oligomer thereof), while the predominant diol comprises a diol, such as ethylene glycol and / or diethylene glycol. The main steps of the PET solvent decomposition facility 30 according to one or more embodiments of the present invention are generally shown in Figure 3 middle.

[0171] In one embodiment or in combination with any of the embodiments mentioned herein, the primary solvent used in solvent decomposition comprises a compound having at least one -OH group. Examples of suitable solvents may include, but are not limited to: (i) water (in which case, solvent decomposition may be referred to as "hydrolysis"), (ii) alcohols (in which case, solvent decomposition may be referred to as "alcohololysis") such as methanol (in which case, solvent decomposition may be referred to as "methanol decomposition") or ethanol (in which case, solvent decomposition may be referred to as "ethanol decomposition"), (iii) glycols such as ethylene glycol or diethylene glycol (in which case, solvent decomposition may be referred to as "glycolysis"), or (iv) ammonia (in which case, solvent decomposition may be referred to as "ammonolysis").

[0172] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the solvent stream, the solvent decomposition solvent may 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 or at least 99 wt% of the main solvent. In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the solvent stream, the solvent may 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, or no more than 1 wt% of other solvents or components.

[0173] In one embodiment or in combination with any of the embodiments mentioned herein, the primary solvent or solvent decomposition solvent may comprise, based on the total weight of the solvent stream or composition, no more than 5, 4, 3, 2, 1, or 0.5 wt% of a nonpolar solvent. Based on the total weight of the solvent stream or composition, the primary solvent or solvent decomposition solvent may comprise, based on the total weight of the solvent stream or composition, no more than 5, 4, 3, 2, 1, or 0.5 wt% of a chlorinated solvent.

[0174] When the solvent decomposition facility 30 uses a glycol (e.g., ethylene glycol) as the primary solvent, the facility may be referred to as a glycolysis facility. In one embodiment or in combination with any of the embodiments mentioned herein, the chemical recovery facility of Figures 1a and 1b may include a glycolysis facility. In a glycolysis facility, PET can be chemically decomposed to form ethylene glycol (EG) as the primary glycol and dimethyl terephthalate (DMT) as the primary 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 glycolysis, EG and DMT can be present in a single product stream.

[0175] When a solvent decomposition facility uses methanol as the primary solvent, it can be called a methanol decomposition facility. The chemical recovery facilities shown in Figures 1a and 1b 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).

[0176] 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%.

[0177] In one embodiment or in combination with any of the embodiments mentioned herein, the recovered terephthaloyl (r-terephthaloyl) stream 158 extracted from the solvent decomposition facility 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 terephthaloyl groups formed in the solvent decomposition facility. Based on the total weight of the stream, it may also contain 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 terephthaloyl groups, or it may contain terephthaloyl groups in amounts ranging from 45 wt% to 99 wt%, 50 wt% to 95 wt%, or 55 wt% to 90 wt%. Additionally, or alternatively, based on the total weight of the stream, the stream may contain 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 main terephthaloyl group. Based on the total weight of stream 154, the γ-terephthaloyl group (or terephthaloyl group) may be present in 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%.

[0178] In addition to providing a recoverable primary glycol stream and a recoverable primary terephthaloyl stream, the solvent decomposition facility may also provide one or more solvent decomposition byproduct streams, as shown in stream 110 in Figures 1a and 1b. These streams may also be drawn from one or more locations within the solvent decomposition facility. As used herein, the term “byproduct” or “solvent decomposition byproduct” refers to any compound from the solvent decomposition facility that is not a primary carboxyl (or terephthaloyl) product of the solvent decomposition facility, a primary glycol product of the solvent decomposition facility, or a primary solvent fed into the solvent decomposition facility. Based on the total weight of the streams, the solvent decomposition byproduct streams may contain 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 solvent decomposition byproducts.

[0179] Solvent decomposition byproducts may comprise either heavy organic solvent decomposition byproduct streams or light organic solvent decomposition byproduct streams. As used herein, the term "heavy organic solvent decomposition byproduct" refers to a solvent decomposition byproduct with a boiling point higher than that of the major terephthaloyl product of the solvent decomposition facility, while the term "light organic solvent decomposition byproduct" refers to a solvent decomposition byproduct with a boiling point lower than that of the major terephthaloyl product of the solvent decomposition facility.

[0180] When the solvent decomposition facility is a methanol decomposition facility, one or more methanol decomposition byproducts may be extracted from the facility. As used herein, the term "methanol decomposition byproduct" refers to any compound from the methanol decomposition facility that is not DMT, EG, or methanol. Based on the total weight of the stream, the methanol decomposition byproduct stream may contain 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 solvent decomposition byproducts. In one embodiment or in combination with any of the embodiments mentioned herein, the methanol decomposition byproduct stream may contain heavy organic methanol decomposition byproducts or light organic methanol decomposition byproducts. As used herein, the term "heavy organic methanol decomposition byproduct" refers to a methanol decomposition byproduct with a boiling point higher than DMT, while the term "light methanol decomposition byproduct" refers to a methanol decomposition byproduct with a boiling point lower than DMT.

[0181] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent decomposition facility may produce at least one heavy organic solvent decomposition byproduct stream. Based on the total weight of organic matter in the stream, the heavy organic solvent decomposition byproduct stream may 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 an organic compound having a boiling point higher than that of the predominant terephthaloyl group (e.g., DMT) produced by the solvent decomposition facility 30.

[0182] Additionally, or alternatively, the solvent decomposition facility may generate at least one light organic solvent decomposition byproduct stream. Based on the total weight of the organic matter in the stream, the light organic solvent decomposition byproduct stream may 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 an organic compound having a boiling point lower than that of the predominant terephthaloyl group (e.g., DMT) generated by the solvent decomposition facility 30.

[0183] Turn again Figure 3 In operation, a feed stream 112, including, for example, mixed plastic waste, can be introduced into the solvent decomposition facility 30 together with a solvent stream 212 (either individually or together via a mixing zone 206). In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 112 to the solvent decomposition facility 30 may include waste plastics in an amount 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, 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 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, not more than 30, not more than 25, not more than 20 wt%, not more than 15, not more than 10 wt%, or in an amount of 5 wt%-99 wt%, 10 wt%-95 wt%, or 15 wt%-90 wt% based on the total weight of the feed stream 112. These quantities of waste plastics may also be present in compositions or various streams within solvent decomposition facilities (e.g., reactors or blending zones 206).

[0184] The waste plastics introduced into the solvent decomposition facility 30 may comprise mixed waste plastics and may include, for example, a mixture of polyethylene terephthalate (PET), polyolefin (PO), and polyvinyl chloride (PVC). For example, in one or more embodiments, based on the total weight of feed stream 112, on a dry basis, the waste plastics fed into the solvent decomposition facility 30 may 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% and / or no more than 99.99, 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, no more than 25 wt% of PET, or based on the total weight of stream 112, the stream may include amounts of 1 wt%-99.9 wt%, 2 wt%-99 wt%, or 5 wt%-95 wt% of PET.

[0185] Alternatively or additionally, based on the total weight of feed stream 112, on a dry basis, the waste plastics introduced into the solvent decomposition facility may 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 or at least 45 and / or no more than 90, no more than 80, 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 or no more than 10 wt% of polyolefins, or based on the total weight of stream 112, the stream may include amounts of polyolefins ranging from 5 wt% to 90 wt%, 10 wt% to 80 wt%, or 15 wt% to 50 wt%.

[0186] Furthermore, in one or more embodiments, based on the total weight of the plastic in the feed stream, on a dry basis, the waste plastic fed to the solvent decomposition facility may 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 8, no more than 6, 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 halogen, or based on the total weight of stream 112, it may be in the range of 0.001 wt%-10 wt%, 0.1 wt%-8 wt%, or 0.25 wt%-3 wt%.

[0187] Prior to being introduced into the solvent decomposition facility 30, waste plastics may be sorted in the pretreatment unit 20, as shown in Figures 1a and 1b and as previously discussed, or the waste plastics may be introduced directly into the solvent decomposition facility 30 without sorting. When the sorting, as previously discussed, results in a PET-enriched waste plastic stream (e.g., stream 112 as shown in Figures 1a and 1b) and a PO-enriched waste plastic stream (e.g., stream 114 as shown in Figures 1a and 1b), at least a portion of the PET-enriched stream 112 may be introduced into the solvent decomposition facility 30, while at least a portion or all of the PO-enriched stream 114 may be introduced into one or more chemical treatment facilities, including (i) a partial oxidation (POX) facility 50; (ii) a pyrolysis facility 60; (iii) a cracking facility 70; (iv) an energy recovery facility 80; and (v) a liquefaction zone 40, as discussed in further detail herein.

[0188] like Figure 3 As shown, the predominantly liquid stream can first pass 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 component may be lower than that of PET and it can be removed as vapor from zone 208. Alternatively, or additionally, at least a portion of the non-PET component 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 component may be separated as a solid from the PET-containing liquid phase.

[0189] 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 polyolefins, 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, while all or part of the non-PET separation zone 208 may 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 a PET-containing stream in the non-PET separation zone 208.

[0190] like Figure 3As 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 oligomers 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.

[0191] 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 As generally shown. Based on the total weight of the by-product stream 140, the polyolefin-containing by-product stream (or decanter olefin by-product stream) 140 may contain 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% of polyolefin.

[0192] The polyolefins present in the polyolefin-containing byproduct stream may comprise primarily polyethylene, primarily polypropylene, or a combination of polyethylene and polypropylene. Based on the total weight of the polyolefins in the polyolefin-containing byproduct stream 140, the polyolefins in the polyolefin-containing byproduct stream comprise 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. Alternatively, based on the total weight of the polyolefins in the polyolefin-containing byproduct stream 140, the polyolefins in the polyolefin-containing byproduct stream comprise 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.

[0193] Based on the total weight of the polyolefin-containing by-product stream 140, the polyolefin-containing by-product stream contains 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% of PET. Additionally, based on the total weight of the polyolefin-containing by-product stream 140, the polyolefin-containing by-product stream contains 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 polyolefins.

[0194] In general, based on the total weight of the polyolefin-containing byproduct stream 140, the polyolefin-containing byproduct stream 140 contains 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 organic compounds. Based on the total weight of the polyolefin-containing byproduct stream 140, the polyolefin-containing byproduct stream 140 may include 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% of inorganic components.

[0195] In one embodiment or in combination with any embodiment mentioned herein, the viscosity of the polyolefin-containing byproduct stream may be at least 1, at least 10, at least 25, at least 50, at least 75, at least 90, at least 100, at least 125, at least 150, at least 200, at least 250, at least 300, at least 350, at least 400, at least 450, at least 500, at least 550, at least 600, at least 650, at least 700, at least 750, at least 800, at least 850, at least 900, or at least 950 poise and / or not exceeding 25,000, not exceeding 24,000, not exceeding 23,000, not exceeding 22,000, not exceeding 21,000, not exceeding 20,000, not exceeding 19,000, not exceeding 18,000, not exceeding 17,000, not exceeding 16,000, not exceeding 15 The values ​​of ,000, not exceeding 14,000, not exceeding 13,000, not exceeding 12,000, not exceeding 11,000, not exceeding 10,000, not exceeding 9,000, not exceeding 8,000, not exceeding 7,000, not exceeding 6,000, not exceeding 5,000, not exceeding 4,500, not exceeding 4,000, not exceeding 3,500, not exceeding 3,000, not exceeding 2,500, not exceeding 2,000, not exceeding 1,750, not exceeding 1,500, not exceeding 1,250, not exceeding 1,200, not exceeding 1,150, not exceeding 1,100, not exceeding 1,050, not exceeding 1,000, not exceeding 950, not exceeding 900, not exceeding 800, and not exceeding 750 poises were measured using a Borlefeld R / S rheometer with a V80-40 paddle rotor, at a shear rate of 10 rad / s and a temperature of 250°C. The viscosity of polyolefin-containing byproduct streams can be in the range of 1 to 25,000 poise, 100 to 10,000 poise, or 1,000 to 5,000 poise, measured at 10 rad / s and 250 °C.

[0196] Based on the total weight of the polyolefin-containing by-product stream 140, the polyolefin-containing by-product stream may contain 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 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 2 wt% of one or more non-reactive solids. 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, soil, glass, plastic fillers, and combinations thereof.

[0197] Based on the total weight of the polyolefin-containing byproduct stream 140, the polyolefin-containing byproduct stream 140 contains one or more of the following fillers in amounts 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 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%. The polyolefin-containing byproduct stream 140 may include fillers in amounts of 100 ppm to 50 wt%, 500 ppm to 10 wt%, or 1000 ppm to 5 wt%.

[0198] Examples of fillers may include, but are not limited to: thixotropic agents such as silica micropowder and clay (kaolin), pigments, colorants, flame retardants such as alumina trihydrate, bromine-based, chlorine-based, borate and phosphorus-based, inhibitors such as wax-based materials, UV inhibitors or stabilizers, conductive additives such as metal particles, carbon particles or conductive fibers, release agents such as zinc stearate, wax and organosilicon, calcium carbonate, and calcium sulfate.

[0199] In one embodiment or in combination with any of the embodiments mentioned herein, the density of the polyolefin-containing byproduct stream 140 may be 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 exceeding 1.5, not exceeding 1.4, not exceeding 1.3, not exceeding 1.2, not exceeding 1.1, not exceeding 1.05, or not exceeding 1.01 g / cm³. 3 The density was measured at 25°C. It can range from 0.80 to 1.4, 0.90 to 1.2, or 0.95 to 1.1 g / cm³. 3 When removed from the non-PET separation zone 208, the temperature of the polyolefin-containing byproduct stream 140 can be 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 exceeding 350, not exceeding 340, not exceeding 335, not exceeding 330, not exceeding 325, not exceeding 320, not exceeding 315, not exceeding 310, not exceeding 305, or not exceeding 300°C. Based on the total weight of the stream, the polyolefin-containing byproduct stream 140 can 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 components with a boiling point higher than that of the predominantly terephthaloyl or DMT.

[0200] As discussed in further detail herein, all or part of the polyolefin-containing byproduct streams may be introduced into one or more downstream chemical recycling facilities, either alone or together with one or more other byproduct streams, streams from one or more other downstream chemical recycling facilities, and / or waste plastic streams (including untreated, partially treated, and / or treated mixed plastic waste).

[0201] Turn again Figure 3 The PET-containing stream 138 (containing dissolved PET and its degradation products) exiting the non-PET separation zone 208 (upstream of the reaction zone 210) can then be transferred to the reaction zone 210, wherein the PET introduced into the reaction zone undergoes 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% decomposition. In some embodiments, the reaction medium within the reaction zone 210 can be agitated or stirred, and one or more temperature control devices (e.g., heat exchangers) can be used to maintain the target reaction temperature. In one embodiment or in combination with any embodiment mentioned herein, the target reaction temperature in reaction zone 210 may 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, or it may be in the range of 50 to 350°C, 60 to 345°C or 85 to 335°C.

