Liquefaction and dehalogenation of waste plastics

Abstract

A method and system for liquefying and dehalogenating waste plastics is provided. Generally, the method includes: (a) liquefying solid waste plastics to produce liquefied waste plastics; (b) heating at least a portion of the molten waste plastics in a heat exchanger, thereby providing heated liquefied waste plastics; (c) sparging a stripping gas into the heated liquefied waste plastics to produce a multi-phase mixture; and (d) phase separating a gas phase from a liquid phase of the multi-phase mixture, thereby providing a halogen-enriched gaseous material and a halogen-depleted liquefied waste plastics.

Description

Background Technology

[0001] When disposed of in landfills after a single use, waste, especially non-biodegradable waste, 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 impossible or economically unrecoverable using conventional recycling technologies. Furthermore, some conventional recycling methods generate waste streams that are themselves economically unrecoverable or unrecyclable, resulting in additional waste streams that must be disposed of or otherwise treated.

[0002] More specifically, most conventional chemical recycling methods used to break down waste plastics into simpler products, such as pyrolysis, combustion, cracking, and gasification, suffer from numerous operational inefficiencies and are unable to effectively recycle a wide variety of waste plastics. For example, these conventional recycling methods can potentially involve high operating costs, especially in terms of energy consumption, which may outweigh any economic benefits of using waste plastics as a feedstock. Therefore, there is a need for an efficient and economical chemical recycling method to break down waste plastics.

[0003] Waste plastics often contain halogens (such as chlorine in polyvinyl chloride), which can be problematic in facilities used for the pyrolysis, gasification, cracking, and / or combustion of waste plastics. Halogens are known to cause corrosion in equipment and piping used to handle halogen-containing streams. Although some metallurgical methods are resistant to halogen corrosion, implementing such methods may be prohibitively costly for new facilities and / or retrofits of existing ones.

[0004] In addition, although various methods are known for removing halogens from streams in conventional chemical processing plants, these halogen removal methods are ineffective and / or prohibitively expensive when applied to facilities that pyrolyze, gasify, crack, and / or incinerate waste plastics. Summary of the Invention

[0005] In one aspect, the present technology relates to a dehalogenation method for waste plastics. Typically, the method includes: (a) liquefying solid waste plastics to produce liquefied waste plastics; (b) injecting stripping gas into the liquefied waste plastics to produce a multiphase mixture; and (c) separating the gas phase from the liquid phase of the multiphase mixture, thereby providing halogen-enriched gaseous material and halogen-depleted liquefied waste plastics.

[0006] In one aspect, the present technology relates to a method for dehalogenating waste plastics. Typically, the method includes: (a) introducing solid waste plastics into a melting tank; (b) removing molten waste plastics from the melting tank, thereby providing removed molten waste plastics; (c) heating at least a portion of the removed molten waste plastics in a heat exchanger, thereby providing heated molten waste plastics; and (d) disengaging halogen-enriched gaseous material from the heated molten waste plastics, thereby providing heated halogen-depleted molten waste plastics.

[0007] In one aspect, the present technology relates to a method for dehalogenating waste plastics. Typically, the method comprises: (a) liquefying solid waste plastics in a melting tank in the presence of at least one dissolving solvent to produce liquefied waste plastics, wherein the dissolving solvent comprises pyrolysis oil; and (b) separating the liquefied waste plastics into halogen-enriched gaseous material and halogen-depleted liquefied waste plastics.

[0008] In one aspect, the technology relates to a waste plastic dehalogenation system. Typically, the system includes: (a) a liquefaction system for at least partially liquefying solid waste plastic into liquefied waste plastic; (b) a halogen stripping tower configured to receive at least a portion of the liquefied waste plastic and inject stripping gas into the liquefied waste plastic to form a multiphase mixture; and (c) a phase separation vessel configured to receive the multiphase mixture and separate the gaseous and liquid phases of the multiphase mixture, thereby providing halogen-enriched gaseous material and halogen-depleted molten waste plastic.

[0009] In one aspect, the technology relates to a waste plastic dehalogenation system. Typically, the system includes: (a) a melting tank for at least partially liquefying solid waste plastic into molten waste plastic; (b) a heat exchanger configured to receive at least a portion of the molten waste plastic and heat at least a portion of the molten waste plastic, thereby providing heated molten waste plastic; and (c) a phase separation vessel configured to receive the heated molten waste plastic and separate the gaseous and liquid phases of the heated molten waste plastic, thereby providing halogen-enriched gaseous material and halogen-depleted molten waste plastic.

[0010] In one aspect, the technology relates to a chemical recycling method. Typically, the method includes: (a) subjecting solid waste plastics to a viscosity reduction treatment to provide liquefied waste plastics with a viscosity of less than 800 poise at 350°C and 10 radians / second; (b) introducing at least a portion of the liquefied waste plastics into a pyrolysis membrane reactor; and (c) converting at least a portion of the liquefied waste plastics in the pyrolysis membrane reactor into a pyrolysis effluent containing pyrolysis gas.

[0011] In one aspect, the technology relates to a chemical recycling method. Typically, the method includes: (a) separating a solid waste plastic feed into a polyolefin enrichment stream and a polyolefin depletion stream; (b) liquefying the polyolefin enrichment stream to provide liquefied waste plastic; (c) introducing at least a portion of the liquefied waste plastic into a pyrolysis membrane reactor; and (d) converting at least a portion of the liquefied waste plastic in the pyrolysis membrane reactor into a pyrolysis effluent containing pyrolysis gas.

[0012] In one aspect, the technology relates to a chemical recycling method. Typically, the method includes: (a) liquefying at least one solid waste plastic to form liquefied waste plastic; (b) removing one or more halogens from the liquefied waste plastic to form halogen-depleted liquefied waste plastic; (c) introducing at least a portion of the halogen-depleted liquefied waste plastic into a pyrolysis membrane reactor; and (d) converting at least a portion of the halogen-depleted liquefied waste plastic in the pyrolysis membrane reactor into a pyrolysis effluent containing pyrolysis gas.

[0013] In one aspect, the technology relates to a chemical recycling method. Typically, the method includes: (a) liquefying solid waste plastics in a melting tank to produce molten waste plastics; (b) subjecting the molten waste plastics to at least one of the following steps: (i) injecting stripping gas into the molten waste plastics to produce a multiphase mixture; and (ii) heating at least a portion of the molten waste plastics in a heat exchanger outside the melting tank, thereby providing heated molten waste plastics; (c) separating the gaseous and liquid phases of the multiphase mixture and / or the heated molten waste plastics, thereby providing halogen-enriched gaseous material and halogen-depleted molten waste plastics; (d) introducing the halogen-depleted molten waste plastics into a pyrolysis membrane reactor; and (e) converting at least a portion of the liquefied waste plastics in the pyrolysis membrane reactor into a pyrolysis effluent containing pyrolysis gas.

[0014] In one aspect, the technology relates to a chemical recycling method. Typically, the method includes: (a) providing liquefied waste plastic; (b) introducing at least a portion of the liquefied waste plastic into a pyrolysis membrane reactor, the pyrolysis membrane reactor comprising a plurality of fixed membrane formation structures and operating at a temperature of at least 525°C; and (c) causing at least a portion of the liquefied waste plastic to flow downward along the fixed membrane formation structures, thereby pyrolyzing the liquefied waste plastic and forming a pyrolysis effluent containing pyrolysis gas.

[0015] In one aspect, the technology relates to a chemical recycling method. Typically, the method includes: (a) providing liquefied waste plastic; (b) introducing at least a portion of the liquefied waste plastic into an upflow pyrolysis membrane reactor, the pyrolysis membrane reactor including a plurality of fixed membrane formation structures; and (c) causing at least a portion of the liquefied waste plastic to flow upward along the fixed membrane formation structures, thereby pyrolyzing the liquefied waste plastic and forming a pyrolysis effluent containing pyrolysis gas.

[0016] In one aspect, the technology relates to chemical recycling facilities. Typically, such facilities include: (a) a waste plastic liquefaction system for liquefying at least one solid waste plastic, wherein the waste plastic melting system includes a halogen removal system for removing one or more halogens from the molten waste plastic, thereby providing halogen-depleted molten waste plastic; and (b) a pyrolysis membrane reactor fluidly connected to the waste plastic melting system and configured to receive at least a portion of the halogen-depleted molten waste plastic and convert at least a portion of the halogen-depleted molten waste plastic into a pyrolysis effluent containing pyrolysis gas.

[0017] In one aspect, the present technology relates to a chemical recycling method. Typically, the method includes: (a) liquefying at least one solid waste plastic in the presence of a dissolving solvent to form liquefied waste plastic, wherein the dissolving solvent comprises pyrolysis oil; (b) introducing at least a portion of the liquefied waste plastic into a pyrolysis membrane reactor; and (c) converting at least a portion of the liquefied waste plastic in the pyrolysis membrane reactor into a pyrolysis effluent comprising pyrolysis gas.