[0202] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent decomposition process can be a low-pressure solvent decomposition process, and the pressure in the solvent decomposition reactor (or reaction zone) 210 can be within 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 psi of atmospheric pressure, or it can be within 55, 75, 90, 100, 125, 150, 200 or 250 psi of atmospheric pressure. The pressure in the solvent decomposition reactor (or reaction zone) 210 may be within 0.35, 0.70, 1, 1.4, 1.75, 2, 2.5, 2.75, 3, 3.5, 3.75, 5, or 6.25 bar gauge pressure (bar) and / or not exceeding 6.9, 8.6, or 35 bar. The pressure in the solvation reactor (or reaction zone) 210 may 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 not exceeding 725 psig (50 barg), not exceeding 650 psig (44.7 barg), not exceeding 600 psig (41.3 barg), not exceeding 550 psig (37.8 barg), not exceeding 500 psig (34.5 barg), not exceeding 450 psig (31 barg), not exceeding 400 psig (27.6 barg) or not exceeding 350 psig (24.1 barg).

[0203] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent decomposition process carried out in reaction zone 210 or facility 30 may be a high-pressure solvent decomposition process, and the pressure in the solvent decomposition reactor may 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 not exceeding 150 barg (2177 barg), not exceeding 145 barg (2104), not exceeding 140 barg (2032 psig), not exceeding 135 barg (1959 psig) 15 psig), not exceeding 130 barg (1886 psig), or not exceeding 125 barg (1814 psig).

[0204] In one or more embodiments, based on the total weight of the reactor composition, the solvent decomposition reaction can be carried out in the presence of at least one acid and / or at least one base in a quantity not exceeding 5, 4, 3, 2, 1, or 0.5 wt%. The solvent decomposition reaction can be carried out in the presence of a catalyst, which, based on the total weight of the reaction medium, comprises at least 25, 50, 75, 100, 125, 150, 175, 200, 250, 300, 350, 400, 450, 500, or 500 ppm by weight and / or no more than 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, or 250 ppm by weight, of at least one acid and / or at least one base, or, based on the total weight of the reaction medium, the acid and / or base may be present in amounts from 25 to 1000 ppm, 50 to 750 ppm, or 100 to 350 ppm by weight.

[0205] Catalyst systems may include sodium-containing bases, potassium-containing bases, or combinations thereof. Examples of suitable acids and bases include, but are not limited to, sodium hydroxide, potassium carbonate, and combinations thereof.

[0206] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent decomposition (or methanol decomposition) reaction can be carried out in the presence of at least one catalyst. The catalyst may comprise, consist of, or be substantially composed of a catalytic metal, including manganese, lithium, zinc, titanium, tin, antimony, magnesium, or combinations thereof; or the catalyst may comprise, consist of, or be substantially composed of a catalytic metal, including manganese, lithium, or combinations thereof. The catalyst may also comprise acetates, carbonates, hydroxides, oxides (especially soluble oxides), methoxides, fluorides, chlorides, bromides, iodides, phosphates, sulfates, nitrates, or combinations thereof of one or more of these catalytic metals.

[0207] Catalyst systems may include one or more catalytic metals (or compounds thereof) alone, or in combination with acids or bases described herein. Catalyst systems may individually comprise one or more acids or bases. In one embodiment or in combination with any of the embodiments mentioned herein, the catalyst system may include a catalytic metal in combination with a base (e.g., calcium carbonate or sodium hydroxide).

[0208] In one embodiment or in combination with any of the embodiments mentioned herein, the catalyst may comprise manganese acetate, lithium acetate, or a combination thereof, or be substantially composed of manganese acetate, lithium acetate, or a combination thereof. For example, the catalyst may comprise manganese acetate, be composed of manganese acetate, or be substantially composed of manganese acetate, or the catalyst may comprise lithium acetate, be composed of lithium acetate, or be substantially composed of lithium acetate.

[0209] In one embodiment or in combination with any of the embodiments mentioned herein, the catalyst may not contain other typical solvent decomposition (or methanol decomposition) catalysts, such as tin, zinc, and / or titanium, such that, based on the total feed to the reactor (or reaction medium or stream, if measured in or removed from the reactor), these catalysts may be present in the solvent decomposition reactor (or reaction medium or stream removed from the reactor) in an amount not exceeding 500, 400, 300, 200, 150, 100, 50, 25, 10, or 5 (ppm, parts per million, ...) by weight, measured by the weight of the catalyst metals. Unless otherwise defined herein, the weight of the catalyst is determined based on the total weight of the catalyst metals.

[0210] The catalyst can be added to the reaction system at one or more locations. For example, all or part of the catalyst can be combined with the waste plastic stream 112 introduced into the solvent decomposition facility and / or all or part of the catalyst can be added to the blending zone 206. When added to the blending zone 206, the catalyst can be combined with the solvent in stream 212, or it can be separated from the catalyst via a catalyst separation line (…). Figure 3 (Not shown in the image) is added. Additionally, or alternatively, all or part of the catalyst may be added to the reaction medium in the stream that exits the blending zone 206 in line 138 before entering reactor 210. In some cases, all or part of the catalyst may be added to reactor 210 via a separate catalyst line (not shown) or via a recovery line (not shown) between reactor 210 and blending zone 206.

[0211] In one embodiment or in combination with any of the embodiments mentioned herein, the reaction medium in the solvent decomposition reactor may comprise PET and / or its decomposition products, including oligomers of PET and monomers (e.g., ethylene glycol and dimethyl terephthalate), at least one type of non-PET plastic (e.g., polyolefins, PVC, and others discussed herein) and / or its decomposition products, a primary solvent, and a catalyst comprising manganese acetate and / or lithium acetate.

[0212] Based on the weight of the feed to the solvent decomposition reactor 210 (ppm of catalyst per unit feed weight), the catalyst (or one or more components of the catalyst) may be 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 90, at least 100, at least 125, at least 150, at least 175, or at least 200 ppm by weight and / or not exceeding 1000, not exceeding 900, not exceeding 800, not exceeding 700, not exceeding The catalyst may be present in amounts exceeding 600, not exceeding 500, not exceeding 450, not exceeding 400, not exceeding 350, not exceeding 300, not exceeding 250, not exceeding 240, not exceeding 230, not exceeding 220, not exceeding 210, not exceeding 200, not exceeding 190, not exceeding 180, or not exceeding 175 ppm, measured by weight of the catalyst metal, or it may be present in amounts ranging from 25 to 1000 ppm, 50 to 800 ppm, 100 to 600 ppm, 125 to 400 ppm, or 150 to 350 ppm. Amounts of catalyst within these ranges may be present in the solvent decomposition reactor or in a sample of the reaction medium or in a stream drawn from the reactor.

[0213] The catalyst can be in any suitable form, and may be heterogeneous or homogeneous with the reaction mixture. In one or more embodiments, the catalyst may be combined with a liquid prior to addition to the solvation facility (or when added to the solvation facility) to provide a liquid-phase catalyst, which can then be introduced into the blending zone 206 and / or the solvation reactor 210. The catalyst may comprise one or more soluble or partially soluble forms of these metals. The catalyst may be combined with a solvent prior to introduction into the blending zone 206.

[0214] In one embodiment or in combination with any embodiment mentioned herein, the average residence time of the reaction medium in reaction zone 210 may 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. Upon leaving reaction zone 210, 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 solvent decomposition or methanol decomposition facility 30 may be decomposed in reactor effluent stream 144.

[0215] In one embodiment or in combination with any of the embodiments mentioned herein, reactor purge stream 142 may be removed from reaction zone 210, and at least a portion may be conveyed as reactor purge byproduct stream 142 to one or more downstream facilities within chemical recovery facility 10. The boiling point of reactor purge byproduct stream 142 may be higher than the boiling point of the primary terephthalamide (or DMT in the case of methanol decomposition) produced from solvent decomposition facility 30.

[0216] In one embodiment or in combination with any embodiment described herein, based on the total weight of stream 142, reactor purification byproduct stream 142 contains 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 terephthaloyl groups. When the solvent decomposition facility is a methanol decomposition facility, based on the total weight of stream 142, reactor purification byproduct stream 142 may contain 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.

[0217] In one embodiment or in combination with any embodiment mentioned herein, reactor purification byproduct stream 142 may contain no more than 25, 20, 15, 10, 5, 2, or 1 wt% of a component with a boiling point higher than that of DMT (or other terephthaloyl groups). Additionally, or alternatively, the melting temperature of reactor purification byproduct stream 142 may be at least 5, 10, 15, 20, or 25 °C lower than the reactor temperature and / or no more than 50, 45, 40, 35, 30, 25, 20, or 15 °C lower, or the melting temperature of byproduct stream 142 may be in an amount ranging from 5 to 50 °C, 10 to 45 °C, or 10 to 40 °C lower than the reactor temperature.

[0218] In addition, based on the total weight of the stream, the reactor purification byproduct stream 142 may include at least 100 ppm and no more than 25 wt% of one or more non-terephthaloyl solids. In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the stream, the total amount of non-terephthaloyl solids in the reactor purification byproduct stream 142 may 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 not exceeding 25, not exceeding 22, not exceeding 20, not exceeding 18, not exceeding 15, not exceeding 12, not exceeding 10, not exceeding 8, not exceeding 5, not exceeding 3, not exceeding 2, or not exceeding 1 wt%.

[0219] In one embodiment or in combination with any embodiment mentioned herein, the total solids content of the reactor purified byproduct stream 142, based on the total weight of the stream, is 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 800. 0, 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).

[0220] Examples of solids may include, but are not limited to, non-volatile catalyst compounds. In one embodiment or in combination with any of the embodiments mentioned herein, the reactor purification byproduct stream may 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 no more than 60,000, no more than 50,000, no more than 40,000, no more than 35,000, no more than 30,000, no more than 25,000, no more than 20,000, no more than 15,000, or no more than 10,000 ppm of non-volatile catalyst metal.

[0221] Examples of suitable non-volatile catalyst metals include, but are not limited to, titanium, zinc, manganese, lithium, magnesium, sodium, methoxides, 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 part of the reactor purification byproduct stream 142 may be introduced, alone or together with one or more other byproduct streams, streams from one or more other downstream chemical recovery facilities, and / or waste plastic streams (including untreated, partially treated, and / or treated mixed plastic waste) into one or more downstream chemical recovery facilities.

[0222] When the reactor is removed from the reaction zone and / or introduced into one or more downstream facilities, the temperature of the reactor purification byproduct stream 142 may be at least 130, at least 135, at least 140, at least 145, at least 150, at least 155, at least 160, at least 165, at least 170, at least 175, at least 180, at least 185, at least 190, at least 195, at least 200, at least 205, at least 210, at least 215, at least 220, at least 225, at least 230, at least 245, at least 250, at least 255, at least 260, at least 265, at least 270, at least 275, at least 280, at least 285, at least 290, at least 295, at least 300, at least 325, or at least 350 °C.

[0223] In one embodiment or in combination with any of the embodiments mentioned herein, such as Figure 3 As generally indicated, the effluent stream 144 from reaction zone 210 in solvent decomposition facility 30 may optionally be conveyed 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 pass through product separation zone 220, where 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 consisting of light organic material 146 and heavy organic material 148. Any suitable method for separating these streams may be used and may include, for example, distillation, extraction, decantation, crystallization, membrane separation, solid / liquid separation such as filtration (e.g., belt filter), and combinations thereof. The resulting heavy and light organic streams may be sent to a downstream separation zone for further purification and / or recovery of desired final products and byproducts.

[0224] like Figure 3As 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 phthaloyl group (r-phthaloyl group), such as the recycled DMT (r-DMT).

[0225] 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.

[0226] In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of the composition (e.g., PET oligomer), the byproduct stream may 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 comprising a portion of polyester that has undergone solvent decomposition. As used herein, the term “polyester portion” or “polyester fraction” refers to a portion or residue of polyester, or a reaction product of a polyester portion or residue. The number-average chain length of these oligomers may be at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8 monomer units (acid and 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 monomer units (acid + diol), and may include a portion of polyester (e.g., PET) being processed.

[0227] Based on the total weight of the stream, the terephthaloyl bottom byproduct stream 160 may contain at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1 or at least 1.5 wt% 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 oligomers. Based on the total weight of the stream, such components may be present in amounts of 0.01 wt% to 40 wt%, 0.05 wt% to 35 wt%, or 1.5 wt% to 10 wt%.

[0228] In one embodiment or in combination with any of the embodiments mentioned herein, the oligomer further comprises at least one ester other than dimethyl terephthalate, at least one carboxylic acid other than terephthalic acid or DMT, and / or at least one diol moiety other than ethylene glycol. For example, the oligomer may also comprise one or more of the following moieties: diethylene glycol, triethylene glycol, 1,4-cyclohexane-diethanol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentanediol, 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), phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, diphenyl-3,4'-dicarboxylic acid, neopentyl glycol, 1,4-cyclohexanedicarboxylic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and combinations thereof.

[0229] The terephthaloyl bottom byproduct stream may also contain predominantly terephthaloyl groups, or DMT in the case of methanol decomposition, in amounts of 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 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, or not more than 40 wt%. Other examples of possible predominant diols (depending on the PET or other processed polymers) may include, but are not limited to, diethylene glycol, neopentyl glycol, 1,4-cyclohexanediol, and 2,2,4,4-tetramethyl-1,3-cyclobutanediol.

[0230] In one embodiment or in combination with any of the embodiments described herein, the terephthaloyl bottom (or DMT bottom) byproduct stream 160 may comprise an oligomer 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. Based on the total weight of the terephthaloyl bottom by-product stream 160, the terephthaloyl bottom by-product stream 160 may include at least 1, at least 100, at least 500 (ppb, parts per billion, etc.) by weight, 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, parts per billion, etc.) 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.

[0231] As discussed in further detail herein, all or part of the terephthaloyl bottom byproduct stream 160 may be introduced into one or more downstream chemical recovery facilities, either alone or together with one or more other byproduct streams, streams from one or more other downstream chemical recovery facilities, and / or waste plastic streams (including untreated, partially treated, and / or treated mixed plastic waste).

[0232] Refer again Figure 3The stream 146, which is mainly composed of light organic matter from the product separation zone 220, can be introduced into the light organic matter separation zone 230. In the light organic matter separation zone 230, the stream 146 can be separated to remove the main solvent (e.g., methanol in methanol decomposition) and to separate the main diol (e.g., ethylene glycol in methanol decomposition) from organic byproducts (or multiple byproducts) that are lighter and heavier than the main diol.

[0233] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent stream 150 extracted from the light organic matter separation zone 230 may 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 a primary solvent, based on the total weight of the stream. When the solvent decomposition facility 30 is a methanol decomposition facility, the stream 150 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, at least 95, or at least 99 wt% methanol, based on the total weight of the stream. All or part of the stream may be recycled back to one or more locations within the solvent decomposition facility for further use.

[0234] In one embodiment or in combination with any of the embodiments mentioned herein, at least one light organic solvent decomposition byproduct stream 152 (also referred to as a “light organic” stream) may also be extracted from the light organic separation zone 230 and may 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 a component with a boiling point below the boiling point of the major terephthaloyl (or DMT) group, which is not the major diol (or ethylene glycol) or the major solvent (or methanol). Additionally, or alternatively, the byproduct stream 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 3, no more than 2, or no more than 1 wt% of a component with a boiling point above the boiling point of DMT, and the boiling point of the stream 152 itself may be below the boiling point of the major terephthaloyl (or DMT) group.

[0235] In one embodiment or in combination with any of the embodiments mentioned herein, the light organic byproduct stream 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, or at least 90 wt% of a component having a boiling point below that of the major glycol (or, if it is the methanol decomposition of PET, below that of ethylene glycol).