[0018] In one aspect, the present technology relates to a chemical recycling method. Typically, a chemical recycling method includes: (a) liquefying at least one solid waste plastic to form liquefied waste plastic; (b) introducing at least a portion of the liquefied waste plastic into a partial oxidation (POX) gasifier; and (c) converting at least a portion of the liquefied waste plastic in the POX gasifier into a syngas composition.

[0019] In one aspect, the present technology relates to a chemical recycling method. Typically, a chemical recycling method includes: (a) liquefying at least one solid waste plastic in a melting tank to form molten waste plastic; (b) removing one or more halogens from the molten waste plastic to form halogen-depleted molten waste plastic; (c) introducing at least a portion of the halogen-depleted molten waste plastic into a partial oxidation (POX) gasifier; and (d) converting at least a portion of the halogen-depleted molten waste plastic in the POX gasifier into a syngas composition.

[0020] In one aspect, the technology relates to chemical recycling facilities. Typically, a chemical recycling facility includes: (a) a waste plastic liquefaction system for liquefying at least one solid waste plastic to form liquefied waste plastic; and (b) a partial oxidation (POX) gasifier fluidly connected to the plastic liquefaction system and configured to receive at least a portion of the liquefied waste plastic and convert at least a portion of the liquefied waste plastic into a syngas composition.

[0021] In one aspect, the technology relates to chemical recycling facilities. Typically, chemical recycling facilities include: (a) a waste plastic melting system for liquefying at least one solid waste plastic to form molten waste plastic, wherein the waste plastic melting system includes a dehalogenation system for removing one or more halogens from the molten waste plastic, thereby providing halogen-depleted molten waste plastic; and (b) a partial oxidation (POX) gasifier fluidly connected to the waste plastic melting system and configured to receive at least a portion of the halogen-depleted molten waste plastic and convert at least a portion of the halogen-depleted molten waste plastic into a syngas composition. Attached Figure Description

[0022] Embodiments of the present invention are described herein with reference to the following accompanying drawings, in which:

[0023] Figure 1 An exemplary chemical recycling facility is described;

[0024] Figure 2 An exemplary separation area of ​​the pretreatment facility is depicted;

[0025] Figure 3 An exemplary solvent decomposition facility is described;

[0026] Figure 4 An exemplary recycling facility with a liquefaction melting tank system is described;

[0027] Figure 5 An exemplary melting tank liquefaction system according to one embodiment is described;

[0028] Figure 6 An exemplary melting tank liquefaction system according to one embodiment is described;

[0029] Figure 7 An exemplary melting tank liquefaction system according to one embodiment is described;

[0030] Figure 8 An exemplary melting tank liquefaction system according to one embodiment is described;

[0031] Figure 9 An exemplary melting tank liquefaction system according to one embodiment is described;

[0032] Figure 10 An exemplary melting tank liquefaction system according to one embodiment is described;

[0033] Figure 11 An exemplary external stripping tower for a liquefaction system is depicted;

[0034] Figure 12 An exemplary external stripping tower for a liquefaction system is depicted;

[0035] Figure 13An exemplary phase-separating container for a liquefaction system is depicted;

[0036] Figure 14 An exemplary phase-separating container for a liquefaction system is depicted;

[0037] Figure 15 An exemplary pyrolysis facility with a liquefaction system and a pyrolysis membrane reactor is described;

[0038] Figure 16 An exemplary falling film pyrolysis reactor is described;

[0039] Figure 17 An exemplary tube perturbation structure for a falling film pyrolysis reactor is depicted;

[0040] Figure 18 An exemplary tube perturbation structure for a falling film pyrolysis reactor is depicted;

[0041] Figure 19 An exemplary upflow membrane pyrolysis reactor is described;

[0042] Figure 20 An exemplary cracking facility is depicted;

[0043] Figure 21 A schematic diagram of the cracker furnace is provided;

[0044] Figure 22 An exemplary partial oxidation gasification facility for converting waste plastics is described;

[0045] Figure 23 An exemplary partial oxidation gasification reactor is described;

[0046] Figure 24 An exemplary injector for a partial oxidation gasification reactor is depicted;

[0047] Figure 25 The reactor construction for Example 6 is described; and

[0048] Figure 26 A diagram showing the "separation efficiency" is provided. Detailed Implementation

[0049] We have discovered an effective and efficient halogen removal technology for chemical recycling facilities. More specifically, we have discovered a system that separates gaseous halogens from liquefied waste plastics before the reaction steps (e.g., pyrolysis, gasification, cracking, or combustion) in the introduction of liquefied waste plastics into the chemical recycling facility.

[0050] 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 may be "at least," "up to," 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 no more than 90 wt%, 85, 70, 60..." means the same as "no more than 90 wt%, or no more than 85 wt%, or no more than 70 wt%..." etc.; and "at least 1%, 2% by weight..." "3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10%..." refers to the same as "at least 1 wt%, or at least 2 wt%, or at least 3 wt%..."; and "at least 5, 10, 15, 20 and / or not more than 99, 95, 90 wt%" refers to 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 more than 99 wt%, or not more than 95 wt%, or not more than 90 wt%...".

[0051] Unless otherwise stated, all concentrations or amounts are by weight.

[0052] Integrated chemical recycling facility

[0053] Turn now Figure 1 This illustrates the main steps of a method for the chemical recycling of waste plastics in a chemical recycling facility 10. It should be understood that... Figure 1 An exemplary embodiment of the present technology is depicted. Figure 1 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 1 The system described in the text.

[0054] like Figure 1 As shown, 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 in Figure 1The diagram is indicated by box 90. Although shown as including all 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 various combinations of at least two, three, four, five, or all of these steps / facilities for the chemical recycling of plastic waste and, in particular, mixed plastic waste. The chemical recycling methods and facilities described herein can be used to convert waste plastics into recycled component products or chemical intermediates for the formation of materials with multiple end uses. 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.

[0055] As used herein, the term "chemical recycling" refers to a waste plastic recycling method 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) that are useful in themselves and / or can be used as feedstocks for another (or one or more) 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 compositions directly and / or indirectly derived from waste plastics, or compositions comprising directly and / or indirectly derived from waste plastics.

[0056] 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.

[0057] 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 substantially 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 may be configured to receive and process waste streams from mechanical recycling facilities and / or waste streams that would typically not be processed by mechanical recycling facilities.

[0058] 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 a solidification or separation facility, 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 such as a separation or solidification facility may be operated by different commercial entities.

[0059] 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, 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 not exceeding 1,000,000, not exceeding 750,000, not exceeding 500,000, not exceeding 450,000, not exceeding 400,000, not exceeding 350,000, not exceeding 300,000, not exceeding 250,000, not exceeding 200,000, not exceeding 150,000, not exceeding 100,000, not exceeding 75,000, not exceeding 50,000, or not exceeding 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.

[0060] 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 units of common type within the facility.

[0061] 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 continuously. 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 intermittently or semi-intermittently. 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 into each facility or its sections.

[0062] in addition, Figure 1 The two or more facilities shown can also co-locate with each other. In one embodiment or in combination with any of the embodiments mentioned herein, at least two, at least three, at least four, at least five, at least six, or all facilities can co-locate. As used herein, the term "co-locating" refers to facilities where at least a portion of the process flow and / or supporting equipment or services are shared between two facilities. Figure 1When two or more facilities are located in the same area, these facilities may meet at least one of the following criteria (i) to (v): (i) the facilities share at least one non-residential utility service; (ii) the facilities share at least one service group; (iii) the facilities are owned and / or operated by parties sharing at least one property boundary; (iv) the facilities are connected by at least one conduit configured to transport at least one process material (e.g., feed into the facility, solid, liquid, and / or gas used by the facility, or generated in the facility) from one facility to another; and (v) the facilities are within 40 miles, 35 miles, 30 miles, 20 miles, 15 miles, 12 miles, 10 miles, 8 miles, 5 miles, 2 miles, or 1 mile of each other, measured from their geographic centers. At least one, at least two, at least three, at least four, or all of the above statements (i) to (v) may be true.

[0063] Regarding (i), examples of suitable 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.

[0064] Regarding (i), examples of suitable 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.

[0065] 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.

[0066] Regarding (iii), the boundary may be, for example, a fence line, a property line, a gate, or a shared boundary with at least one boundary of land or facilities owned by a third party.

[0067] 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 transporting materials within a conduit 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 vessels configured to store materials carried by the conduit. In some cases, temporary storage between the outlet of one facility and the inlet 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.

[0068] Turn again Figure 1 A stream 100 of waste plastics, which may be mixed plastic waste (MPW), can be introduced into the chemical recycling facility 10. As used herein, the terms “waste plastics” and “plastic waste” refer to used, discarded, and / or discarded plastic materials, such as plastic materials typically sent to landfills. 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 plastics” 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 plastics” 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 reclaimers. When partially treated waste plastics are provided 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.