[0236] In one embodiment or in combination with any of the embodiments mentioned herein, the light organic solvent decomposition byproduct stream 152 can be generated in a solvent decomposition facility containing a primary solvent (e.g., methanol). For example, the light organic solvent byproduct stream 152 may 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 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% of a primary solvent.

[0237] In addition, the byproduct stream 152 may 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 may be present in amounts from 1 ppm to 50 wt%, from 50 ppm to 0.5 wt%, or from 100 ppm to 0.05 wt% based on the total weight of the byproduct stream.

[0238] In addition, the light organic byproduct stream 152 may 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 may 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.

[0239] The light organic byproduct stream 152 may also include at least one additional component selected from the group consisting of: tetrahydrofuran (THF), methyl acetate, silicates, 2,5-methyldioxolane, 1,4-cyclohexanediethanol, 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, formic acid. Methyl ester, n-butanol, acetic acid, dibutyl ether, heptane, dibutyl terephthalate, dimethyl phthalate, dimethyl 1,4-cyclohexanedicarboxylate, 1-methoxyethanol, 2-methoxyethanol, 2-methyl-1,3-dioxolane, 1,1-dimethoxy-2-butene, 1,1-dimethoxyethane, 1,3-propanediol, 2,5-dimethyl-1,3,5-hexadiene, 2,5-dimethyl-2,4-hexadiene, α-methylstyrene, diethylene glycol methyl ether, 1,3,6-trioxane (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-methylcaprolactam, dimethyl azelate, neopentyl glycol and combinations thereof.

[0240] In one embodiment or in combination with any of the embodiments mentioned herein, the additional component may be selected from the group consisting of: silane, 2,5-methyldioxolane, 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, dibutyl ether, heptane, dibutyl terephthalate, dimethyl 1,4-cyclohexanedicarboxylate, 1,1-dimethoxy-2-butene, 1,3-propanediol, 2,5-dimethyl-1,3,5-hexadiene, 2,5-dimethyl-2,4-hexadiene, α-methylstyrene, 1,3,6-trioxanediol. (formal), dimethoxydimethylsilane, dimethyl ether, diisopropyl ketone, hexamethylcyclotrisiloxane, hexamethyldisiloxane, methoxytrimethylsilane, methyl 4-ethylbenzoate, methyl hexanoate, methyl lactate, methyl laurate, methyl methoxyethyl terephthalate, methyl nonanoate, methyl oleate, methyl palmitate, methyl stearate, octamethylcyclotetrasiloxane, styrene, trimethylsilanol, 1,1-dimethoxy-2-butene, 4-methylmorpholine, 1,3,3-trimethoxypropane, methyl myristate, dimethyl adipate, N-methylcaprolactam, dimethyl azelate, neopentyl glycol and combinations thereof.

[0241] In one embodiment or in combination with any of the embodiments mentioned herein, the additional component may be selected from the group consisting of: 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, dimethoxydimethylsilane, methoxytrimethylsilane, methyl nonanoate, methyl oleate, methyl stearate, and combinations thereof.

[0242] In one embodiment or in combination with any of the embodiments described herein, the additional component may be selected from the group consisting of: 1,1-dimethoxy-2-butene, 4-methylmorpholine, 1,3,3-trimethoxypropane, methyl myristate, dimethyl adipate, N-methylcaprolactam, dimethyl azelate, neopentyl glycol, and combinations thereof.

[0243] In one embodiment or in combination with any of the embodiments mentioned herein, the average boiling point of the light organic byproduct stream 152 is lower than the boiling point of the primary solvent (e.g., methanol when the solvent decomposition facility is a methanol decomposition facility). In one embodiment or in combination with any of the embodiments described herein, the average boiling point of the light organic byproduct stream 152 may be lower than the boiling point of the primary glycol (e.g., ethylene glycol for solvent decomposition of PET).

[0244] Turn now Figure 4 It shows from Figure 3 The diagram shows several streams extracted from the light organic matter separation zone 230. Specifically, as shown... Figure 4 As shown, at least one solvent stream 150, at least one water stream 155, at least one glycol stream 154, and one or more by-product streams can be extracted from the light organic matter separation zone 230. These by-product streams are selected from the group consisting of: low-boiling agent stream 190, solvent azeotrope or medium-boiling agent stream 192, water azeotrope or medium-boiling agent stream 194, and glycol azeotrope or medium-boiling agent stream 196. Additionally, as discussed in detail previously, the glycol bottoms by-product stream 156 can also be extracted from the light organic matter separation zone 230. It should be understood that each of the above streams is named according to the component present in the majority amount. That is, the stream names used above reflect the majority component in the stream, which, based on the total weight of the stream, is present in an amount of 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%.

[0245] like Figure 4 As shown, feed stream 146 can be introduced into light organic matter separation zone 230. Based on the total weight of organic components (excluding DMT) in the stream, the feed stream 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, or at least 90 wt% of organic components with a boiling point greater than the boiling point of the predominantly terephthaloyl (or DMT) group. Figure 3 As shown, the stream 146 may originate from the product separation zone and / or from the reaction zone of the solvent decomposition (or methanol decomposition) facility. Figure 4 The light organic matter separation zone 230, generally shown, can employ any suitable type of separation technique, including, for example, distillation, extraction, decantation, and combinations thereof. Two or more different types of separation techniques can be used in series or in parallel to provide... Figure 4 The product and byproduct streams are shown.

[0246] like Figure 4 As shown, the feed stream 146 introduced into the light organic matter recovery zone 230 can be separated into one or more additional streams, including, for example, a low-boiling agent stream 190, a solvent azeotrope or medium-boiling agent stream 192, a solvent stream 150, a water azeotrope or medium-boiling agent stream 194, a water stream 155, a glycol azeotrope or medium-boiling agent stream 196, a glycol stream 154, and a glycol bottoms stream 156. Figure 3 The light organic byproduct stream 152 extracted from the light organic matter recycling zone shown may include one or more of these streams, individually or in combination. For example, such as Figure 4As generally shown, at least two, three, or more streams can be combined to form a light organic by-product stream 152. This combination can, for example, take place in a light organic by-product mixing zone 232, or one or more streams can be simply combined in a tank or other device (not shown). In some cases, Figure 4 The at least three, at least four, or even at least five streams shown can be combined to form a light organic byproduct stream 152. All or part of these streams, individually or in combination, can be sent to one or more downstream treatment or recycling facilities, as described herein.

[0247] In one embodiment or in combination with any of the embodiments mentioned herein, the light organic byproduct stream 152 may contain at least one azeotrope. As used herein, the term "azeotrope" refers to a mixture of two or more components that have a constant boiling point when the mixture boils. The light organic byproduct stream 152 may include a component that forms an azeotrope with a primary solvent (e.g., methanol), a component that forms an azeotrope with water, and / or a component that forms an azeotrope with a primary glycol (e.g., ethylene glycol). When formed, two or more azeotropes or azeotrope-containing streams may be combined to form at least a portion of the light organic byproduct stream 152, or one or more azeotropes may be sent to one or more downstream chemical processing facilities shown in Figures 1a and 1b, respectively.

[0248] In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152 comprises 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 or at least 85 and / or 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 or no more than 60 wt% of a primary solvent azeotrope, based on the total weight of the light organic byproduct stream. In one embodiment or in combination with any embodiment described herein, the light organic byproduct stream 152, based on its total weight, comprises 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 or at least 85 and / or 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 or no more than 60 wt% of a methanol (or other primary solvent) azeotrope. In one embodiment or in combination with any embodiment mentioned herein, the light organic byproduct stream 152 may not be or may not contain an azeotrope with the primary solvent (or methanol), or based on the total weight of stream 152, it may include an amount of such azeotrope no more than 10, no more than 5, no more than 3, no more than 2, no more than 1 or no more than 0.5 wt%.

[0249] In one embodiment or in combination with any of the embodiments mentioned herein, the light organic byproduct stream 152 may comprise a medium-boiling agent stream having a boiling point between that of the low-boiling agent and the main solvent. Based on the total weight of the stream, it may 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, or at least 90 wt% of a component having a boiling point between that of the low-boiling agent and the main solvent. This may be referred to as a solvent medium-boiling agent stream and may not contain or be a solvent (or methanol) azeotrope, or based on the total weight of the stream, it may comprise 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 such a component.

[0250] In one embodiment or in combination with any embodiment mentioned herein, the light organic byproduct stream 152 contains 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 or at least 85 and / or 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 or no more than 60 wt% of an azeotrope of water, based on the total weight of the light organic byproduct stream 152.

[0251] In one embodiment or in combination with any of the embodiments described herein, the light organic byproduct stream 152 may comprise a medium-boiling agent stream having a boiling point between the boiling point of the primary solvent (or methanol) and the boiling point of water. This may be referred to as an aqueous azeotropic stream and may not contain an aqueous azeotrope, or may contain no more than 20, 15, 10, 5, 2, 1, or 0.5 wt% of an aqueous azeotrope based on the total weight of the stream.

[0252] In one embodiment or in combination with any embodiment mentioned herein, the light organic byproduct stream 152 contains 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 or at least 85 and / or 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 or no more than 60 wt% of a major diol (or ethylene glycol) azeotrope, or may be present in amounts ranging from 5 wt% to 99 wt%, 10 wt% to 95 wt%, or 15 wt% to 85 wt% based on the total weight of the stream.

[0253] In one embodiment or in combination with any of the embodiments mentioned herein, the light organic by-product stream comprises, based on the total weight of the light organic by-product stream, 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 or at least 85 wt% and / or 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 or no more than 60 wt% of an azeotrope of ethylene glycol (or another major diol), or, based on the total weight of the stream, it may be present in amounts ranging from 5 wt% to 99 wt%, 10 wt% to 95 wt%, or 15 wt% to 85 wt%.

[0254] In one embodiment or in combination with any of the embodiments mentioned herein, the light organic byproduct stream 152 may comprise a medium-boiling agent stream having a boiling point between the boiling point of water and the boiling point of the primary glycol (or ethylene glycol). This may be referred to as a glycol medium-boiling agent stream and may not contain or be a glycol (or ethylene glycol) azeotrope, or may contain no more than 20, 15, 10, 5, 2, 1, or 0.5 wt% glycol azeotrope based on the total weight of the stream.

[0255] Additionally, in one embodiment or in combination with any of the embodiments mentioned herein, the light organic byproduct stream 152 removed from the solvent decomposition (or methanol decomposition) facility may 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 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% of the main solvent (or methanol), or it may be present in amounts ranging from 2 wt% to 90 wt%, 5 wt% to 85 wt%, or 10 wt% to 70 wt%.

[0256] Similarly, in one embodiment or in combination with any of the embodiments mentioned herein, the light organic byproduct stream 152 taken from the solvent decomposition (or methanol decomposition) facility may 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 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% of a major diol (or ethylene glycol), or it may be present in amounts ranging from 2 wt% to 90 wt%, 5 wt% to 85 wt%, or 10 wt% to 70 wt%. Based on the total weight of the stream, the light organic byproduct stream 152 may include 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 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 or no more than 10 wt% of water, or based on the total weight of the stream 152, it may be present in amounts ranging from 2 wt% to 50 wt%, 5 wt% to 45 wt%, or 5 wt% to 65 wt%.

[0257] As discussed in further detail herein, all or part of the light organic byproduct stream 152 (or one or more streams constituting the light organic byproduct stream 152) may be introduced into one or more downstream chemical recycling facilities, either alone or together 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 (untreated, partially treated, and / or treated).

[0258] Refer again Figure 4 The low-boiling agent stream 190 removed from the light organic matter recovery zone 230 may primarily comprise components with boiling points lower than the boiling point of the primary solvent (or methanol) and / or lower than the boiling point of any low-boiling solvent azeotrope (if present). In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of the low-boiling agent stream 190, the low-boiling agent stream 190 may contain 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 components with boiling points lower than the primary solvent.

[0259] As discussed in further detail herein, one or more light organic byproduct streams, either individually or in part, may be introduced into one or more downstream chemical recycling facilities, either alone or together with one or more other byproduct streams, streams from one or more other downstream chemical recycling facilities, and / or waste plastic streams, including mixed plastic waste (untreated, partially treated, and / or treated).

[0260] In one embodiment or in combination with any of the embodiments mentioned herein, solvent stream 150 may also be withdrawn from light organic matter separation zone 230, and based on the total weight of stream 150, the solvent stream may include at least 2, at least 5, at least 10, at least 15, at least 25, at least 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 a primary solvent. When the solvent decomposition facility is a methanol decomposition facility, based on the total weight of the stream, the stream may contain at least 2, at least 5, at least 10, at least 15, at least 25, at least 30, at least 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% methanol. All or part of the stream may be recycled back to the inlet of the solvent decomposition facility for further use.

[0261] Refer again Figure 4In one embodiment or in combination with any of the embodiments mentioned herein, water stream 155 may also be removed from the light organic matter recovery zone 230 of the solvent decomposition facility. Based on the total weight of stream 155, water stream 155 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% water. Depending on the content of organic components in water stream 155, it may optionally be sent to a downstream water treatment facility prior to further treatment and / or use.

[0262] In addition, such as Figure 3 and Figure 4 As shown, a stream primarily comprising major diol 154 can also be extracted 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 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).

[0263] like Figure 3 As shown, the bottom byproduct stream 156 containing diols can also be taken from the light organic matter separation zone 230. The terms "diol bottom" or "diol sludge" (or, more specifically, "EG bottom" or "EG sludge" in methanol decomposition) refer to a product with a boiling point (or azeotropic point) higher than that of the major diol but lower than that of the major terephthaloyl group.

[0264] 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).

[0265] 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 on its own (in a free state) or as part of another compound.

[0266] Other possible primary diols (depending on the PET or other processed polymers) may include, but are not limited to, diethylene glycol, triethylene glycol, 1,4-cyclohexane-diethanol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentanediol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentanediol-(1,3), 2-ethylhexanediol-(1,3), and 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 may not be ethylene glycol or may not contain ethylene glycol. Molecules of these diols may also be present in any oligomers of the polyester in this or other byproduct streams. Additionally, other non-terephthaloyl and / or non-diol components may also be present in these streams. Examples of such components include isophthalates and other acid residues with boiling points higher than the predominantly terephthaloyl group.

[0267] In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of the diols in the bottom by-product stream 156 of the diol column, diols other than the primary diol (or ethylene glycol in the case of methanol decomposition) may be present in the bottom by-product stream 156 in the following amounts: 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 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%.

[0268] In one embodiment or in combination with any of the embodiments mentioned herein, in the bottom byproduct stream 156 of the glycol column, at least one diol other than the main diol has a weight ratio to the main diol of 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, in the bottom byproduct stream 156 of the diol column, the weight ratio of at least one diol other than the main diol to the main diol is not more than 5:1, not more than 4.5:1, not more than 4:1, not more than 3.5:1, not more than 3:1, not more than 2.5:1, not more than 2:1, not more than 1.5:1, not more than 1.25:1 or not more than 1:1, or in the range of 0.5:1-5:1, 0.70:1-3:1, or 0.80:1-2.5:1.

[0269] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent decomposition facility 30 may generate two or more byproduct streams, which may 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 part of one or more solvent decomposition byproduct streams (as shown in stream 110 in Figures 1a and 1b) may be introduced into at least one downstream processing facility, 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 facilities previously mentioned.

[0270] In one embodiment or in combination with any of the embodiments mentioned herein, two or more (or portions thereof) solvent decomposition byproduct streams may be introduced into the same downstream processing facility, while in other embodiments, two or more (or portions thereof) solvent decomposition byproduct streams may 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 may be introduced into a downstream facility, while in other embodiments, the stream may be separated 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 may be introduced into a downstream processing facility.

[0271] Referring again to Figures 1a and 1b, in one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of at least one solvent decomposition byproduct stream 110 may be combined with at least a portion of the PO-enriched plastic stream 114 removed from the pretreatment facility 20, as shown in Figures 1a and 1b. The amount of a 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 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 40 wt%. As shown in Figures 1a and 1b, the combined stream can then be introduced into one or more locations of a chemical recovery facility, including, for example, into a POX gasification facility 50, a pyrolysis facility 60, a cracker facility 70 and / or an energy generation facility 80, as well as a separation facility and / or for further sale and / or use, as shown in Figure 1b.

[0272] Liquefaction / Dehalogenation

[0273] As shown in Figures 1a and 1b, PO-enriched waste plastic stream 114 (combined with or not combined with solvent decomposition byproduct stream 110) may optionally be introduced into a liquefaction zone or step prior to introduction into one or more downstream treatment facilities. As used herein, the term "liquefaction" zone or step refers to a chemical treatment zone or step in which at least a portion of the introduced plastic is liquefied. The step of liquefying plastics may include chemical liquefaction, physical liquefaction, or a combination thereof. Exemplary methods for liquefying polymers introduced into the liquefaction zone may include (i) heating / melting; (ii) dissolving in a solvent; (iii) depolymerization; (iv) plasticization, and combinations thereof. Additionally, one or more of options (i) through (iv) may be accompanied by the addition of a blending agent or liquefying agent to help facilitate the liquefaction (reduction of viscosity) of the polymer material. Thus, a variety of rheology modifiers (e.g., solvents, depolymerizing agents, plasticizers, and blending agents) can be used to enhance the flow and / or dispersibility of liquefied waste plastics.

[0274] When added to liquefaction zone 40, at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of plastic (typically waste plastic) undergoes viscosity reduction to provide a predominantly liquid flow. In some cases, viscosity reduction can be promoted by heating (e.g., adding vapor that comes into direct or indirect contact with the plastic), while in others, it can be promoted by combining the plastic with a solvent capable of dissolving it. Examples of suitable solvents may include, but are not limited to, alcohols such as methanol or ethanol, glycols such as ethylene glycol, diethylene glycol, triethylene glycol, neopentyl glycol, cyclohexanediol, glycerol, pyrolysis oil, engine oil, and water. As shown in Figures 1a and 1b, solvent flow 141 may be added directly to liquefaction zone 40, or it may be combined with one or more flows (not shown in Figures 1a and 1b) fed to liquefaction zone 40.

[0275] In one embodiment or in combination with any embodiment mentioned herein, the solvent may comprise a recycled solvent component, the recycled solvent component material of which, based on the total weight of the stream, is, 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, 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%. Alternatively or additionally, based on the total weight of the stream, the recycled solvent component in line 141 may be 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, 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, or no more than 1 wt%. Alternatively, based on the total weight of the stream, it can be in the range of 1wt%-99wt%, 5wt%-90wt%, or 10wt%-75wt%.

[0276] The recycled components may originate from one or more streams within the chemical recycling facility 10, such as from solvent decomposition byproduct streams (e.g., formed from the solvent decomposition of waste plastic streams including PET) and / or from pyrolysis oil streams (e.g., formed from the pyrolysis of waste plastic streams comprising polyolefins and / or byproducts from the solvent decomposition of waste PET). Several examples of streams that can be introduced into the liquefaction zone 40 as solvent 141 are shown in Figures 1a and 1b. All or part of each of these streams may be used as a solvent. Solvent stream 141 may be introduced directly into the liquefaction tank of the liquefaction zone 40 (not shown in Figures 1a and 1b) separately from the waste plastic stream, such that the combination of solvent and waste plastic takes place in the liquefaction tank, and / or the solvent may be combined with one or more streams introduced into the liquefaction zone 40, such that the combined stream is introduced into the liquefaction tank of the liquefaction zone 40.

[0277] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent may comprise streams drawn from one or more other facilities within the chemical recovery facility. For example, the solvent may comprise streams drawn from at least one of the solvent decomposition facility 30, pyrolysis facility 60, and cracking facility 70. The solvent may be or comprise at least one solvent decomposition byproduct described herein, or may be or comprise pyrolysis oil.

[0278] In some cases, plastics can be depolymerized, thereby reducing the number-average chain length of the plastic, for example, by contact with a depolymerizing agent. In one embodiment or in combination with any of the embodiments mentioned herein, at least one of the previously listed solvents may be used as a depolymerizing agent, while in one or more other embodiments, the depolymerizing agent may include organic acids (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 inorganic acids such as sulfuric acid (for polyolefins). The depolymerizing agent can reduce the melting point and / or viscosity of the polymer by lowering its number-average chain length.

[0279] Alternatively or additionally, plasticizers can be used in the liquefaction zone to reduce the viscosity of the plastic. Plasticizers for polyethylene include, for example, dioctyl phthalate, dioctyl terephthalate, glyceryl tribenzoate, polyethylene glycol with a molecular weight up to 8,000 Daltons, sunflower oil, paraffin wax, paraffin oil, mineral oil, glycerin, EPDM, and EVA with a molecular weight of 400-1,000 Daltons. Plasticizers used for polypropylene include, for example, dioctyl sebacate, paraffin oil, isooctyl resinate, plasticizing oil (Drakeol 34), naphthenic and aromatic treated oils, and glycerin. Plasticizers used in polyesters include, for example, polyalkylene ethers (e.g., polyethylene glycol, poly(tetrahydrofuran), polypropylene glycol, or mixtures thereof) with a molecular weight in the range of 400-1500 Daltons, glyceryl monostearate, epoxidized soybean oil fatty acid octyl ester, epoxidized soybean oil, epoxidized tall oleate, epoxidized linseed oil, polyhydroxy fatty acids, glycols (e.g., ethylene glycol, pentylene glycol, hexanediol, etc.), phthalates, terephthalates, trimellitates, and polyethylene glycol di-(2-ethylhexanoate). When used, the plasticizer may be present in amounts 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 flow, or it may be in the range of 0.1 wt%-10 wt%, 0.5 wt%-8 wt%, or 1 wt%-5 wt% based on the total weight of the flow.

[0280] Furthermore, one or more methods for liquefying waste plastic streams may also include adding at least one blending agent to the plastic before, during, or after the liquefaction process. Such blending agents may include, for example, emulsifiers and / or surfactants, and may be used to more fully mix 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 may be present in amounts 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 may range from 0.1 wt% to 10 wt%, 0.5 wt% to 8 wt%, or 1 wt% to 5 wt%, based on the total weight of the stream.

[0281] As generally shown in Figures 1a and 1b, when combined with a PO-enriched plastic stream 114, a solvent decomposition byproduct stream 110 (which may include one or more solvent decomposition byproducts described herein) may be added before the PO-enriched plastic stream 114 is introduced into the liquefaction zone 40 (as shown in line 113) and / or after the liquefied plastic stream is removed from the liquefaction zone 40 (as shown in line 115). In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion or all of one or more byproduct streams may also be introduced directly into the liquefaction zone, as shown in Figures 1a and 1b. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PO-enriched plastic stream 114 may completely bypass the liquefaction zone 40 in line 117 and may optionally be combined with at least one solvent decomposition byproduct stream 110, also as shown in Figures 1a and 1b.

[0282] Additionally, as shown in Figures 1a and 1b, a portion of the pyrolysis oil stream 143 extracted from the pyrolysis facility 60 can be combined with the PO-enriched plastic stream 114 to form liquefied plastic. Although shown as being introduced directly into the liquefaction zone 40, all or part of the pyrolysis oil stream 143 can be combined with the PO-enriched plastic stream 114 before being introduced into the liquefaction zone 40 or after the PO-enriched plastic stream 114 leaves the liquefaction zone 40. When in use, the pyrolysis oil can be added individually or in combination with one or more other solvent streams at one or more locations described herein.

[0283] In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of the feed stream introduced into one or more downstream processing facilities, the feed stream from liquefaction zone 40 to one or more downstream chemical recovery facilities may contain 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 one or more solvent decomposition byproduct streams.

[0284] For example, feed streams 116, 118, 120, and 122 to each of the POX facility 50, pyrolysis facility 60, cracking facility 70, energy recovery facility 80, and / or chemical recovery facility 10, and any other facility 90, may include PO-enriched waste plastics and a quantity of one or more solvent decomposition byproducts described herein. Based on the total weight of streams 116, 118, 120, and 122, one or more of streams 116, 118, 120, and 122 may include one or more solvent decomposition byproduct streams not exceeding 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 2, or 1 wt%. These quantities may be applied to a single stream or to two or more of these streams in combination.

[0285] Alternatively, or additionally, based on the total weight of the stream, the liquefied (or reduced viscosity) plastic stream taken from the liquefaction zone 40 may contain 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, or based on the total weight of the stream, the amount of PO may be in the range of 1 wt% to 95 wt%, 5 wt% to 90 wt%, or 10 wt% to 85 wt%.

[0286] In one embodiment or in combination with any of the embodiments mentioned herein, the liquefied plastic stream may be a molten plastic stream or may contain plastic dissolved in a liquid solvent. As used herein, the term "dissolved" means at least partially broken down by chemical and / or physical mechanisms.

[0287] 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 5%, or no more than 1% of the viscosity of the PO enriched stream introduced into the liquefaction zone 40.

[0288] like Figure 5 As shown, at least one solvent decomposition byproduct stream 110 and a non-PET waste plastic stream (e.g., a PO enrichment stream) 114 can be fed into the liquefaction zone 40. The solvent decomposition byproduct stream 110 introduced into the liquefaction zone 40 may include one or more polyolefin-containing byproduct streams, reactor purification byproduct streams, light organic byproduct streams, terephthaloyl sludge byproduct streams, and glycol sludge byproduct streams, originating from solvent decomposition (or methanol decomposition) facilities as previously discussed. The solvent decomposition byproduct stream 110 introduced into the liquefaction zone 40 may include at least one, at least two, at least three, at least four, or all of these streams combined before or within the liquefaction zone 40. Based on the total weight of one or more feed streams, the feed to liquefaction zone 40 (whether a single or combined stream) 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 or at least 75 and / or 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 or no more than 50 wt% of at least one solvent decomposition byproduct stream.

[0289] In one embodiment or in combination with any of the embodiments mentioned herein, based on the total weight of one or more feed streams, the feed to liquefaction zone 40 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, or at least 75 and / or 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, or no more than 50 wt% of non-PET plastics, such as waste plastics. Waste plastics may primarily comprise polyolefins, such as polyethylene and / or polypropylene extracted from the pretreatment facilities shown in Figures 1a and 1b. Based on the total weight of one or more streams, such streams may 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% polyolefins. Alternatively, based on the total weight of one or more streams, it may 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, no more than 25, no more than 20, or no more than 15 wt% polyolefins.

[0290] Based on the total weight of one or more streams, non-PET waste plastics may also contain 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 or at least 40 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, no more than 20, no more than 15, no more than 10, no more than 7 or no more than 5 wt% of PET, or based on the total weight of one or more streams, it may be present in amounts ranging from 1 wt% to 40 wt%, 2 wt% to 20 wt%, or 5 wt% to 10 wt%.

[0291] In one embodiment or in combination with any embodiment mentioned herein, the weight ratio of waste plastics to solvent decomposition byproduct streams in the combination is at least 0.75:1, at least 0.90:1, at least 1:1, at least 1.5:1, at least 2:1, at least 3:1, at least 4:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1, at least 10:1, at least 11:1, at least 12:1, at least 13:1, at least 14:1, at least 15:1, at least 16:1, at least 17... :1. At least 18:1, at least 19:1 or at least 20:1 and / or no more than 100:1, no more than 75:1, no more than 70:1, no more than 65:1, no more than 60:1, no more than 50:1, no more than 45:1, no more than 40:1, no more than 35:1, no more than 30:1, no more than 25:1, no more than 20:1, or no more than 15:1, or it may be in the range of 0.75:1 to 100:1, 1:1 to 50:1, or 1.5:1 to 20:1.

[0292] like Figure 5 As shown, at least one predominantly vapor stream 164 and at least one predominantly liquid stream 161 can be extracted from the liquefaction zone 40. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the vapor 164 may optionally be fed to a scrubber 440, such as a caustic alkali or amine scrubber, which may use a scrubbing liquid to remove all or part of the unwanted components, such as chlorine and other halogens, as well as sulfur, carbon dioxide, aldehydes, and combinations thereof. Based on the total amount of unwanted components introduced into the scrubber 440, the scrubber 440 may remove at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of one or more unwanted components introduced into the scrubber.

[0293] The resulting vapor stream 164 can then be introduced into one or more of an energy recovery facility, a POX gasification facility, and a cracking facility. Optionally, at least a portion of the stream introduced into the POX gasification facility and / or cracking facility can be combined with a stream of pyrolysis oil (or pyrolysis gas, not shown), and the combined stream can be introduced into a downstream facility. In some embodiments, based on the total weight of the streams, the combined stream 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, or at least 50 and / or no more than 99, 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 wt% liquefied vapor. Alternatively, or additionally, based on the total weight of the stream, the combined stream may include 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 and / or 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% of pyrolysis oil. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the vapor stream may be cooled and / or compressed (via compressor 450 as shown in Figure 1b) before being introduced into one or more downstream processing facilities.

[0294] In addition, such as Figure 5 As shown, the predominantly liquid stream 161 drawn from liquefaction zone 40 can be introduced into at least one of the following: (i) a POX vaporization facility; (ii) an energy recovery facility; and (iii) a pyrolysis facility. In one embodiment or in combination with any of the embodiments mentioned herein, the predominantly liquid stream can be introduced, alone or in combination with one or more other streams, into at least one, at least two, or all three facilities as described in detail herein.

[0295] Figure 6 The basic components of a liquefaction system that can be used as liquefaction zone 40 in the chemical recovery facility shown in Figures 1a and 1b are illustrated. 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.

[0296] 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 6It 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 disengagement vessel 320. These various exemplary components and their functions in the liquefaction zone 40 will be discussed in more detail below.

[0297] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 6 As shown, the liquefaction zone 40 includes a melting tank 310 and a heater. The melting tank 310 receives 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 of the embodiments mentioned herein, the melting tank 310 may 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 may be added to and / or mixed with the PO enriched plastic in or before the melting tank 310.

[0298] In one embodiment or any of the embodiments mentioned herein ( Figure 6 (Not shown in the image) The heater for the liquefaction zone 40 can take the form of an internal heat exchange coil located in the melting tank 310, a jacket on the outside of the melting tank 310, heat tracing on the outside of the melting tank 310, and / or an electric heating element on the outside of the melting tank 310. Alternatively, as... Figure 6 As shown, the heater of the liquefaction zone 40 may include an external heat exchanger 340 that receives the liquefied plastic stream 171 from the melting tank 310, heats it, and returns at least a portion of the heated liquefied plastic stream 173 to the melting tank 310.