[0069] 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, the 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.

[0070] In one embodiment or in combination with any of the embodiments mentioned herein, the MPW comprises at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of PET and / or at least 1, at least 2, at least 5, at least 10, at least 15, or at least 20 wt% of PO, based on the total weight of the plastics in the MPW. In one or more embodiments, the MPW may also comprise small amounts of one or more plastic components other than PET and PO (and optionally PVC), in total amounts 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 plastics in the MPW.

[0071] In one embodiment or in combination with any embodiment mentioned herein, the MPW comprises at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% PET, based on the total weight of the stream. Alternatively or additionally, the MPW comprises no more than 99.9, no more than 99, no more than 97, no more than 92, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, or no more than 5 wt% PET, based on the total weight of the stream.

[0072] MPW streams may contain non-PET components in amounts of at least 0.1, at least 0.5, at least 1, at least 2, at least 5, at least 7, at least 10, at least 15, at least 20, at least 25, at least 30, or at least 35 and / or 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 7 wt%, based on the total weight of the stream. Non-PET components may be present in amounts of 0.1 wt%–50 wt%, 1 wt%–20 wt%, or 2 wt%–10 wt%, based on the total weight of the stream. Examples of such non-PET components 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.

[0073] In one embodiment or in combination with any of the embodiments mentioned herein, all or part of the MPW may be derived from urban sources or include urban waste. The urban 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 urban waste stream (or a portion thereof).

[0074] 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 amounts of 65wt%-99.9wt%, 70wt%-99wt%, or 80wt%-97wt%, based on the total weight of the stream. Non-PET components in such streams 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. In one embodiment or in combination with any of the embodiments mentioned herein, non-PET components may include other plastics in amounts of 2wt%-35wt%, 5wt%-30wt%, or 10wt%-25wt%, based on the total weight of the stream, particularly when, for example, the MPW includes colored, sorted plastics.

[0075] 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 streams 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.

[0076] 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.

[0077] 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.

[0078] 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).

[0079] 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, such diols 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 copolyesters thereof. Examples of aliphatic polyesters may include, but are not limited to, polylactic acid (PLA), polyglycolic acid, polycaprolactone, and polyadipate. Polymers may include mixed aliphatic-aromatic copolyesters, including, for example, mixed terephthalate / adipate esters.

[0080] 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 such plastic is present in an amount ranging from 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%, based on the total weight of the stream, or may be present in an amount ranging from 1 wt% to 45 wt%, 2 wt% to 40 wt%, or 5 wt% to 40 wt%, based on the total weight of the stream. 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.

[0081] In one embodiment or in combination with any embodiment mentioned herein, the waste plastic may comprise at least one type of plastic having terephthalate repeating units, wherein such plastic is present in an amount of at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85 or at least 90 and / or not exceeding 99.9, not exceeding 99, not exceeding 97, not exceeding 95, not exceeding 90 or not exceeding 85 wt%, based on the total weight of the stream, or may be present in an amount in the range of 30 wt%-99.9 wt%, 50 wt%-99.9 wt%, or 75 wt%-99 wt%, based on the total weight of the stream.

[0082] 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 plastic in the waste plastic stream, or it 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.

[0083] 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. In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics may include polymers including linear low-density polyethylene (LLDPE), polymethylpentene, polybutene-1, and copolymers thereof. In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics may comprise flash-spun high-density polyethylene.

[0084] Waste plastics may include thermoplastic polymers, thermosetting polymers, or combinations thereof. In one embodiment or in combination with any of the embodiments mentioned herein, 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, based on the total weight of the stream, or may be present in amounts of 0.1 wt%-45 wt%, 1 wt%-40 wt%, 2 wt%-35 wt%, or 2 wt%-20 wt%, based on the total weight of the stream.

[0085] Alternatively or additionally, 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, based on the total weight of the stream, or may be present in amounts ranging from 0.1 wt% to 45 wt%, 1 wt% to 40 wt%, or 2 wt% to 15 wt%, based on the total weight of the stream. Examples of cellulose material may include cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, cellulose acetate butyrate, and regenerated cellulose such as viscose. In addition, cellulose materials may include cellulose derivatives having an acyl substitution degree of less than 3, not more than 2.9, not more than 2.8, not more than 2.7 or not more than 2.6 and / or at least 1.7, at least 1.8 or at least 1.9, or 1.8 to 2.8, or 1.7 to 2.9, or 1.9 to 2.9.

[0086] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic may contain STYROFOAM or expanded polystyrene.

[0087] Waste plastics may originate from one or more of several sources. In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics may originate from plastic bottles, diapers, eyeglass frames, films, packaging materials, carpets (residential, commercial and / or automotive), textiles (clothing and other fabrics), and combinations thereof.

[0088] 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, which may be present in the waste plastic in an amount of at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 5, at least 7, at least 10, at least 12, at least 15, at least 20, at least 25, at least 30, at least 35 or at least 40 and / or not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40 or not more than 35 wt%, based on the total weight of all plastics, or may be present in the waste plastic in an amount of 0.1 wt%-90 wt%, 1 wt%-75 wt%, 2 wt%-50 wt%, based on the total weight of plastics.

[0089] In one embodiment or in combination with any of the embodiments mentioned herein, the total plastic composition of the waste plastics fed to the 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 following contents of the total plastic composition in the waste plastics fed into the chemical recycling facility 10 may include plastics without resin ID codes 4-7: at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30 or at least 35 and / or not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10 or not more than 5 wt%, or may be in the range of 0.1wt%-60wt%, 1wt%-55wt%, or 2wt%-45wt%, based on the total weight of the plastic composition.

[0090] 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. The total amount of plastics in waste plastics that are not classified as resin ID codes 3-7 or ID codes 3, 5, 6 or 7 can be at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 and / or not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 wt%, based on the total weight of plastics in the waste plastic stream, or it can be in the range of 0.1 wt%-95 wt%, 0.5 wt%-90 wt%, or 1 wt%-80 wt%, based on the total weight of plastics in the waste plastic stream.

[0091] In one embodiment or in combination with any of the embodiments mentioned, 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.

[0092] 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 with, attached to, or otherwise physically and / or chemically associated with at least one other polymer and / or non-polymer solid. The polymer may be a synthetic polymer or plastic, such as PET, olefins, and / or nylon. The non-polymer solid may be a metal, such as aluminum, or other non-plastic solid as described herein. Multicomponent polymers may include metallized plastics.

[0093] 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 linked together in 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 an adhesive layer or co-extruded layer. An adhesive between two layers is not considered a single layer. A multilayer polymer may include: a PET-containing layer and one or more additional layers, wherein at least one of the additional layers is a synthetic or natural polymer other than PET, or a polymer without repeating ethylene terephthalate units, or a polymer without repeating alkyl glycol terephthalate units ("non-PET polymer layer"), or other non-polymer solid.

[0094] 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 compatibilizers, PET, and at least one other synthetic or natural polymer plastic (e.g., non-PET plastic) combined in a single physical phase. As used herein, the term "compensator" refers to an agent that can combine at least two otherwise immiscible polymers in a physical mixture (i.e., a blend).

[0095] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises no more than 20, no more than 10, no more than 5, no more than 2, no more than 1, or no more than 0.1 wt% of nylon, on a dry plastic basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises 0.01 wt%-20 wt%, 0.05 wt%-10 wt%, 0.1 wt%-5 wt%, or 1 wt%-2 wt% of nylon, on a dry plastic basis.

[0096] In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises no more than 40, no more than 20, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of a multi-component plastic, on a dry plastic basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises 0.1 wt%-40 wt%, 1 wt%-20 wt%, or 2 wt%-10 wt% of a multi-component plastic, on a dry plastic basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises no more than 40, no more than 20, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of a multilayer plastic, on a dry plastic basis. In one embodiment or in combination with any of the mentioned embodiments, the MPW comprises 0.1 wt%-40 wt%, 1 wt%-20 wt%, or 2 wt%-10 wt% of a multilayer plastic, on a dry plastic basis.

[0097] In one embodiment or in combination with any of the embodiments mentioned, 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 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 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.

[0098] 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 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 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 containing cellulose fibers and their waste. Exemplary manufactured cellulose products include, but are not limited to, paper and paperboard.

[0099] 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 at least 0.001, at least 0.01, at least 0.05, at least 0.1 or at least 0.25 wt% and / or no more than 10, no more than 5, no more than 4, no more than 3, no more than 2, no more than 1, no more than 0.75 or no more than 0.5 wt% of polyvinyl chloride (PVC), based on the total weight of the plastics in the waste plastic feed.