[0299] like Figure 6 As shown, when using an external heat exchanger 340 to provide heat to the liquefaction zone 40, a circulation loop can be used to continuously add heat to the PO enrichment material. In one embodiment or in combination with any of the embodiments mentioned herein, the circulation loop includes a melting tank 310, an external heat exchanger 340, a conduit (shown as line 171) connecting the melting tank and the external heat exchanger, and a pump 151 for circulating the liquefied waste plastic in the circulation loop. When using the circulation loop, the resulting liquefied PO enrichment material can be distributed as part of the circulating PO enrichment stream via... Figure 6 The catheter 161 shown is continuously removed from the liquefaction zone 40.

[0300] In one embodiment or in combination with any of the embodiments mentioned herein, the liquefaction zone 40 may optionally include equipment for removing halogens from the PO enriched material. When the PO enriched material is heated in the liquefaction zone 40, halogen-enriched gas can be evaporated. By separating the evaporated halogen-enriched gas from the liquefied PO enriched material, the concentration of halogens in the PO enriched material can be reduced.

[0301] In one embodiment or in combination with any of the embodiments mentioned herein, dehalogenation can be facilitated by injecting stripping gas (e.g., steam) into the liquefied PO enrichment material in the melting tank 310 or at another location in the circulation loop. Figure 6 As shown, the stripping tower 330 and the phase separation vessel 320 can be arranged in a circulation loop downstream of the external heat exchanger 340 and upstream of the molten tank 310. Figure 6 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.

[0302] This two-phase medium, introduced into the phase-separation vessel 320 via flow 175, can then flow through the vessel (e.g., by gravity) through the vessel, where the halogen-enriched gas phase separates from the halogen-depleted liquid phase and is removed from the vessel 320 via flow 162. Alternatively, as Figure 6 As shown, a portion of the heated liquefied plastic 173 from the external heat exchanger 340 can bypass the stripping tower 330 and be directly introduced into the phase separation vessel 320.

[0303] 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 in 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 phase-separated halogen-enriched gaseous streams from the separation vessel 162 and from the melting tank 310 in line 164 can be removed from the liquefaction zone 40 for further processing and / or disposal.

[0304] 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.

[0305] 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.

[0306] pyrolysis

[0307] In one embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility 10 generally described in Figures 1a and 1b may 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 the equipment, piping, and control devices necessary for the pyrolysis of waste plastics and raw materials derived therefrom.

[0308] Figure 7 An exemplary pyrolysis facility 60 is described for converting waste plastic stream 116 (e.g., liquefied waste plastic from a liquefaction zone) into pyrolysis gas, pyrolysis oil, and pyrolysis residues. It should be understood that... Figure 7 An exemplary embodiment of the present technology is depicted. Therefore, Figure 7 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 7 The system described in the text.

[0309] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 116 to the pyrolysis facility 60 may comprise at least one of the following: (i) at least one solvent decomposition byproduct stream as previously described, and (ii) a PO enrichment stream of waste plastics. One or more of these streams may be introduced into the pyrolysis facility 60 continuously, or one or more of these streams may be introduced intermittently. When multiple types of feed streams are present, each feed stream may be introduced separately, or all or part of the feed streams may be combined to allow the combined streams to be introduced into the pyrolysis facility 60. When combining, it may be done continuously or intermittently. The feed introduced into the pyrolysis facility 60 may be in the form of liquefied plastics (e.g., liquefied, melted, plasticized, depolymerized, or a combination thereof), plastic pellets or granules, or a slurry thereof.

[0310] Usually, such as Figure 7 The pyrolysis facility 60 is depicted to include a pyrolysis reactor 510 and a separator 520 for separating product streams from the reactor. Although not described in... Figure 7 As described, the separator 520 of the pyrolysis facility 60 may include various types of equipment, including but not limited to filtration systems, multi-stage separators, condensers and / or quench towers.

[0311] When in pyrolysis reactor 510, at least a portion of the feed may undergo a pyrolysis reaction 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 by pyrolysis that is gaseous at 25°C. As used herein, the term “pyrolysis oil” refers to a composition obtained by pyrolysis that is liquid at 25°C and 1 atm. As used herein, the term “pyrolysis residue” refers to a composition obtained by pyrolysis that is not pyrolysis gas or pyrolysis oil and primarily comprises pyrolysis coke and pyrolysis heavy wax. As used herein, the term “pyrolysis coke” refers to a carbonaceous composition obtained by pyrolysis that is solid at 200°C and 1 atm. As used herein, the term “pyrolysis heavy wax” refers to a C20+ hydrocarbon obtained by pyrolysis that is not pyrolysis coke, pyrolysis gas, or pyrolysis oil. Pyrolysis gas and pyrolysis oil can leave the pyrolysis reactor 500 as pyrolysis vapor stream 170.

[0312] Pyrolysis is a process involving the chemical and thermal decomposition of an introduced feedstock. Although all pyrolysis processes can generally be characterized by a substantially oxygen-free reaction environment, the pyrolysis process can be further defined by factors such as the pyrolysis reaction temperature within the reactor, the residence time in the pyrolysis reactor, the type of reactor, the pressure within the pyrolysis reactor, and the presence or absence of a pyrolysis catalyst.

[0313] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reactor 510 may 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. The pyrolysis reactor 510 includes a membrane reactor, such as a falling film reactor or an upflow membrane reactor.

[0314] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reaction may include heating and converting the feedstock in a substantially oxygen-free atmosphere or in an atmosphere containing less oxygen than ambient air. For example, based on the internal volume of the reactor, the atmosphere within the pyrolysis reactor 510 may contain no more than 5, 4, 3, 2, 1, or 0.5 vol% (vol%, volume percent) of oxygen.

[0315] In one embodiment or in combination with any of the embodiments mentioned herein, the riser gas and / or feed gas can be used to introduce feedstock into the pyrolysis reactor 510 and / or to promote various reactions within the pyrolysis reactor 510. For example, the riser gas and / or feed gas may include nitrogen, carbon dioxide, and / or steam, and may consist substantially of nitrogen, carbon dioxide, and / or steam, or may consist of nitrogen, carbon dioxide, and / or steam. The riser gas and / or feed gas may be added together with the waste plastic stream 116 before being introduced into the pyrolysis reactor 510 and / or may be added directly to the pyrolysis reactor 510. The riser gas and / or feed gas may include steam and / or reducing gases, such as hydrogen, carbon monoxide, and combinations thereof.

[0316] Furthermore, the temperature in the pyrolysis reactor 510 can be adjusted to facilitate the production of certain final 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.

[0317] Additionally, or alternatively, the pyrolysis temperature in the pyrolysis reactor may 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, no more than 425°C, or no more than 400°C. More specifically, 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.

[0318] In one embodiment or in combination with any embodiment mentioned herein, the residence time of the feedstock in the pyrolysis reactor may 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 in the pyrolysis reactor may 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 in the pyrolysis reactor may 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. Furthermore, the residence time of the raw material in 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 specifically, the residence time of the raw material in the pyrolysis reactor can be within the range of 0.1-10 seconds, 0.5-10 seconds, 30 minutes-4 hours, 30 minutes-3 hours, or 1 hour-2 hours.

[0319] In one embodiment or in combination with any embodiment mentioned herein, the pressure within the pyrolysis reactor may be maintained at 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 may 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 may 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, unless otherwise stated, the term "bar" refers to gauge pressure.

[0320] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis catalyst may be introduced into the feed stream 116 prior to its introduction into the pyrolysis reactor 510 and / or directly into the pyrolysis reactor 510. The catalyst may be homogeneous or heterogeneous and may include, for example, certain types of zeolites and other mesoscopic catalysts. In some embodiments, the pyrolysis reaction may not be catalyzed (e.g., carried out in the absence of a pyrolysis catalyst), but non-catalyzed, heat-retaining inert additives, such as sand, may be included in the reactor 510 to facilitate heat transfer. This catalyst-free pyrolysis method may be referred to as "thermal pyrolysis".

[0321] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reaction in the pyrolysis reactor 510 can occur in the 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.

[0322] In one embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or pyrolysis vapor may contain 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, which may be in vapor form in the pyrolysis effluent when leaving the heated reactor; however, these vapors may subsequently condense into the resulting pyrolysis oil. Additionally, or alternatively, the pyrolysis effluent or pyrolysis vapor may contain 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, which may be in vapor form in the pyrolysis effluent when leaving the heated reactor. Based on the total weight of the pyrolysis effluent or pyrolysis vapor, the pyrolysis effluent or pyrolysis vapor may contain 20wt%-99wt%, 25wt%-80wt%, 30wt%-85wt%, 30wt%-80wt%, 30wt%-75wt%, 30wt%-70wt%, or 30wt%-65wt% of pyrolysis oil.

[0323] In one embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or pyrolysis vapor may contain 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% of pyrolysis gas. Additionally, or alternatively, the pyrolysis effluent or pyrolysis vapor may contain 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% of pyrolysis gas. Based on the total weight of the stream, the pyrolysis effluent may contain 1 wt%-90 wt%, 10 wt%-85 wt%, 15 wt%-85 wt%, 20 wt%-80 wt%, 25 wt%-80 wt%, 30 wt%-75 wt%, or 35 wt%-75 wt% of pyrolysis gas.

[0324] In one embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or pyrolysis vapor may contain 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% of pyrolysis residue. Additionally, or alternatively, the pyrolysis effluent may contain 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% of pyrolysis residue. Based on the total weight of the stream, the pyrolysis effluent may contain pyrolysis residue in the range of 0.1 wt%-25 wt%, 1 wt%-15 wt%, 1 wt%-8 wt%, or 1 wt%-5 wt%.

[0325] In one embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or pyrolysis vapor may contain no more than 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or 0.5 wt% free water. As used herein, “free water” means water pre-added (as a liquid or vapor) to the pyrolysis unit and water generated in the pyrolysis unit.

[0326] The pyrolysis system described herein can produce pyrolysis effluents 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 directly used in various downstream applications based on their formulations. Various characteristics and properties of the pyrolysis oil, pyrolysis gas, and pyrolysis residue are described below. It should be noted that while all of the following characteristics and properties can be listed individually, it is conceivable that each of the following characteristics and / or properties of the pyrolysis gas, pyrolysis oil, and / or pyrolysis residue is not mutually exclusive and can be combined and exist in any combination.

[0327] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may primarily comprise hydrocarbons (e.g., C4-C30 hydrocarbons) having 4 to 30 carbon atoms per molecule. As used herein, the term “Cx” or “Cx hydrocarbon” refers to a hydrocarbon compound comprising a total of “x” carbon atoms per molecule and encompasses all alkenes, alkanes, aromatics, 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, will fall under the general description “C4”. Based on the total weight of the pyrolysis oil stream 174, the C4-C30 hydrocarbon content of the pyrolysis oil may 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%.

[0328] In one embodiment or in combination with any embodiment mentioned herein, the pyrolysis oil may primarily comprise C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons. For example, based on the total weight of the pyrolysis oil, the pyrolysis oil may contain 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 C5-C25, C5-C22, or C5-C20 hydrocarbons. Based on the total weight of the pyrolysis oil, the C5-C12 hydrocarbon content of the pyrolysis oil may 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%. Additionally, or alternatively, the C5-C12 hydrocarbon content of the pyrolysis oil may 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%. Based on the total weight of the stream, the C5-C12 hydrocarbon content of the pyrolysis oil can be in the range of 10wt%-95wt%, 20wt%-80wt%, or 35wt%-80wt%.

[0329] In one embodiment or in combination with any embodiment mentioned herein, depending on reactor conditions and whether a catalyst is used, the pyrolysis oil may also comprise various amounts of olefins and aromatic hydrocarbons. Based on the total weight of the pyrolysis oil, the pyrolysis oil contains 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 aromatic hydrocarbons. Additionally, or alternatively, the pyrolysis oil may 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 aromatic hydrocarbons. As used herein, the term "aromatic hydrocarbon" refers to the total amount (by weight) of any compound containing an aromatic moiety, such as benzene, toluene, xylene, and styrene.

[0330] In one embodiment or in combination with any embodiment mentioned herein, the alkane (e.g., straight-chain or branched alkanes) content of the pyrolysis oil may 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, at least 55, at least 60, or at least 65 wt%, based on the total weight of the pyrolysis oil. Additionally, or alternatively, the alkane content of the pyrolysis oil may be 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 alkane content of the pyrolysis oil may be in the range of 25 wt%-90 wt%, 35 wt%-90 wt%, or 50 wt%-80 wt%.

[0331] In one embodiment or in combination with any embodiment mentioned herein, the intermediate boiling point of the pyrolysis oil may 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 not exceeding 250°C, not exceeding 245°C, not exceeding 240°C, not exceeding 235°C, not exceeding 230°C, not exceeding 225°C, not exceeding 220°C, not exceeding 215°C, not exceeding 210°C, not exceeding 205°C, not exceeding 200°C, not exceeding 195°C, not exceeding 190°C, not exceeding 185°C, not exceeding 180°C, not exceeding 175°C, not exceeding 170°C, not exceeding 165°C, not exceeding 160°C, not exceeding 155°C, not exceeding 150°C, not exceeding 145°C, not exceeding 140°C, not exceeding 135°C, not exceeding 130°C, not exceeding 125°C, or not exceeding 120°C, as measured according to ASTM D5399. The intermediate boiling point of pyrolysis oil can be in the range of 75 to 250°C, 90 to 225°C, or 115 to 190°C. As used herein, "intermediate boiling point" refers to the median boiling point temperature of pyrolysis oil, wherein 50% by volume of the pyrolysis oil boils above the intermediate boiling point and 50% by volume boils below the intermediate boiling point.

[0332] In one embodiment or in combination with any of the embodiments mentioned herein, the boiling point range of the pyrolysis oil is such that at least 90% of the pyrolysis oil vaporizes at temperatures of 250°C, 280°C, 290°C, 300°C, or 310°C, as measured according to ASTM D-5399.

[0333] The methane content of the pyrolysis gas, based on its total weight, 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 not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, or not more than 20 wt%. In one embodiment or in combination with any embodiment mentioned herein, the methane content of the pyrolysis gas can be in the range of 1 wt%-50 wt%, 5 wt%-50 wt%, or 15 wt%-45 wt%.

[0334] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the pyrolysis gas, the C3 and / or C4 hydrocarbon content (including all hydrocarbons having 3 or 4 carbon atoms per molecule) of the pyrolysis gas 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, 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%. The C3 hydrocarbon content, C4 hydrocarbon content, or combined C3 and C4 hydrocarbon content of the pyrolysis gas can be in the range of 10 wt%-90 wt%, 25 wt%-90 wt%, or 25 wt%-80 wt%.

[0335] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas may account for 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 total ethylene and propylene content of the pyrolysis gas may be at least 25, at least 40, at least 50, at least 60, at least 70, or at least 75 wt%.

[0336] 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% of C20+ hydrocarbons, based on the total weight of the pyrolysis residue. As used herein, “C20+ hydrocarbon” means a hydrocarbon compound containing a total of at least 20 carbon atoms per molecule and encompasses all alkenes, alkanes, and isomers having that number of carbon atoms.

[0337] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the pyrolysis residue, 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. 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 a carbon-containing composition derived from pyrolysis that is solid at 25°C and 1 atm. Based on the total weight of the carbon-containing solids, the carbon-containing solids contain 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.