[0100] Additionally or alternatively, waste plastics (e.g., MPW) fed to a chemical recycling facility may contain 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, inhibitors, UV inhibitors and stabilizers, conductive metals or carbon, mold release agents such as zinc stearate, waxes, and silicones).

[0101] In one embodiment or in combination with any of the embodiments mentioned, 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 or the composition. The amount of liquid in the MPW may be 0.01 wt%-25 wt%, 0.5 wt%-10 wt%, or 1 wt%-5 wt%, based on the total weight of 100 MPW streams.

[0102] In one embodiment or in combination with any of the mentioned embodiments, 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 35 wt%-65 wt%, 40 wt%-60 wt%, or 45 wt%-55 wt%, based on the total weight of the waste plastics.

[0103] In one embodiment or in combination with any of the embodiments mentioned, 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. The amount of textiles (including textile fibers) in the MPW in flow 100 may not exceed 50, 40, 30, 20, 15, 10, 8, 5, 2, 1, 0.5, 0.1, 0.05, 0.01, or 0.001 wt%, based on the weight of MPW flow 100. The amount of textiles in MPW flow 100 may be 0.1 wt%-50 wt%, 5 wt%-40 wt%, or 10 wt%-30 wt%, based on the total weight of MPW flow 100.

[0104] 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: textiles, and fibers separated from textiles or other fiber-containing products, waste or substandard fibers or yarns or textiles, 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] Synthetic fibers are those fibers that are synthesized, 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). TM Cuprammonium filament (CuPro), Modal, acetates such as polyvinyl acetate, polyamides including nylon, polyesters such as PET, olefin polymers such as polypropylene and polyethylene, polycarbonate, polysulfate, polysulfone, polyethers such as polyether-urea called spandex or elastic fiber, polyacrylate, acrylonitrile copolymer, polyvinyl chloride (PVC), polylactic acid, polyglycolic acid, sulfonated polyester fibers and combinations thereof.

[0112] Before entering a chemical recycling facility, textiles can be reduced in size by shredding, tearing, rakeing, grinding, crushing, or cutting to produce smaller textiles. Textiles can also be densified (e.g., granulation) before entering the chemical recycling facility. Examples of densification methods include extrusion (e.g., extruding into granules), molding (e.g., molding into briquettes), and coalescence (e.g., by externally applied heat, heat generated by friction, or by adding one or more binders, which may themselves be non-native polymers). Alternatively, or additionally, textiles can be any form mentioned herein and can be... Figure 1 One or more of the aforementioned steps are performed in the pretreatment facility 20 before being processed in the remaining facilities of the chemical recovery facility 10 shown.

[0113] In one embodiment or in combination with any of the embodiments mentioned herein, the combination of polyethylene terephthalate (PET) and one or more polyolefins (PO) accounts for a proportion of Figure 1 The waste plastics (e.g., MPW) fed into the chemical recycling facility from the flow 100 shall comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt%. 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, based on the total weight of the plastics in the waste plastics introduced into the chemical recycling facility 10.

[0114] In one embodiment or in combination with any of the embodiments 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, 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 plastic in the waste plastic introduced into the chemical recycling facility 10.

[0115] 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, based on the total weight of the plastic in the waste plastic, or PO may be present in an amount ranging from 5 wt% to 75 wt%, 10 wt% to 60 wt%, or 20 wt% to 35 wt%, based on the total weight of the plastic in the waste plastic introduced into the chemical recycling facility 10.

[0116] 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) includes 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. Such return facilities are typically found, for example, in grocery stores.

[0117] 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 (e.g., a municipal recycling facility (MRF) or a recycling facility) or as a plastic-containing mixture comprising waste plastics sorted by consumers and left at the curbside or at a central convenience station for collection. In one or more such embodiments, the waste plastics comprise one or more MRF products or byproducts, recycling byproducts, sorted plastic-containing mixtures, and / or PET-containing waste plastics from a plastics manufacturing facility comprising 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, on a dry plastic basis, or 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, on a dry plastic basis.

[0118] In one or more such embodiments, the waste plastic comprises a quantity of PET-containing recycled byproducts or plastic mixtures comprising 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, 99, or 90 wt% of PET, on a dry plastic basis, or may be in the range of 1 wt%-99.9 wt%, 1 wt%-99 wt%, or 10 wt%-90 wt% of PET, on a dry plastic basis. The recycling facility may also include a process for producing high-purity PET (at least 99 wt% or at least 99.9 wt%) recycled byproducts, but in a form undesirable for mechanical recycling facilities. As used herein, the term “recycled byproduct” 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 byproducts described above and below are generally considered waste products and may be sent to landfills.

[0119] In one or more such embodiments, the waste plastic comprises a quantity of recycled wet fines 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% of PET, on a dry plastic basis. In one or more such embodiments, the waste plastic comprises a quantity of a mixture of colored plastics 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 99 wt% of PET, on a dry plastic basis. In one or more such embodiments, the waste plastic comprises a quantity of eddy waste stream 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, 99, or 98 wt% of PET, on a dry plastic basis. In one or more such embodiments, the waste plastic comprises a quantity of recycled sheet waste containing 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, on a dry plastic basis, or it may be in the range of 0.1 wt%-99.9 wt%, 1 wt%-99 wt%, or 10 wt%-98 wt% of PET, on a dry plastic basis. In one or more such embodiments, the waste plastic comprises a quantity of dry fines containing 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, on a dry plastic basis.

[0120] Chemical recycling facility 10 may also include infrastructure for receiving waste plastics (e.g., MPW) as described herein, to facilitate delivery of the 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 the waste plastics from vehicles, as well as storage facilities and one or more conveying systems for transporting the 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.

[0121] 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 articles (i.e., not bundled or unpackaged), containers (e.g., boxes, sacks, trailers, railway vehicles, loader buckets), stockpiles (e.g., on concrete slabs in buildings), solid / liquid slurries (e.g., pumped slurries of plastics in water), and / or loose materials conveyed physically (e.g., granules on a conveyor belt) or pneumatically (e.g., granules mixed with air and / or inert gases in a conveyor pipe).

[0122] 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 nearly all of the articles are introduced into the chemical recycling facility 10 (or pretreatment facility 20), one or more crushing or granulation steps may be used 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.

[0123] The places that can exist will now be described in further detail below. Figure 1 The general configuration and operation of each facility in the chemical recovery facility shown, starting with the pretreatment facility. Optionally, although... Figure 1 As not shown, at least one stream from the chemical recycling facility may be sent to an industrial landfill or other similar treatment or disposal facility.

[0124] Preprocessing

[0125] like Figure 1 As shown, 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 (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. The pretreatment facility described herein may 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.

[0126] Crushing and granulation

[0127] In one embodiment or in combination with any of the embodiments mentioned herein, waste plastics (e.g., MPW) may be provided in bales of unsorted or pre-sorted plastics or in other large aggregate forms. The bales or aggregates of plastic undergo an initial process in which they are dispersed. 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 disperse 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.

[0128] 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.

[0129] 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.

[0130] 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 3 / 4 inch, or less than 1 / 2 inch. In one or more other embodiments, the D90 particle size of the plastic material leaving the granulating apparatus is 1 / 16 inch to 1 inch, 1 / 8 inch to 3 / 4 inch, 1 / 4 inch to 5 / 8 inch, or 3 / 8 inch to 1 / 2 inch.

[0131] Washing and drying

[0132] 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 the waste plastics include Escherichia coli, Salmonella, Clostridium difficile, Staphylococcus aureus, Listeria monocytogenes, Staphylococcus epidermidis, Pseudomonas aeruginosa, and Pseudomonas fluorescens.

[0133] 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, in one or more embodiments, waste plastics may 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), may 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.

[0134] 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.

[0135] 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.

[0136] Separation

[0137] In one embodiment or in combination with any of the embodiments mentioned herein, the steps of the pretreatment facility 20 or the chemical recycling method or facility 10 may include at least one separation step or zone. The separation step or 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 (polycrystalline plastic).

[0138] 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.

[0139] 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).

[0140] 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).

[0141] 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 enriched with a concentration or mass of PET 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:

[0142]

[0143] as well as

[0144]

[0145] Where PETe is the concentration of PET in PET enriched product stream 112, based on undiluted dry weight;

[0146] PETM is the concentration of PET in the MPW feed stream 100, on a dry basis; and

[0147] PETd is the concentration of PET in PET-depleted product stream 114, on a dry basis.

[0148] In one embodiment or in combination with any of the embodiments mentioned herein, when a stream containing MPW100 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:

[0149]

[0150] as well as

[0151]

[0152] Where PVCe is the concentration of PVC in PET enriched product stream 112, based on undiluted dry weight;

[0153] PVCm is the concentration of PVC in the MPW feed stream 100, based on undiluted dry weight; and

[0154] Wherein PVCd is the concentration of PVC in PET depleted product stream 114, based on undiluted dry weight.

[0155] 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:

[0156]

[0157] as well as

[0158]

[0159] Where POd is the concentration of polyolefin in PET lean product stream 114, based on undiluted dry weight;

[0160] POm is the concentration of PO in the MPW feed stream 100, on a dry basis; and

[0161] POe is the concentration of PO in PET enriched product stream 112, on a dry basis.

[0162] 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 depletion stream 114, relative to the MPW feed stream 100 (PVC depletion percentage based on feed) or the PET enriched product stream 112 (PVC depletion percentage based on product), is determined by the following formula:

[0163]

[0164] as well as

[0165]

[0166] Where PVCm is the concentration of PVC in the MPW feed stream 100, based on undiluted dry weight;

[0167] PVCd is the concentration of PVC in PET lean product stream 114, on an undiluted dry weight basis; and

[0168] PVCe is the concentration of PVC in PET enriched product stream 112, on an undiluted dry weight basis.

[0169] The PET depletion stream 114 is PET-depleted 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 PET depletion percentage of 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:

[0170]

[0171] as well as

[0172]

[0173] Where PETm is the concentration of PET in the MPW feed stream 100, on an undiluted dry basis;

[0174] PETd is the concentration of PET in PET-depleted product stream 114, on an undiluted dry basis; and

[0175] PETe is the concentration of PET in PET enriched product stream 112, based on undiluted dry weight.

[0176] 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.

[0177] In one embodiment or in combination with any embodiment mentioned herein, the PET enrichment stream exiting 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 PET enrichment stream 112. 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 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%, based on the total weight of plastic in PET enrichment stream. 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).

[0178] PET enriched stream 112 can also be depleted 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 (PGA), polyphenylene sulfide (PPS), thermoplastic styrene elastomers (TPS), and amorphous thermoplastic polyimide. (TPI), liquid crystal polymer (LCP), glass fiber reinforced PET, chlorinated polyvinyl chloride (CPVC), polybutylene terephthalate (PBT), polyphthalamide (PPA), polyvinylidene chloride (PVDC), ethylene tetrafluoroethylene copolymer (ETETE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene copolymer (FEP), polychlorotrifluoroethylene (PCTFE), and perfluoroalkoxy (PFA), any of which may include carbon, glass, and / or mineral fillers, and has a higher density than PET and PVC.

[0179] In one embodiment or in combination with any embodiment mentioned herein, 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% of PO, based on the total weight of the plastic in the PET enrichment stream 112. 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). 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, based on the total weight of the PET enrichment stream 112.

[0180] Additionally or alternatively, the PET enrichment stream 112 may contain no more than 2, 1, 0.5, or 0.1 wt% of a binder on a dry basis. Typical binders include carpet adhesives, latex, styrene-butadiene rubber, etc. Furthermore, the PET enrichment stream 112 may contain no more than 4, 3, 2, 1, 0.5, or 0.1 wt% of plastic fillers and solid additives on a dry basis. Exemplary fillers and additives include silica, 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.

[0181] In one embodiment or in combination with any of the embodiments mentioned herein, the PET depleted (or PO enriched) stream 114 exiting the separation zone 22 or 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 114. The PET depleted (or PO enriched) stream may be PVC depleted and may contain, 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 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 PO introduced into the pretreatment facility 20 or separation zone 22.

[0182] PO enrichment stream 114 may also be lean-containing PET and / or other plastics, including PVC. In one embodiment or in combination with any of the embodiments mentioned herein, the PET lean (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, based on the total weight of the plastics in the PET lean or PO enrichment stream. PO enrichment (or PET lean) 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.

[0183] In one embodiment or in combination with any of the embodiments mentioned herein, the PET depletion or PO enrichment stream 114 may further 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 PET depletion or PO enrichment stream 114. The depleted PET or PO enrichment stream 114 contains no more than 4, 2, 1, 0.5, or 0.1 wt% of binder, based on the total weight of the stream.

[0184] 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 were measured using a Brookfield R / S rheometer with a V80-40 paddle rotor, which operated at a shear rate of 10 rad / s and a temperature of 350°C.

[0185] Alternatively or additionally, the melt viscosity of the PET-depleted or PO-enriched stream may be no more than 25,000, 24,000, 23,000, 22,000, 21,000, 20,000, 19,000, 18,000, or 17,000 poise (measured at 10 rad / s and 350 °C). Alternatively, the melt viscosity of the stream may 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).

[0186] 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 a PET supplementary stream 112 and a PO enriched 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 the respective densities of the materials, and includes both flotation-sinking separation and centrifugal density separation.

[0187] 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, magnesium 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.

[0188] 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 comprise carbon tetrachloride, chloroform, dichlorobenzene, dimethyl sulfate, and / or trichloroethylene. The specific components and concentration of the liquid medium can be selected according to the desired target separation density for the separation stage. Centrifugal density separation processes can also utilize the liquid medium described above to improve separation efficiency at the target separation density.

[0189] 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.

[0190] 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.

[0191] As used herein, the term "target separation density" refers to a density above which materials undergoing a density separation process preferentially separate into a higher density output, while below which materials separate into a lower density output. The target separation density specifies a density value above which all plastics and other solid materials separate into a higher density output, and below which all plastics and other solid materials separate into a lower density output. 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.

[0192] 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.

[0193] Refer again Figure 1 The PET enriched stream 112 and PO enriched stream 114 can be introduced into one or more downstream treatment facilities (or undergo one or more downstream treatment 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.

[0194] Solvent decomposition

[0195] 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.

[0196] When the ester undergoing solvent decomposition includes PET, the solvent decomposition carried out in a 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 a solvent decomposition facility. As used herein, the term "major diol" refers to the major diol product extracted from a 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:

[0197]

[0198] 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.

[0199] In one embodiment or in combination with any of the embodiments mentioned herein, the primary solvent used in the 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 the solvent decomposition may be referred to as “hydrolysis”), (ii) alcohols (in which case the solvent decomposition may be referred to as “alcohololysis”), such as methanol (in which case the solvent decomposition may be referred to as “methanol decomposition”) or ethanol (in which case the solvent decomposition may be referred to as “ethanol decomposition”), (iii) glycols such as ethylene glycol or diethylene glycol (in which case the solvent decomposition may be referred to as “glycolysis”), or (iv) ammonia (in which case the solvent decomposition may be referred to as “ammonolysis”).

[0200] In one embodiment or in combination with any embodiment mentioned herein, 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 a primary solvent, based on the total weight of the solvent stream. In one embodiment or in combination with any embodiment mentioned herein, 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, based on the total weight of the solvent stream.

[0201] When the solvent decomposition facility 30 uses a glycol such as 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, Figure 1 Chemical recycling facilities may include glycolysis facilities. In glycolysis facilities, PET can be chemically broken down to form ethylene glycol (EG) as the main glycol and dimethyl terephthalate (DMT) as the main terephthaloyl group. When the PET contains waste plastics, the EG and DMT formed in the solvent decomposition facility may contain recycled ethylene glycol (r-EG) and recycled dimethyl terephthalate (r-DMT). When formed by glycolysis, EG and DMT can exist in a single product stream.

[0202] When a solvent decomposition facility uses methanol as the primary solvent, it can be called a methanol decomposition facility. Figure 1 Chemical recovery facilities may include methanol decomposition facilities. One example of a methanol decomposition facility is... Figure 3 The diagram schematically depicts that PET can be chemically decomposed to form ethylene glycol (EG) as the main glycol and dimethyl terephthalate (DMT) as the main terephthaloyl group. When PET contains waste plastics, the EG and DMT formed in the solvent decomposition facility may contain recycled ethylene glycol (r-EG) and recycled dimethyl terephthalate (r-DMT).

[0203] In one embodiment or in combination with any of the embodiments mentioned herein, the stream 154 of recovered component diol (r-diol) taken 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. 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., 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, based on the total weight of the stream, or these may be present in amounts of 0.5 wt%–45 wt%, 1 wt%–40 wt%, or 2 wt%–15 wt%, based on the total weight of the stream. The γ-diol may be present in stream 154 in amounts ranging from 45 wt%–99.9 wt%, 55 wt%–99.9 wt%, or 80 wt%–99.9 wt%, based on the total weight of stream 154.

[0204] In one embodiment or in combination with any of the embodiments mentioned herein, the recovered component predominantly terephthaloyl (r-terephthaloyl) stream 158 removed 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 predominantly terephthaloyl (e.g., DMT) formed in the solvent decomposition facility 30. 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 predominantly terephthaloyl, or predominantly terephthaloyl may be present in amounts of 45 wt% to 99 wt%, 50 wt% to 90 wt%, or 55 wt% to 90 wt%, based on the total weight of the stream. Additionally or alternatively, 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 predominantly terephthaloyl group, based on the total weight of the stream. γ-terephthaloyl (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%, based on the total weight of stream 154.