[0338] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the pyrolysis gas, pyrolysis oil, and pyrolysis residue may be fed to one or more other chemical processing facilities, including, for example, an energy recovery facility 80, a partial oxidation facility 50, one or more other facilities 90 previously discussed, and a 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 (also known as pyoil) stream 174 may 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 may 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 may be fed to one or more separation facilities (not shown in Figures 1a and 1b) to form a purer stream of pyrolysis gas, pyrolysis oil, and / or pyrolysis residue, which may then be fed to the energy recovery facility 80, the cracking facility 70, the POX gasification facility 50, and combinations thereof. Additionally, or alternatively, all or part of the pyrolysis oil stream 176 may be combined with the PO enriched waste plastic stream 114 to provide a liquefied plastic stream for feeding into one or more downstream facilities described herein.

[0339] Cracking

[0340] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of one or more streams from pyrolysis facility 60 or from one or more other facilities shown in Figures 1a and 1b may be introduced into cracking facility 70. As used herein, the term “cracking” refers to the breaking down of complex organic molecules into simpler molecules by the breaking of carbon-carbon bonds. A “cracking facility” is a facility that includes all the equipment, piping, and control devices necessary for cracking feedstocks derived from waste plastics. A cracking facility may include one or more cracker furnaces and a downstream separation zone including equipment for processing the effluent from the cracker furnaces. As used herein, the terms “cracker” and “cracking” are used interchangeably.

[0341] Turning now to Figure 8a, a cracking facility 70 according to one or more embodiments of the present technology is illustrated. Typically, the cracking facility 70 includes a cracker furnace 720 and a separation zone 740 downstream of the cracker furnace 720 for separating the furnace effluent into various final products, such as a recovered component olefin (r-olefin) stream 130. As shown in Figure 8a, at least a portion of the pyrolysis gas stream 172 and / or pyrolysis oil stream 174 from the pyrolysis facility 60 can be fed to the cracking facility 70. The pyrolysis oil stream 174 can be introduced into the 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 Figure 8a, a stream of alkanes 132 (e.g., ethane and / or propane) can be withdrawn from the separation zone and may include recovered component alkanes (r-alkanes). All or part of the alkanes can be recovered via stream 134 to the inlet of the cracker furnace 720, also as shown in Figure 8a. When in use, the pyrolysis oil stream, pyrolysis gas stream 172, and recovered alkane stream 174 can optionally be combined with the cracker feed stream 136 to form the feed stream 119 to the cracking facility 720.

[0342] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 119 to the cracking unit 70 may comprise at least one of the following: (i) one or more solvent decomposition byproduct streams 110 as described above, (ii) a PO enrichment 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 may be introduced into the cracking unit 70 continuously, or one or more of these streams may be introduced intermittently. When multiple types of feed streams are present, each feed stream may be introduced separately, or all or part of the feed streams may be combined so that the combined streams may be introduced into the cracking unit 70. When combining, it may be done continuously or intermittently. One or more feed streams introduced into the cracking unit 70 may be in the form of a predominantly gaseous stream, a predominantly liquid stream, or a combination thereof.

[0343] As shown in Figure 8a, the streams of pyrolysis gas 172 and / or pyrolysis oil 174 may be introduced into the cracker facility 70 together with or as part of the cracker feed stream 136. In some embodiments, based on the total weight of the stream 119, the cracker feed stream 119 may contain 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 pyrolysis gas, pyrolysis oil, or a combination of pyrolysis gas and pyrolysis oil. Alternatively, or additionally, based on the total weight of stream 119, cracker feed stream 119 may contain no more than 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, or 20 wt% of pyrolysis gas, pyrolysis oil, or a combination of pyrolysis gas and pyrolysis oil, or based on the total weight of stream 119, it may contain amounts of these components ranging from 1 wt% to 95 wt%, 5 wt% to 90 wt%, or 10 wt% to 85 wt%.

[0344] In some embodiments, based on the total weight of the cracker feed stream 119, the cracker feed stream 119 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% 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 hydrocarbon feed other than pyrolysis gas and pyrolysis oil, or based on the total weight of the cracker feed stream 119, it may contain 5 wt%-95 wt%, 10 wt%-90 wt%, or 15 wt%-85 wt% of hydrocarbon feed other than pyrolysis gas and pyrolysis oil.

[0345] In one embodiment or in combination with any of the embodiments described herein, the cracker feed stream 119 may comprise a composition primarily containing C2-C4 hydrocarbons. As used herein, the term "primarily C2-C4 hydrocarbons" refers to a stream or composition containing at least 50 wt% C2-C4 hydrocarbon components. Examples of specific types of C2-C4 hydrocarbon streams or compositions include propane, ethane, butane, and LPG. The cracker feed stream 119 may contain 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, as a weight percentage based on the total weight of the feed, and / or not exceeding 100, or not exceeding 99, or not exceeding 95, or not exceeding 92, or not exceeding 90, or not exceeding 85, or not exceeding 80, or not exceeding 75, or not exceeding 70, or not exceeding 65, or not exceeding 60, in each case, as a weight percentage of C2 to C4 hydrocarbons or straight-chain alkanes, based on the total weight of the feed. The cracker feed stream 119 may contain primarily propane, primarily ethane, primarily butane, or a combination of two or more of these components.

[0346] In one embodiment or in combination with any of the embodiments described herein, the cracker feed stream 119 may comprise a composition containing primarily C5-C22 hydrocarbons. As used herein, "primarily C5-C22 hydrocarbons" means a stream or composition containing at least 50 wt% C5-C22 hydrocarbon components. Examples include gasoline, naphtha, middle distillates, diesel, and kerosene.

[0347] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the stream, the cracker feed stream 119 may contain 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, as a weight percentage, and / or not more than 100, or not more than 99, or not more than 95, or not more than 92, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, in each case, as a weight percentage of C5 to C22 or C5 to C20 hydrocarbons, or, based on the total weight of the stream, it may include an amount of C5 to C22 hydrocarbons in the range of 20wt%-100wt%, 25wt%-95wt%, or 35wt%-85wt%.

[0348] In one embodiment or in combination with any embodiment mentioned herein, the C15 and heavier (C15+) content of the cracker feed stream 119 may be at least 0.5, or at least 1, or at least 2, or at least 5, in each case as a weight percentage 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 as a weight percentage, or, based on the total weight of the stream, it may be in the range of 0.5wt%-40wt%, 1wt%-35wt%, or 2wt%-30wt%.

[0349] In one embodiment or in combination with any of the embodiments mentioned herein, the feed to the cracker furnace may comprise vacuum gas oil (VGO), hydrogenated vacuum gas oil (HVGO), or atmospheric gas oil (AGO). Based on the total weight of stream 119, cracker feed stream 119 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 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, or, based on the total weight of stream 119, it may be present in amounts ranging from 5 wt% to 99 wt%, 10 wt% to 90 wt%, 15 wt% to 85 wt%, or 5 wt% to 50 wt%.

[0350] As shown in Figure 8a, the cracker feed stream 119 is introduced into the cracker furnace 720. Turning now to Figure 8b, a schematic diagram of the cracker furnace 720 suitable for the chemical recovery facility and / or cracker facility described herein is shown. As shown in Figure 8b, the cracker furnace 720 may include a convection section 746, a radiant section 748, and a cross section 750 located between the convection section 746 and the radiant section 748. The convection section 746 is a portion of the furnace that receives heat from the hot flue gas and includes a set of tubes or coils 752 through which the cracker stream passes. In the convection section 746, the cracker stream is heated by convection from the hot flue gas passing through it. Although shown in Figure 8b as including horizontally oriented convection section tubes 752a and vertically oriented radiant section tubes 752b, it should be understood that the tubes may be configured in any suitable configuration. For example, the convection section tubes 752a may be vertical. The radiant section tubes 752b may be horizontal. Additionally, although shown as a single tube, the cracker furnace 720 may include one or more tubes or coils, which may include at least one split, bend, U-shape, elbow, or combination thereof. When multiple tubes or coils are present, they may be arranged in parallel and / or in series.

[0351] The radiant section 748 is a section of the furnace 720 where heat is primarily transferred via radiation from the high-temperature gas into the heating tubes. The radiant section 748 also includes multiple burners 756 for introducing heat into the lower part 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 oriented into this firebox. The cross section 750 includes conduits for connecting the convection section 746 and the radiant section 748, and allows the transfer of heated cracker flow from one section to another, either inside or outside the furnace 720.

[0352] As the hot combustion gases rise through the furnace body, they can pass through a 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 cracker furnace 720 may have a single convection (preheating) section and a single radiant section, while in other embodiments, the furnace may include two or more radiant sections sharing a common convection section. At least one induced draft fan 760 near the furnace body controls the flow of hot flue gas and the heating distribution through the furnace 720, and one or more heat exchangers 761 are available for cooling the furnace effluent. In addition to the heat exchangers 761 at the furnace outlet shown in Figure 8b (e.g., delivery line heat exchangers or TLEs), or alternatively with… Figure 6 Together with the exchanger 761 at the furnace outlet shown in b, liquid quenching (not shown) can be used to cool the cracked olefin-containing effluent 125.

[0353] In one or more embodiments, the pyrolysis gas may be introduced at the inlet of the cracker furnace, or all or part of the pyrolysis gas may be introduced downstream of the furnace outlet, at a location upstream of or within the separation zone of the cracker facility. When introduced into or upstream of the separation zone, the pyrolysis gas may be introduced upstream of the last stage of compression, or before the inlet of at least one fractionating column in the fractionation zone of the separation zone.

[0354] Prior to entering the cracker facility 70, in one or more embodiments, the crude pyrolysis gas stream 172 from the pyrolysis facility may undergo one or more separation steps to remove one or more components from the stream. Examples of these components may include, but are not limited to, halogens, aldehydes, oxygen-containing compounds, nitrogen-containing compounds, sulfur-containing compounds, carbon dioxide, water, gasified metals, and combinations thereof. In one or more embodiments, based on the total weight of the pyrolysis gas stream 172, the pyrolysis gas stream 172 introduced into the cracker facility 70 contains 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.

[0355] In one embodiment or in combination with any of the embodiments mentioned herein, cracker facility 70 may include a single cracking furnace, or it may have at least two, at least three, at least four, at least five, at least six, at least seven, or at least eight or more cracking furnaces operating in parallel. Any furnace or each furnace may be a gas cracker, a liquid cracker, or a cracking furnace. The furnace may 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, the cracker feed stream containing 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 total weight of all cracker feeds to the furnace.

[0356] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker 720 may be a liquid or naphtha cracker receiving a cracker feed stream containing at least 50 wt%, or at least 75 wt%, or at least 85 wt% liquid hydrocarbons (when measured at 25°C and 1 atm) having a carbon number of C5-C22.

[0357] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream 119 can be cracked in a gas furnace. The gas furnace is a furnace having at least one coil that receives (or is operated to receive or configured to receive) a predominantly gaseous feed (more than 50 wt% of the feed is vapor) (“gas coil”) at a coil inlet at the inlet of the convection zone. The gas coil may receive a predominantly C2-C4 or predominantly C2-C3 feedstock to the inlet of the coil in the convection zone, or alternatively, has at least one coil that receives more than 50 wt% ethane and / or more than 50% propane and / or more than 50% LPG, or in any of these cases, receives 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 zone.

[0358] The gas furnace may have more than one gas coil. In one embodiment or in combination with any embodiment mentioned herein, at least 25%, or at least 50%, or at least 60%, or all of the coils in the convection zone or the furnace's convection box are gas coils. The gas coil receives a gaseous feed at its coil inlet at the inlet of the convection zone, wherein 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 steam.

[0359] 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 a coil inlet at the convection zone inlet.

[0360] 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.

[0361] 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 FIG8b.

[0362] In one embodiment or in combination with any of the embodiments mentioned herein, when two or more streams from the chemical recovery facility 10 shown in Figures 1a and 1b are combined with another stream from facility 10 to form cracker feed stream 119, such combination can occur upstream of or within the cracker furnace 720. Alternatively, the different feed streams can be introduced into the furnace 720 separately and can pass through part or all of the furnace 720 simultaneously, while being isolated from each other by feeding into separate tubes 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 devices in the separation facility.

[0363] When two or more streams from a chemical recovery facility are combined with another stream to form a cracker feed stream, this combination can occur upstream of the cracker or inside the cracker. Alternatively, the different feed streams can be introduced into the furnace separately and can pass through part or all of the furnace simultaneously, while being isolated from each other by feeding into separate tubes within the same furnace (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.

[0364] 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.

[0365] The temperature of the cracked olefin-containing effluent 125 removed from the furnace outlet may 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 °C, in each case being °C, and / or not exceeding 1000, or not exceeding 990 °C. Or not exceeding 980, or not exceeding 970, or not exceeding 960, or not exceeding 950, or not exceeding 940, or not exceeding 930, or not exceeding 920, or not exceeding 910, or not exceeding 900, or not exceeding 890, or not exceeding 880, or not exceeding 875, or not exceeding 870, or not exceeding 860, or not exceeding 850, or not exceeding 840, or not exceeding 830, in each case being °C, within the range of 730 to 900 °C, 750 to 875 °C, or 750 to 850 °C.

[0366] In one embodiment or in combination with any embodiment mentioned herein, the yield of olefins—ethylene, propylene, butadiene, or combinations thereof—may 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 as a percentage. As used herein, the term “yield” means the mass of product produced from the mass of feedstock / the mass of feedstock × 100%. Based on the total weight of the effluent, the olefin-containing effluent contains 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 as a weight percentage) of ethylene, propylene, or ethylene and propylene.

[0367] In one embodiment or in combination with any of the embodiments mentioned herein, the olefin-containing effluent stream 125 may contain 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% of C2-C4 olefins. Based on the total weight of the olefin-containing effluent stream 125, stream 125 may primarily contain ethylene, primarily contain propylene, or primarily contain both ethylene and propylene. The weight ratio of ethylene to propylene in the olefin-containing effluent 125 may 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 not exceeding 3:1, not exceeding 2.9:1, not exceeding 2.8:1, not exceeding 2.7:1, not exceeding 2.5:1, not exceeding 2.3:1, not exceeding 2.2:1, not exceeding 2.1:1, not exceeding 2:1, not exceeding 1.7:1, not exceeding 1.5:1, or not exceeding 1.25:1.

[0368] Turning again to Figure 8a, in one embodiment or in combination with any of the embodiments mentioned herein, when introduced into cracker facility 70, pyrolysis gas 172 may be introduced into the inlet of cracker furnace 720, or all or part of the pyrolysis gas may be introduced downstream of the furnace outlet, at a location upstream or inside the separation zone 740 of cracker facility 70. When introduced into or upstream of separation zone 740, pyrolysis gas may be introduced upstream of the last stage of compression, or before the inlet of at least one fractionating column in the fractionation section of separation zone 740.

[0369] Prior to entering cracker facility 70, in one embodiment or in combination with any of the embodiments mentioned herein, the crude pyrolysis gas stream from the pyrolysis facility may undergo one or more separation steps to remove one or more components from the stream. Examples of these components may include, but are not limited to: halogens, aldehydes, oxygen-containing compounds, nitrogen-containing compounds, sulfur-containing compounds, carbon dioxide, water, gasified metals, and combinations thereof. Based on the total weight of the pyrolysis gas stream 172, the pyrolysis gas stream 172 introduced into cracker facility 70 contains 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.

[0370] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of stream 172, the total ethylene content of pyrolysis stream 172 may 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%. Alternatively, or additionally, based on the total weight of stream 172, the total propylene content of pyrolysis stream 172 may 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 the stream, the combined metric of ethylene and propylene in the 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%.