[0205] In addition to providing a main diol stream and a main terephthaloyl stream for recovery, the solvent decomposition facility can also provide one or more solvent decomposition byproduct streams, such as... Figure 1 As shown in stream 110, it can also be withdrawn 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 major carboxyl (terephthaloyl) product of the solvent decomposition facility, a major diol product of the solvent decomposition facility, or a major solvent fed into the solvent decomposition facility. The solvent 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, based on the total weight of the stream.

[0206] 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.

[0207] When the solvent decomposition facility is a methanol decomposition facility, one or more methanol decomposition byproducts can be recovered 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. A methanol decomposition byproduct stream may contain at least 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of one or more solvent decomposition byproducts, based on the total weight of the stream. 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.

[0208] 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. The heavy organic solvent decomposition byproduct stream may contain at least 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 wt% of organic compounds having a boiling point higher than that of the predominant terephthaloyl group (e.g., DMT) produced by the solvent decomposition facility 30, based on the total weight of organic matter in the stream.

[0209] Additionally or alternatively, the solvent decomposition facility may produce at least one light organic solvent decomposition byproduct stream. The light organic solvent decomposition byproduct stream may contain at least 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 wt% of organic compounds having a boiling point lower than that of the major terephthaloyl group (e.g., DMT) produced by the solvent decomposition facility 30, based on the total weight of organic matter in the stream.

[0210] Turn again Figure 3In operation, the stream of mixed plastic waste and solvent introduced (alone or together) into the solvent decomposition facility 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 non-PET components may have a lower boiling point than PET and can be removed as vapor from zone 208. Alternatively or additionally, at least a portion of the non-PET components may have a slightly higher or lower density than PET and can be separated by forming a two-phase liquid stream followed by the removal of one or both non-PET phases. Finally, in some embodiments, the non-PET components may be separated as solids from the PET-containing liquid phase.

[0211] In one embodiment or in combination with any of the embodiments mentioned herein, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the non-PET component separated from the PET-containing stream comprises a polyolefin, such as polyethylene and / or polypropylene. Figure 3 The dashed lines generally indicate that all or part of the non-PET separation zone 208 may be upstream of the reaction zone 210, while all or part of the non-PET separation zone 208 may be 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.

[0212] like Figure 3 As shown, 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, 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, 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.

[0213] Non-PET components can be removed from solvent decomposition (or methanol decomposition) facility 30 as polyolefin-containing byproduct stream 140, such as... Figure 3As generally shown. The polyolefin byproduct stream (or decanter olefin byproduct 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, based on the total weight of the byproduct stream 140.

[0214] The polyolefins present in the polyolefin-containing by-product stream may consist primarily of polyethylene, primarily of polypropylene, or a combination of polyethylene and polypropylene. The polyolefins in the polyolefin-containing by-product stream contain at least 70, 75, 80, 85, 90, 92, 94, 95, 97, 98, or 99 wt% polyethylene, based on the total weight of the polyolefins in the polyolefin-containing by-product stream 140. Alternatively, the polyolefins in the polyolefin-containing by-product stream contain at least 70, 75, 80, 85, 90, 92, 94, 95, 97, 98, or 99 wt% polypropylene, based on the total weight of the polyolefins in the polyolefin-containing by-product stream 140.

[0215] The polyolefin-containing by-product stream contains no more than 10, 5, 2, 1, 0.75, 0.50, 0.25, 0.10, or 0.05 wt% PET, based on the total weight of the polyolefin-containing by-product stream 140. Additionally, the polyolefin-containing by-product stream contains at least 0.01, 0.05, 0.10, 0.50, 1, or 1.5 and / or no more than 40, 35, 30, 25, 20, 15, 10, 5, or 2 wt% components other than polyolefins, based on the total weight of the polyolefin-containing by-product stream 140.

[0216] Overall, 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, based on the total weight of the polyolefin-containing byproduct stream 140.

[0217] The polyolefin-containing byproduct 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, based on the total weight of the polyolefin-containing byproduct stream 140. Non-reactive solids refer to solid components that do not chemically react with PET. Examples of non-reactive solids include, but are not limited to, sand, soil, glass, plastic fillers, and combinations thereof.

[0218] Polyolefin by-product stream 140 contains one or more of the following fillers in amounts: at least 100, at least 250, at least 500, at least 750, at least 1000, at least 1500, at least 2000, at least 2500, at least 5000, at least 7500 ppm by weight, or at least 1, at least 1.5, at least 2, at least 5, at least 10, at least 15, at least 20, or at least 25 wt% and / or not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, not more than 5, not more than 2, or not more than 1 wt%, based on the total weight of polyolefin by-product stream 140. Polyolefin by-product stream 140 may contain fillers in amounts from 100 ppm to 50 wt%, from 500 ppm to 10 wt%, or from 1000 ppm to 5 wt%.

[0219] 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, and release agents such as zinc stearate, waxes and organosilicon, calcium carbonate and calcium sulfate.

[0220] In one embodiment or in combination with any of the embodiments mentioned herein, the density of the polyolefin 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. 3When 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. The polyolefin-containing byproduct stream 140 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 components with a boiling point higher than that of the predominantly terephthaloyl or DMT, based on the total weight of the stream.

[0221] As discussed in further detail herein, all or part of a polyolefin-containing byproduct stream may be introduced, 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) into one or more downstream chemical recycling facilities.

[0222] 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, where at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the PET introduced into the reaction zone undergoes decomposition. In some embodiments, the reaction medium within the reaction zone 210 can be stirred or agitated, 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.

[0223] 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 10.35 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).

[0224] 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 psig), at least 120 barg (1741 psig) or at least 125 barg (1814 psig) and / or not more than 150 barg (2177 barg), not more than 145 barg (2104 psig), not more than 140 barg (2032 psig), not more than 135 barg (1959 psig), not more than 130 barg (1886 psig), or not more than 125 barg (1814 psig).

[0225] 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.

[0226] 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 fed as reactor purge byproduct stream 142 into 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.

[0227] In one embodiment or in combination with any of the embodiments mentioned herein, reactor purification byproduct stream 142 comprises at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of predominantly terephthaloyl groups, based on the total weight of stream 142. When the solvent decomposition facility is a methanol decomposition facility, reactor purification byproduct stream 142 may comprise at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of DMT, based on the total weight of stream 142.

[0228] Additionally, 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, based on the total weight of stream 142. In one embodiment or in combination with any embodiment mentioned herein, 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 more than 25, not more than 22, not more than 20, not more than 18, not more than 15, not more than 12, not more than 10, not more than 8, not more than 5, not more than 3, not more than 2, or not more than 1 wt%, based on the total weight of the stream.

[0229] In one embodiment or in combination with any embodiment mentioned herein, the total solids content of the reactor purified byproduct stream 142 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 8000, at least 8500. At least 9000, at least 9500 ppm (ppm by weight) or at least 1, at least 2, at least 5, at least 8, at least 10 or at least 12 wt% and / or not more than 25, not more than 22, not more than 20, not more than 17, not more than 15, not more than 12, not more than 10, not more than 8, not more than 6, not more than 5, not more than 3, not more than 2 or not more than 1 wt% or not more than 7500, not more than 5000, or not more than 2500 ppm (ppm by weight), based on the total weight of the stream.

[0230] 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.

[0231] 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 a portion 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.

[0232] In one embodiment or in combination with any of the embodiments mentioned herein, such as Figure 3As generally indicated, the effluent stream 144 from the reaction zone 210 in the solvent decomposition facility 30 may optionally be conveyed through a non-PET separation zone 208 located downstream of the reactor, as previously described. The resulting effluent stream 144 from the reactor or (if present) from the non-PET separation zone 208 may pass through a product separation zone 220, wherein at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of heavy organic material is separated from the feed stream 144 to form a stream primarily composed of light organic material 146 and a stream of 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.

[0233] like Figure 3 As shown, a heavy organic stream 148 extracted from product separation zone 220 can be introduced into heavy organic matter separation zone 240. This heavy organic stream may contain, 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, based on the total weight of the stream. In heavy organic matter separation zone 240, a predominantly terephthalic product stream 158 can be separated from a terephthalic bottoms product 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, 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 terephthalic (or DMT), based on the total weight of the stream. In one embodiment or in combination with any of the embodiments mentioned herein, at least some or all of the predominant terephthaloyl group may comprise a recycled terephthaloyl group (r-terephthaloyl group), such as the recycled DMT (r-DMT).

[0234] 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.

[0235] In one embodiment or in combination with any of the embodiments mentioned herein, 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, based on the total weight of the composition (e.g., PET oligomers). As used herein, the terms “polyester portion” or “polyester fraction” refer 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 + 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.

[0236] In one embodiment or in combination with any of the embodiments mentioned 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. 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 (ppb, 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, based on the total weight of the terephthaloyl bottom by-product stream 160.