[0371] Upon exiting the cracker furnace, the olefin-containing effluent 125 can be rapidly cooled (e.g., quenched) to prevent the generation 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 reach a temperature of 500 to 760°C.

[0372] The resulting cooled effluent can then be separated in a gas-liquid separator, and the vapor can be compressed in a gas compressor having, for example, 1-5 compression stages, with optional interstage cooling and liquid removal. The gas flow pressure at the outlet of the first set of compression stages is in the range of 7 to 20 barg, 8.5 to 18 barg, or 9.5 to 14 barg. The resulting compressed stream is then treated by contact with an acid gas removal agent to remove acid gases, including halogens, CO2, and H2S. Examples of acid gas removal agents include, but are not limited to, caustic alkalis and various types of amines. In one embodiment or in combination with any of the embodiments mentioned herein, a single contactor may be used, while in other embodiments, a dual-tower absorber-stripper configuration may be employed.

[0373] The processed 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 moisture removal method can be used, including, for example, molecular sieves or other similar methods. The resulting stream can then be fed to a fractionation section, where olefins and other components can be separated into various high-purity products or intermediate streams. In some embodiments, all or part of the pyrolysis gas can be introduced before and / or after one or more stages of a second compressor. Similarly, the pressure of the pyrolysis gas is within 20 psi, 50 psi, 100 psi, or 150 psi of the pressure of the stream it is combined with.

[0374] In one embodiment, or in combination with any of the embodiments mentioned herein, a feed stream from the quenching zone may be introduced into at least one column within the fractionation zone of the separation zone. As used herein, the term "fractionation" refers to the general process of separating two or more materials with different boiling points. Examples of equipment and methods utilizing fractionation include, but are not limited to, distillation, rectification, stripping, and gas-liquid separation (single-stage).

[0375] In one embodiment or in combination with any of the embodiments mentioned herein, the fractionation section of a cracker facility may include one or more of the following: a demethanizer, a deethaner, a depropanizer, an ethylene separator, a propylene separator, a debutanizer, and combinations thereof. As used herein, the term "demethanizer" refers to a tower whose light key component is methane. Similarly, "deethaner" and "depropanizer" refer to towers having ethane and propane as light key components, respectively.

[0376] Any suitable column arrangement can be used such that the fractionation section provides at least one olefin product stream and at least one alkane stream. In one embodiment or in combination with any of the embodiments mentioned herein, the fractionation section may provide: at least two olefin streams, such as ethylene and propylene; and at least two alkane streams, such as ethane and propane; and additional streams, including, for example, methane and lighter components, and butane and heavier components.

[0377] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the olefin stream, the olefin stream taken from the fractionation section 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% and / or no more than 100, no more than 99, no more than 97, no more than 95, no more than 90, no more than 85 or no more than 80 wt% of olefins. The olefins may be primarily ethylene or primarily propylene. Based on the total weight of the olefins in the olefin stream, the olefin stream 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% and / or no more than 99, no more than 97, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70 or no more than 65 wt% of ethylene. Based on the total weight of the olefin stream, the olefin stream may contain 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 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% of ethylene, or based on the total weight of the olefin stream, it may be present in amounts of 20 wt%-80 wt%, 25 wt%-75 wt%, or 30 wt%-70 wt%.

[0378] Alternatively, or additionally, based on the total weight of olefins in the olefin stream, the olefin stream 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% and / or no more than 99, no more than 97, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, or no more than 65 wt% of propylene. In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the olefin stream, the olefin stream may contain 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 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% of propylene, or based on the total weight of the olefin stream, it may be present in amounts of 20 wt%-80 wt%, 25 wt%-75 wt%, or 30 wt%-70 wt%.

[0379] As the compressed stream passes through the fractionation section, it passes through a demethanizer, where methane and lighter (CO, CO2, H2) components are separated from ethane and heavier components. The demethanizer can operate at temperatures of at least -145, or at least -142, or at least -140, or at least -135 °C in each case, and / or, not exceeding -120, not exceeding -125, not exceeding -130, not exceeding -135 °C. The bottom stream from the demethanizer comprises 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, a percentage of the total amount) of ethane and heavier components.

[0380] 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 may be introduced into a deethanizer, wherein C2 and lighter components are separated from C3 and heavier components by fractionation. The deethanizer may operate at the following overhead temperatures and pressures: overhead temperatures of at least -35, or at least -30, or at least -25, or at least -20 °C in each case, and / or, not exceeding -5, not exceeding -10, not exceeding -15, or not exceeding -20 °C; and overhead pressures of at least 3, or at least 5, or at least 7, or at least 8, or at least 10 barg in each case, and / or, not exceeding 20, or not exceeding 18, or not exceeding 17, or not exceeding 15, or not exceeding 14, or not exceeding 13 barg in each case. The deethanizer 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% of the total C2 and lighter components introduced into the column in the overhead stream, in each case as a percentage of the total amount. Based on the total weight of the overhead stream, the overhead stream removed from the deethanizer contains 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% of ethane and ethylene, in each case as a percentage by weight.

[0381] In one embodiment or in combination with any of the embodiments mentioned herein, the C2 and lighter overhead streams from the deethaner column can be further separated in an ethane-ethylene fractionator column (ethylene fractionator or ethylene separator). In the ethane-ethylene fractionator, the ethylene and lighter component streams can be withdrawn from the top of the column or as a side stream from the upper part of the column, while ethane and any remaining heavier components are removed in the bottom stream. The ethylene fractionator can be operated at the following top temperature and pressure: 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 °C in each case, and / or, not exceeding -15, or not exceeding -20, or not exceeding -25 °C in each case; and a top pressure of at least 10, or at least 12, or at least 15 barg in each case, and / or, not exceeding 25, not exceeding 22, or not exceeding 20 barg. Based on the total weight of the stream, the overhead stream, which may be rich in ethylene, may contain 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, by weight percentage) of ethylene, and may be sent to downstream processing units for further processing, storage, or sale.

[0382] Based on the total weight of the bottom stream, the bottom stream of the ethane-ethylene fractionator may 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, by weight percentage) of ethane. As previously described, all or part of the extracted ethane may be recovered as an additional feedstock, alone or in combination with pyrolysis oil and / or pyrolysis gas, to the inlet of the cracker furnace.

[0383] In some embodiments, at least a portion of the compressed stream can be separated in a depropanizer, wherein C3 and lighter components are removed as overhead vapor, while C4 and heavier components exit the column in the liquid bottom. The depropanizer can operate at an overhead temperature of at least 20, or at least 35, or at least 40 °C in each case, and / or no greater than 70, 65, 60, 55 °C, and at least 10, or at least 12, or at least 15, in each case, barg, and / or no greater than 20, or no greater than 17, or no greater than 15, in each case, barg, at an overhead pressure. The depropanizer 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, a percentage of the total amount of C3 and 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 propane stripper contains 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.

[0384] In one embodiment or in combination with any of the embodiments mentioned herein, the overhead stream from the depropanizer may be introduced into a propane-propylene fractionator (propylene fractionator or propylene diverter), wherein propylene and any lighter components are removed from the overhead stream, and propane and any heavier components exit the column in the bottom stream. The propylene fractionator may operate at the following overhead temperatures and pressures: an overhead temperature of at least 20, or at least 25, or at least 30, or at least 35 °C in each case, and / or, not exceeding 55, not exceeding 50, not exceeding 45, or not exceeding 40 °C; and an overhead pressure of at least 12, or at least 15, or at least 17, or at least 20, or in each case, barg, and / or, not exceeding 20, or not exceeding 17, or not exceeding 15, or not exceeding 12, or in each case, barg. Based on the total weight of the stream, the overhead stream, which may be rich in propylene, may contain 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, by weight percentage) of propylene, and may be sent to downstream processing units for further processing, storage, or sale.

[0385] Based on the total weight of the bottom stream, the bottom stream from the propane-propylene fractionator may 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, by weight percentage) of propane. As discussed above, all or part of the extracted propane may be recovered as an additional feedstock, alone or in combination with pyrolysis oil and / or pyrolysis gas, to the cracker furnace.

[0386] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the compressed stream may be fed to a debutanizer to separate C4 and lighter components (including butene, butane, and butadiene) from C5 and heavier (C5+) components. The debutanizer may be operated at the following overhead temperatures and pressures: overhead temperature: at least 20, or at least 25, or at least 30, or at least 35, or at least 40 °C in each case, and / or, not exceeding 60, or not exceeding 65, or not exceeding 60, or not exceeding 55, or not exceeding 50 °C in each case; overhead pressure: at least 2, or at least 3, or at least 4, or at least 5 barg in each case, and / or, not exceeding 8, or not exceeding 6, or not exceeding 4, or not exceeding 2 barg in each case. The butane removal 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, the percentage of the total amount of C4 and lighter components introduced into the column in the overhead stream.

[0387] In one embodiment or in combination with any of the embodiments mentioned herein, the overhead stream removed from the butane dehydrogenator contains 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 wt% of butadiene, in each case as a weight percentage. The bottom stream from the butane dehydrogenator primarily comprises C5 and heavier components, in an amount of at least 50, or at least 60, or at least 70, or at least 80, or at least 90, or at least 95 wt% of the total stream weight. The bottom stream from the butane dehydrogenator may be sent for further separation, processing, storage, sale, or use. In one embodiment or in combination with any of the embodiments described herein, the overhead stream or C4 from the butane dehydrogenator may be subjected to any conventional separation method, such as extraction or distillation processes, to extract a more concentrated butadiene stream.

[0388] In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of one or more streams may be introduced into one or more facilities shown in Figures 1a and 1b, while in other embodiments, all or part of the streams removed from the separation zone of the cracking facility may be sent for further separation and / or storage, transportation, sale and / or use.

[0389] Partial oxidation (POX) gasification

[0390] In one embodiment or in combination with any of the embodiments described herein, a chemical recycling facility may also include a partial oxidation (POX) gasification facility. As used herein, the term “partial oxidation” refers to the high-temperature conversion of a carbon-containing feedstock into syngas (carbon monoxide, hydrogen, and carbon dioxide), wherein the conversion takes place in the presence of a substoichiometric amount of oxygen. The conversion may be a conversion of a hydrocarbon-containing feedstock and may be carried out using a smaller amount of oxygen than the stoichiometric amount required for complete oxidation of the feedstock, i.e., all carbon is oxidized to carbon dioxide and all hydrogen is oxidized to water. Reactions occurring within a partial oxidation (POX) gasifier include the conversion of a carbon-containing feedstock into syngas, and specific examples include, but are not limited to, partial oxidation, water-gas shift, water-gas primary reaction, Boudouard reaction, oxidation, methanation, hydrogen reforming, steam reforming, and carbon dioxide reforming. The feedstock for POX gasification may include solids, liquids, and / or gases. A “partial oxidation facility” or “POX gasification facility” is a facility that includes all equipment, piping, and control devices required for the POX gasification of waste plastics and feedstocks derived therefrom.

[0391] In a POX gasification facility, the feed stream can be converted into syngas in the presence of substoichiometric amounts of oxygen. In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream to the POX gasification facility may comprise one or more PO-enriched waste plastics, at least one solvent decomposition byproduct stream, a pyrolysis stream (including pyrolysis gas, pyrolysis oil, and / or pyrolysis residues), and at least one stream from a cracking facility. One or more of these streams may be introduced into the POX gasification facility continuously or intermittently. When multiple types of feed streams are present, each may be introduced separately, or all or part of the streams may be combined to introduce a combined stream into the POX gasification facility. When present, the combination may be continuous or intermittent. The feed stream may be in the form of a gas, liquid or liquefied plastic, solid (typically pulverized), or slurry.

[0392] A POX gasification facility includes at least one POX gasification reactor. An exemplary POX gasification reactor 52 is shown in... Figure 7The POX vaporization unit may include a gas-feed, liquid-feed, or solid-feed reactor (or vaporizer). In one embodiment or in combination with any of the embodiments mentioned herein, the POX vaporization facility may perform liquid-feed POX vaporization. As used herein, "liquid-feed POX vaporization" refers to a POX vaporization process in which the feed to the process comprises, by weight, a component that is liquid at 25°C and 1 atm. Additionally, or alternatively, the POX vaporization unit may perform gas-feed POX vaporization. As used herein, "gas-feed POX vaporization" refers to a POX vaporization process in which the feed to the process comprises, by weight, a component that is gaseous at 25°C and 1 atm.

[0393] Additionally, or alternatively, the POX gasification unit can perform solid feed POX gasification. As used herein, “solid feed POX gasification” refers to a POX gasification process in which the feed to the process comprises (by weight) components that are solid at 25°C and 1 atm.

[0394] POX vaporization processes with gas feed, liquid feed, and solid feed can be co-fed with smaller amounts of other components of different phases at 25°C and 1 atm. Therefore, a gas-feed POX vaporizer can be co-fed with liquids and / or solids, but only in amounts less than the amount of gas (by weight) fed to the gas-phase POX vaporizer; a liquid-feed POX vaporizer can be co-fed with gas and / or solids, but only in amounts less than the amount of liquid (by weight) fed to the liquid-feed POX vaporizer; and a solid-feed POX vaporizer can be co-fed with gas and / or liquids, but only in amounts less than the amount of solids (by weight) fed to the solid-feed POX vaporizer.

[0395] In one embodiment or in combination with any of the embodiments mentioned herein, the total feed of a gas-feed POX vaporizer may contain at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of a component that is gaseous at 25°C and 1 atm; the total feed of a liquid-feed POX vaporizer may contain at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of a component that is liquid at 25°C and 1 atm; and the total feed of a solid-feed POX vaporizer may contain at least 60, at least 70, at least 80, at least 90, or at least 95 wt% of a component that is solid at 25°C and 1 atm.

[0396] like Figure 7As generally shown, the gasification feed stream 116 may be introduced into the gasification reactor together with the oxidant stream 180. The feed stream 116 and the oxidant stream 180 may be injected into a pressurized gasification zone via an injector assembly, the 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).

[0397] In one embodiment or in combination with any of the embodiments mentioned herein, the oxidant in stream 180 comprises an oxidizing gas, which may include air, oxygen-enriched air, or molecular oxygen (O2). Based on the molar percentage of all components in the oxidant stream 180 injected into the reaction (combustion) zone of the gasification reactor 52, 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 mol% (mol%, mole percent) of molecular oxygen. Taking into account the amount of feed stream and the amount of feed introduced, the processing conditions, and the reactor design, the specific amount of oxygen supplied to the reaction zone relative to the components in feed stream 116 may be sufficient to obtain maximum or near-maximum yields of carbon monoxide and hydrogen derived from the gasification reaction.

[0398] Oxidizing agents can include other oxidizing gases or liquids besides or in place of air, oxygen-enriched air, and molecular oxygen. Examples of suitable oxidizing liquids include water (which can be added as a liquid or as a vapor) and ammonia. Examples of suitable oxidizing gases include carbon monoxide, carbon dioxide, and sulfur dioxide.

[0399] In one embodiment or in combination with any of the embodiments mentioned herein, the atomizing enhancement fluid is fed together with the feedstock and oxidant into the gasification zone. As used herein, the term "atomizing enhancement fluid" refers to a liquid or gas operable to reduce viscosity to reduce dispersion energy or to increase energy available to aid dispersion. The atomizing enhancement fluid may be mixed with the plastic-containing feedstock before it is fed into the gasification zone, or added separately to the gasification zone, for example, to a jet assembly connected to the gasification reactor. In one embodiment or in combination with any of the embodiments mentioned herein, the atomizing enhancement fluid is water and / or steam. However, in one embodiment or in combination with any of the embodiments mentioned herein, steam and / or water are not supplied to the gasification zone.

[0400] In one embodiment or in combination with any of the embodiments mentioned herein, a gas stream rich in carbon dioxide or nitrogen (e.g., greater than the molar amount present in air, or at least 2, 5, 10, or 40 mol%) is introduced into the vaporizer. These gases can be used as carrier gases to propel the feedstock into the vaporization zone. Due to the pressure within the vaporization zone, these carrier gases can be compressed to provide the power for introduction into the vaporization zone. The gas stream may be identical or different in composition from the atomization-enhancing fluid. In one or more embodiments, the gas stream also functions as an atomization-enhancing liquid.

[0401] In one embodiment or in combination with any of the embodiments mentioned herein, a hydrogen-rich gas stream (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 fed into the vaporizer. Hydrogen may be added to influence the partial oxidation reaction, thereby controlling the composition of the resulting syngas.

[0402] In one embodiment or in combination with any of the embodiments mentioned herein, a gas stream containing more than 0.01 mol% or more than 0.02 mol% carbon dioxide is not introduced into the vaporizer or vaporization zone. Alternatively, a 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 not introduced into the vaporizer or vaporization zone. Furthermore, a hydrogen gas stream containing more than 0.1, more than 0.5, more than 1, or more than 5 mol% hydrogen is not introduced into the vaporizer or vaporization zone. Furthermore, a methane gas stream containing more than 0.1, more than 0.5, more than 1, or more than 5 mol% methane is not introduced into the vaporizer or vaporization zone. In some embodiments, the only gaseous stream introduced into the vaporization zone is an oxidant.

[0403] As previously described, the gasification process can be a partial oxidation (POX) gasification reaction. Typically, to increase the yield of hydrogen and carbon monoxide, the oxidation process involves partial rather than complete oxidation of the gasified feedstock, and therefore can operate in an oxygen-deficient 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 requirement of the gasifier can exceed the theoretically required amount by at least 5%, at least 10%, at least 15%, or at least 20% of the carbon content of the gasified feedstock to carbon monoxide. Generally, satisfactory operation is obtained when the total oxygen supply exceeds the theoretical requirement by 10% to 80%. Examples of suitable oxygen amounts per pound of carbon could be in the ranges of 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.

[0404] By introducing separate feed and oxidant streams that collide with each other within the reaction zone, mixing of the feed and oxidant streams can be completed entirely within the reaction zone. In one embodiment or in combination with any of the embodiments mentioned herein, the oxidant stream is introduced into the reaction zone of the gasifier at a high speed, exceeding the flame propagation rate and improving mixing with the feed stream. In one embodiment or in combination with any of the embodiments mentioned herein, the oxidant can be injected into the gasification zone at a rate in the range of 25 to 500, 50 to 400, or 100 to 400 feet per second. These values ​​will be the velocity of the gaseous oxidant stream at the injector-gasification zone interface, or the injector tip velocity. Mixing of the feed and oxidant streams can also be completed outside the reaction zone. For example, in one embodiment or in combination with any of the embodiments mentioned herein, the feed, oxidant, and / or atomization enhancement fluid can be combined in a conduit upstream of the gasification zone or in an injection assembly connected to the gasification reactor.

[0405] In one embodiment or in combination with any of the embodiments mentioned herein, the gasification feed stream, oxidant, and / or atomization enhancement liquid may 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 does not require preheating the feed stream to effectively gasify the feed, and the preheating step can lead to a reduction in the energy efficiency of the process.

[0406] In one embodiment or in combination with any of the embodiments mentioned herein, the type of gasification technology employed may be a partially oxidizing fluidized bed gasifier that produces syngas. This technology differs 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 without conflict with this disclosure. However, other types of gasification reactors may also be used within the scope of this technology in one embodiment or in combination with any of the embodiments mentioned herein.

[0407] In one embodiment or in combination with any of the embodiments mentioned herein, the gasifier / gasification reactor may be non-catalytic, meaning that the gasifier / gasification reactor does not contain a catalyst bed, and the gasification process is non-catalytic, meaning that the catalyst is not introduced into the gasification zone as a discrete, unbound catalyst. Furthermore, in one embodiment or in combination with any of the embodiments mentioned herein, the gasification process may not be a slag-discharge gasification process; that is, it is not operated under slag-discharge conditions (far above the melting temperature of the ash) that allow molten slag to form in the gasification zone and flow downwards along the refractory wall.

[0408] In one embodiment or in combination with any of the embodiments mentioned herein, all reaction zones in the gasification zone and optionally in the gasifier / gasification reactor can operate at temperatures of at least 1000°C, at least 1100°C, at least 1200°C, at least 1250°C, or at least 1300°C and / or not exceeding 2500°C, not exceeding 2000°C, not exceeding 1800°C, or not exceeding 1600°C. The reaction temperature can be self-generated. Advantageously, the gasifier operating in steady-state mode can be at a self-generated temperature and does not require the application of external energy to heat the gasification zone.

[0409] In one embodiment or in combination with any of the embodiments mentioned herein, the vaporizer is primarily a gas-feed vaporizer.

[0410] In one embodiment or in combination with any of the embodiments mentioned herein, the gasifier is a non-slag-discharge gasifier or operates under conditions that do not form slag.

[0411] In one embodiment or in combination with any of the embodiments mentioned herein, the vaporizer may operate under positive pressure rather than negative pressure.

[0412] In one embodiment or in combination with any of the embodiments mentioned herein, the vaporizer can operate at pressures of at least 200 psig (1.38 MPa), 300 psig (2.06 MPa), 350 psig (2.41 MPa), 400 psig (2.76 MPa), 420 psig (2.89 MPa), 450 psig (3.10 MPa), 475 psig (3.27 MPa), 500 psig (3.44 MPa), and 500 psig (3.44 MPa) within the vaporization zone (or combustion chamber). Operate at pressures of 50 psig (3.79 MPa), 600 psig (4.13 MPa), 650 psig (4.48 MPa), 700 psig (4.82 MPa), 750 psig (5.17 MPa), 800 psig (5.51 MPa), 900 psig (6.2 MPa), 1000 psig (6.89 MPa), 1100 psig (7.58 MPa), or 1200 psig (8.2 MPa). Additionally, or alternatively, the vaporizer may operate within the vaporization zone (or combustion chamber) at pressures not exceeding 1300 psig (8.96 MPa), 1250 psig (8.61 MPa), 1200 psig (8.27 MPa), 1150 psig (7.92 MPa), 1100 psig (7.58 MPa), 1050 psig (7.23 MPa), 1000 psig (6.89 MPa), 900 psig (6.2 MPa), 800 psig (5.51 MPa), or 750 psig (5.17 MPa).

[0413] Examples of suitable pressure ranges include 300-1000 psig (2.06-6.89 MPa), 300-750 psig (2.06-5.17 MPa), 350-1000 psig (2.41-6.89 MPa), 350-750 psig (2.06-5.17 MPa), 400-1000 psig (2.67-6.89 MPa), 420-900 psig (2.89-6.2 MPa), 450-900 psig (3.10-6.2 MPa), 475-900 psig (3.27-6.2 MPa), 500-900 psig (3.44-6.2 MPa), 550-900 psig (3.79-6.2 MPa), and 600-900 psig (4.79-6.2 MPa). psig (4.13-6.2 MPa), 650-900 psig (4.48-6.2 MPa), 400-800 psig (2.67-5.51 MPa), 420-800 psig (2.89-5.51MPa), 450-800 psig (3.10-5.51 MPa), 500-800 psig (3.44-5.51 MPa), 550-800 psig (3.79-5.51 MPa), 600-800 psig (4.13-5.51MPa), 650-800 psig (4.48-5.51 MPa), 400-750 psig (2.67-5.17 MPa), 420-750 psig (2.89-5.17 MPa), 450-750 psig (3.10-5.17 MPa), 475-750 psig (3.27-5.17 MPa), 500-750 psig (3.44-5.17 MPa) or 550-750 psig (3.79-5.17 MPa).

[0414] Typically, the average residence time of the gas in the gasifier reactor can be very short to increase throughput. Because the gasifier can operate at high temperatures and pressures, a near-complete conversion of the feedstock to gas can occur within a very short timeframe. In one embodiment or in combination with any of the embodiments mentioned herein, the average residence time of the gas in the gasifier can be no more than 30 seconds, no more than 25 seconds, no more than 20 seconds, no more than 15 seconds, no more than 10 seconds, or no more than 7 seconds.

[0415] To avoid scaling from downstream equipment and intermediate piping of the gasifier, the resulting synthesis gas stream 127 may have a low tar content or no tar content. In one embodiment or in combination with any of the embodiments mentioned herein, the synthesis gas stream exiting the gasifier may contain no more than 4, 3, 2, 1, 0.5, 0.2, 0.1, or 0.01 wt% tar based on the weight of all condensable solids in the synthesis gas stream. For measurement purposes, condensable solids refer to those compounds and elements that condense at 15°C and 1 atm. Examples of tar products include naphthalene, cresol, xylenol, anthracene, phenanthrene, phenol, benzene, toluene, pyridine, catechol, biphenyl, benzofuran, benzaldehyde, acenaphthene, fluorene, naphthol, benzanthracene, pyrene, phenanthrene, benzo[a]pyrene, and other high molecular weight aromatic polynuclear compounds. Tar content can be determined by GC-MSD.

[0416] Typically, the crude synthesis gas stream 127 discharged from the gasification container includes gases such as hydrogen, carbon monoxide, and carbon dioxide, and may include other gases such as methane, hydrogen sulfide, and nitrogen, depending on the fuel source and reaction conditions.

[0417] In one embodiment or in combination with any of the embodiments mentioned herein, the crude synthesis gas stream 127 (the stream exiting the vaporizer and prior to any further treatment by scrubbing, shifting, or acid gas removal) may have the following composition, in dry basis mole percentages, based on the number of...

Claims

1. A method for treating waste plastics, the method comprising: (a) In a solvent decomposition tank of a solvent decomposition facility, a waste plastic stream comprising polyethylene terephthalate (PET) and at least one non-PET plastic is combined with a solvent to provide a predominantly liquid stream; wherein, based on the total weight of the waste plastic stream, the non-PET plastic comprises 0.01 wt% to 10 wt% of polyvinyl chloride (PVC); and the solvent is methanol. (b) Adding a catalyst to the predominantly liquid stream, wherein the catalyst comprises lithium acetate, manganese acetate, or a combination thereof, wherein, based on the total weight of the predominantly liquid stream, the catalyst further comprises 50 to 750 ppm by weight of a base, including sodium-containing bases, potassium-containing bases, or combinations thereof; the catalyst does not contain tin, zinc, and / or titanium; and (c) The predominantly liquid stream is fed into a solvent decomposition reactor in a solvent decomposition facility, and in the solvent decomposition reactor, methanol is used to decompose at least a portion of the PET to form a predominantly terephthaloyl, a predominantly diol, and at least one byproduct stream.

2. A method for treating waste plastics, the method comprising: (a) In a solvent decomposition tank of a solvent decomposition facility, a waste plastic stream comprising polyethylene terephthalate (PET) and at least one non-PET plastic is combined with a solvent to provide a predominantly liquid stream; wherein, based on the total weight of the waste plastic stream, the non-PET plastic comprises 0.01 wt% to 10 wt% of polyvinyl chloride (PVC); and the solvent is methanol. (b) Transferring at least a portion of the predominantly liquid stream to a solvent decomposition reactor in a solvent decomposition facility; (c) Adding a catalyst to at least one of the waste plastic, the solvent, or the predominantly liquid stream, wherein the catalyst comprises lithium acetate, manganese acetate, or a combination thereof, and wherein, based on the total weight of the predominantly liquid stream, the catalyst further comprises 50 to 750 ppm by weight of a base, including sodium-containing bases, potassium-containing bases, or combinations thereof; the catalyst does not contain tin, zinc, and / or titanium; and (d) In a solvent decomposition reactor, methanol decomposes at least a portion of the PET to form a predominantly terephthaloyl group, a predominantly diol, and at least one byproduct stream.

3. The method according to claim 1 or 2, wherein at least a portion of the at least one byproduct stream is introduced into at least one of: (i) a pyrolysis facility; (ii) a cracking facility; (iii) a partial oxidation POX gasifier facility; (iv) an energy recovery facility; and (v) a liquefaction zone.

4. The method according to claim 2, wherein, Step (c) includes adding the catalyst together with the waste plastic, or step (c) includes adding the catalyst together with the solvent, or step (c) includes adding the catalyst into the predominantly liquid stream during at least a portion of the delivery in step (b).

5. The method according to claim 1 or 2, wherein, Based on the total weight of the predominantly liquid flow, the catalyst is present in an amount ranging from 25 to 1000 ppm by weight.

6. The method according to claim 1 or 2, wherein, The catalyst contains manganese.

7. The method according to claim 1 or 2, wherein, Based on the total weight of the predominantly liquid flow, the catalyst contains 100 to 600 ppm of manganese acetate and 100 to 350 ppm of sodium hydroxide by weight.

8. The method according to claim 1 or 2, wherein, Based on the total weight of the waste plastics, the non-PET plastics contain 10wt%-80wt% of polyolefin (PO).

9. The method according to claim 1 or 2, wherein, Based on the total weight of the waste plastics, the PET is present in the waste plastics in an amount of at least 25 wt%.

10. The method according to claim 1 or 2, wherein, The solvent decomposition facility is co-located with at least one of the following: (i) a partial oxidation POX gasification facility; (ii) a pyrolysis facility; (iii) a cracking facility; (iv) an energy recovery facility; and (v) a liquefaction zone; wherein the co-location cooperation refers to facilities in which at least a portion of the process flow and / or support equipment or services are shared between the two facilities.

11. The method according to claim 1 or 2, wherein, The solvent decomposition facility operates continuously with an average feed rate of at least 500 pounds per hour over an average year.

12. A solvent decomposition method composition, said composition comprising: Polyethylene terephthalate (PET) and / or its degradation products; At least one type of non-PET plastic and / or its decomposition products, wherein, Based on the total weight of the composition, the non-PET plastic contains 0.01 wt% to 10 wt% of polyvinyl chloride; The primary solvent, wherein the primary solvent is methanol; and A catalyst comprising manganese acetate and / or lithium acetate; wherein, based on the total weight of the composition, the catalyst further comprises 50 to 750 ppm by weight of a base, the base comprising a sodium-containing base, a potassium-containing base, or a combination thereof; the catalyst does not contain tin, zinc, and / or titanium.

13. The composition according to claim 12, wherein, The catalyst contains manganese.

14. The composition according to claim 12 or 13, wherein, Based on the total weight of the composition, the catalyst contains 100 to 600 ppm of manganese acetate and 100 to 350 ppm of sodium hydroxide by weight.

15. The composition according to claim 12 or 13, wherein the non-PET plastic comprises 10 wt% to 80 wt% of a polyolefin based on the total weight of the composition, or wherein, The PET is present in an amount ranging from 5 wt% to 95 wt% based on the total weight of the composition.

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