[0237] As discussed in further detail herein, all or part of the terephthaloyl bottom byproduct stream 160 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.

[0238] Refer again Figure 3The light organic stream 146 from product separation zone 220 can be introduced into light organic separation zone 230. In light organic separation zone 230, 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.

[0239] 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 150. 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% of 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.

[0240] 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) component, 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 stream 152 itself may be below the boiling point of the major terephthaloyl (or DMT).

[0241] 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.

[0242] 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 the byproduct stream 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.

[0243] 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.

[0244] 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, Methyl formate, n-butanol, acetic acid, dibutyl ether, heptane, dibutyl terephthalate, dimethyl phthalate, dimethyl 1,4-cyclohexyldicarboxylate, 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), dimethyl dimethoxysilane, dimethyl ether, diisopropyl ketone, EG benzoate, hexamethylcyclotrisiloxane, hexamethyldisiloxane, methoxytrimethylsilane, ethyl 4-methylbenzoate, 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.

[0245] 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, 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, or treated mixed plastic waste.

[0246] Additionally, a stream primarily comprising major diol 154 may 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 include at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of major diol, based on the total weight of stream 154. Major diol stream 154 may also include recovered components, such that major diol product stream 154 has 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 recovered components, based on the total weight of the stream. The major diol (or ethylene glycol) may include γ-diol (or γ-ethylene glycol).

[0247] 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 bottoms" or "diol sludge" (or, more specifically, EG bottoms or EG sludge in methanol decomposition) refer to components with a boiling point (or azeotropic point) higher than that of the major diol but lower than that of the major terephthaloyl group.

[0248] 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).

[0249] In one embodiment or in combination with any of the embodiments mentioned herein, the bottom byproduct stream 156 of the glycol column may comprise a primary glycol and at least one other glycol. For example, the bottom byproduct stream 156 of the glycol column 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 glycol (or ethylene glycol), based on the total weight of the byproduct stream 156. The primary glycol (or ethylene glycol) may be present on its own (in a free state) or as part of another compound.

[0250] Other possible primary diols (depending on PET or other treated polymers) may include, but are not limited to, diethylene glycol, triethylene glycol, 1,4-cyclohexanediol, 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 include 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.

[0251] In one embodiment or in combination with any embodiment mentioned herein, a diol other than the primary diol (or ethylene glycol in the case of methanol decomposition) may be present in the diol bottom byproduct stream 156 in an amount of at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70 or at least 75 and / or 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 or no more than 35 wt%, based on the total weight of the diol in the diol bottom byproduct stream 156.

[0252] 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 does not exceed 5:1, 4.5:1, 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1, 1.25:1, or 1:1, or is in the range of 0.5:1 to 5:1, 0.70:1 to 3:1, or 0.80:1 to 2.5:1.

[0253] In one embodiment or in combination with any of the embodiments mentioned herein, the solvent decomposition facility 30 can 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. One or more solvent decomposition byproduct streams (such as...) Figure 1 All or part of the stream (shown in 110) is 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 aforementioned optional facilities.

[0254] In one embodiment or in combination with any of the embodiments mentioned herein, two or more (or portions of two or more) solvent decomposition byproduct streams may be introduced into the same downstream processing facility, while in other embodiments, two or more (or portions of two or more) 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.

[0255] Refer again Figure 1 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 reacted with, for example, from... Figure 1The combination of at least a portion of the PO-enriched plastic stream 114 taken from the pretreatment facility 20 shown. The amount of a single byproduct stream 110 (or all byproduct streams when two or more are combined) in the combined stream having PO-enriched plastic can vary and 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%, based on the total weight of the combined stream. Figure 1 As shown, the combined stream can then be introduced into one or more locations of a chemical recovery facility, including, for example, a POX gasification facility 50, a pyrolysis facility 60, a cracking facility 70, and / or an energy generation facility 80.

[0256] Liquefaction / Dehalogenation

[0257] like Figure 1 As shown, the 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) to (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 improve the flow and / or dispersibility of liquefied waste plastics.

[0258] Refer again Figure 1 PO-enriched waste plastic streams and / or solvent decomposition byproducts from the solvent decomposition system may be introduced into the liquefaction system or step prior to introduction into one or more downstream treatment facilities. Additionally or alternatively, unsorted waste plastics (e.g., untreated and / or partially treated waste plastics) and / or any sorted waste plastics from pretreatment facilities or other sources may be introduced into the liquefaction system or step prior to introduction into one or more downstream treatment facilities. In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics fed into the liquefaction system or step may be provided as a waste stream from another treatment facility, such as a municipal recycling facility (MRF) or a recycled waste stream, or as a plastic-containing mixture comprising waste plastics sorted by consumers and left for curbside collection.

[0259] In one embodiment or in combination with any of the embodiments mentioned herein, the plastic stream fed into the liquefaction system 40 may comprise a sorted waste plastic stream rich in PO and containing small amounts of PET and PVC, such as a PO-enriched waste plastic stream. For example, the plastic stream fed into the liquefaction system 40 may contain at least 10, at least 15, at least 25, at least 50, at least 75, or at least 90 and / or no more than 99, no more than 98, 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, or no more than 30 wt% of one or more polyolefins, based on the total weight of the stream. Additionally or alternatively, the plastic stream fed into the liquefaction system 40 may contain no more than 25, no more than 10, no more than 5, no more than 2, no more than 1, or no more than 0.5 wt% of PET and / or PVC, based on the total weight of the stream.

[0260] In one embodiment or in combination with any of the embodiments mentioned herein, the plastic stream fed into the liquefaction system 40 may comprise an unsorted waste plastic stream containing a significant amount of PET. For example, in one or more embodiments, the plastic stream fed into the liquefaction system 40 may contain 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, or at least 30 and / or no more than 95, no more than 90, no more than 80, or no more than 70 wt% of PET, based on the total weight of the stream. Additionally or alternatively, the plastic stream fed into the liquefaction system 40 may contain at least 5, at least 10, at least 15, at least 20, at least 25, or at least 30 and / or no more than 95, no more than 90, no more than 80, or no more than 70 wt% of one or more polyolefins, based on the total weight of the stream.

[0261] In one embodiment or in combination with any of the embodiments mentioned herein, the plastic stream fed into the liquefaction system 40 may contain at least 50, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of one or more solid waste plastics, based on the total weight of the feed stream introduced into the liquefaction system 40. Therefore, in one or more embodiments, the plastic stream fed into the liquefaction system contains a very high solids content.

[0262] Additionally or alternatively, the plastic stream fed into the liquefaction system 40 may be in the form of a slurry and may contain one or more slurry-forming liquids, such as water. In such embodiments, the plastic stream fed into the liquefaction system 40 may contain at least 1, at least 2, at least 3, at least 4, at least 5, at least 10, at least 15, at least 20, or at least 25 and / or 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, or no more than 5 wt% of one or more slurry-forming liquids, based on the total weight of the feed stream introduced into the liquefaction system 40.

[0263] When added to liquefaction system 40, at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of plastic (typically waste plastic) undergoes a decrease in viscosity. 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.

[0264] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics added to the liquefaction system can be at least partially dissolved by contacting the plastics with at least one solvent. Typically, the dissolution step can be carried out at pressures and temperatures sufficient to at least partially dissolve the solid waste plastics. 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. Figure 1 As shown, solvent stream 141 can be added directly to liquefaction system 40, or it can be added in conjunction with one or more streams fed into liquefaction system 40. Figure 1 (Not shown in the image) combination. When pyrolysis oil is used as a solvent in solvent stream 141, this pyrolysis oil may be derived from pyrolysis facility 60 or purchased from an external source.

[0265] When used, the solvent may be 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 feed stream introduced into the liquefaction system 40. Additionally or alternatively, the solvent may be present in an amount not exceeding 60, 50, 40, 30, 20, or 15 wt%, based on the total weight of the feed stream introduced into the liquefaction system 40. For example, the total feed stream introduced into the liquefaction system 40 may contain one or more solvents ranging from 1 wt% to 50 wt%, 2 wt% to 40 wt%, or 5 wt% to 30 wt%.

[0266] 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. Figure 1 As shown, the solvent can be derived from the pyrolysis oil from the pyrolysis facility 60 via pipeline 143.

[0267] When Figure 1 When generally combined with the PO enriched plastic stream 114, as shown herein, a solvent decomposition byproduct stream (which may include one or more solvent decomposition byproducts described herein) may be added before the PO enriched waste plastic stream 114 is introduced into the liquefaction system 40 (as shown in line 113) and / or after the liquefied plastic stream is removed from the liquefaction system 40 (as shown in line 115). In one embodiment or in combination with any embodiment mentioned herein, at least a portion or all of one or more byproduct streams may also be directly introduced into the liquefaction zone, such as... Figure 1 As shown in the figure. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the PO enriched waste plastic stream 114 can completely bypass the liquefaction system 40 in pipeline 117, and may optionally be connected to... Figure 1 The at least one solvent decomposition byproduct stream 110 shown is combined.

[0268] Additionally, at least 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 plastics, such as... Figure 1 As shown. Although shown as being introduced directly into liquefaction system 40, all or part of the pyrolysis oil stream 143 may be combined with the PO enriched plastic stream 114 before being introduced into liquefaction system 40 or after the PO enriched plastic stream 114 leaves liquefaction system 40. When in use, the pyrolysis oil may be added alone or in combination with one or more other solvent streams at one or more locations described herein.

[0269] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastics added to the liquefaction system 40 can be depolymerized, such that the number-average chain length of the plastic is reduced by contact with a depolymerizing agent. Typically, the depolymerization step can be carried out at pressures and temperatures sufficient to at least partially liquefy the solid waste plastics. In one embodiment or in combination with any of the embodiments mentioned herein, at least one of the aforementioned solvents used for dissolution can also 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 and / or nitric acid (for polyolefins). The depolymerizing agent can reduce the melting point and / or viscosity of the polymer by lowering its number-average chain length.

[0270] When used, the depolymerizing agent may be 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 feed stream introduced into the liquefaction system 40. Additionally or alternatively, the depolymerizing agent may be present in an amount not exceeding 60, not exceeding 50, not exceeding 40, not exceeding 30, not exceeding 20, or not exceeding 15 wt%, based on the total weight of the feed stream introduced into the liquefaction system 40. For example, the total feed stream introduced into the liquefaction system 40 may contain one or more depolymerizing agents of 1 wt%-50 wt%, 2 wt%-40 wt%, or 5 wt%-30 wt%.

[0271] In one embodiment or in combination with any of the embodiments mentioned herein, the waste plastic added to the liquefaction system can come into contact with plasticizers in the liquefaction system to reduce the viscosity of the plastic. In such embodiments, the plasticizing step can be carried out in a heated container, such as a melting tank described below, and / or in a stirred mixer, such as a calendering mixer and / or an extruder. During the plasticizing step, the plasticizer can be incorporated into the plastic while it is liquefied in the liquefaction container. 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 to 1,000 Daltons. Plasticizers 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 to 1500 Daltons, glyceryl monostearate, octyl epoxidized soybean oleate, epoxidized soybean oil, epoxidized tall oleate, epoxidized linseed oil, polyhydroxyalkanoates, glycols (e.g., ethylene glycol, pentylene glycol, hexanediol, etc.), phthalates, terephthalates, trimellitates and polyethylene glycol di-(2-hexanoate ethyl ester). When used, the plasticizer may be present in an amount of at least 0.1, at least 0.5, at least 1, at least 2 or at least 5 wt% and / or not more than 10, not more than 8, not more than 5, not more than 3, not more than 2 or not more than 1 wt%, based on the total weight of the stream, or it may be present 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 feed stream introduced into the liquefaction system 40.

[0272] Furthermore, one or more methods for liquefying waste plastic streams may also include adding at least one liquefying agent to the plastic before, during, or after the liquefaction process. This liquefying agent may include, for example, emulsifiers and / or surfactants, and may be used to more completely blend the liquefied plastic into a single phase, particularly when density differences between the plastic components of the mixed plastic stream result in multiple liquid or semi-liquid phases. When used, the liquefying agent may be present in an amount of at least 0.1, at least 0.5, at least 1, at least 2, or at least 5 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, or no more than 1 wt%, based on the total weight of the feed stream introduced into the liquefaction system 40, or it may be present 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 feed stream introduced into the liquefaction system 40.

[0273] As described above, one or more methods for liquefying a stream of waste plastics in liquefaction system 40 may include a heating / melting step, which may be carried out in a melting tank system to form a molten feed, such as molten waste plastics. During this step, at least a portion of the plastic may be heated above its melting temperature and / or glass transition temperature to form molten waste plastics. As used herein, “molten feed” means a feed that is substantially liquid and contains at least one component that is substantially liquid and has been heated above its melting temperature and / or glass transition temperature. Similarly, as used herein, “molten waste plastics” means waste plastics that are substantially liquid and have been heated above their melting temperature and / or glass transition temperature.

[0274] In one embodiment or in combination with any embodiment mentioned herein, the viscosity of the liquefied plastic stream leaving the liquefaction system 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, 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. Additionally or alternatively, the viscosity of the liquefied plastic stream leaving the liquefaction zone (measured at 350°C and 10 rad / s and expressed in poise) is no more than 95%, no more than 90%, no more than 75%, no more than 50%, no more than 25%, no more than 10%, no more than 5%, or no more than 1% of the viscosity of the PO enriched stream introduced into the liquefaction zone.

[0275] Figure 4 The basic components of a liquefaction system are shown, which can be used as... Figure 1 The liquefaction system 40 in the chemical recovery facility shown. It should be understood that... Figure 4 An exemplary embodiment of the liquefaction system 40 is depicted. Figure 4 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 4 The system described in the text.

[0276] like Figure 4 As shown, solid waste plastic feed, such as PO-enriched waste plastic stream, can be derived from waste plastic source 20, such as the pretreatment facility described herein. Then, waste plastic feed 114 can be introduced into a liquefaction system, which in... Figure 4The image depicts a melting tank system 310 comprising at least one melting tank. When in the melting tank system 310, at least a portion of the plastic feed 114 can be heated above its melting temperature and / or glass transition temperature to form liquefied (i.e., molten) waste plastic.

[0277] Furthermore, when in the melting tank system 310, at least a portion of the halogens present in the plastic feed stream 114 can be removed from the plastic feed stream. More specifically, in one or more embodiments, the liquefaction system may also include equipment for removing halogens from the waste plastic feed stream. For example, when the waste plastic is heated in the melting tank system 310, halogen-enriched gases can be evaporated. The evaporated halogen-enriched gas 164 can be phase-separated from the resulting liquefied plastic material, resulting in a liquefied (i.e., molten) plastic stream 161 with a reduced halogen content. Figure 4 As shown, the resulting dehalogenated liquefied waste plastic 161 can then be introduced via pipeline 118 into downstream treatment facilities, such as the pyrolysis reactor in the pyrolysis facility 60 and / or via pipeline 118 into the POX vaporizer in the POX facility 50, while halogen-enriched gas 164 can be removed from the system.

[0278] For example Figure 4 As shown, the resulting pyrolysis vapor 170 can be separated (as described below) into a pyrolysis gas stream 172 and a pyrolysis oil stream 174. The resulting heavy pyrolysis residue 176 can be removed from the pyrolysis system 50 for other downstream applications. Furthermore, in one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the pyrolysis oil stream 174 can be recycled back to the melting tank system 310 via line 143 to provide pyrolysis oil to the melting tank system 310, wherein the pyrolysis oil can act as a dissolving solvent, as described above. Additionally or alternatively, as described above, another dissolving solvent can be added to the melting tank system via line 141.

[0279] In one embodiment or in combination with any of the embodiments mentioned herein, at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 50%, at least 75%, at least 90%, or at least 99% of the pyrolysis oil stream 174 may be recycled back to the liquefaction system 40, such as the melting tank system 310, via line 143 for use as a dissolving solvent. In some embodiments, all of the pyrolysis oil stream 174 may be recycled back to the liquefaction system 40 via line 143.

[0280] Figure 4 It is also shown that dehalogenated liquefied waste plastic 161 can be introduced via pipeline 118 into the POX vaporizer of POX facility 50 to produce syngas 128. Syngas 128 can undergo additional treatment as discussed below.

[0281] In one embodiment or in combination with any of the embodiments mentioned herein, from the liquefaction system 40, for example Figure 4 The liquefied waste plastic stream 161 from the melting tank system 310 can be selectively transported and formulated to the POX facility 50 and the pyrolysis facility 60. For example, 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% and / or no more than 99%, no more than 95%, or no more than 92% of the liquefied waste plastic stream 161 can be guided and delivered to the POX facility 50 via line 116. In some embodiments, 10%-99%, 20%-99%, 40%-95%, or 70%-95% of the liquefied waste plastic stream 161 can be guided and delivered to the POX facility 50 via line 116.

[0282] Additionally, or in alternatives, in one embodiment or in combination with any of the embodiments mentioned herein, at least 1%, at least 2%, at least 3%, at least 4%, at least 5%, at least 10%, or at least 15% and / or no more than 90%, no more than 50%, no more than 30%, or no more than 20% of the liquefied waste plastic stream 161 may be guided and fed to the pyrolysis facility 60 via pipeline 118. In some embodiments, 1%-90%, 1%-50%, 1%-30%, or 1%-20% of the liquefied waste plastic stream 161 may be guided and fed to the pyrolysis facility 60 via pipeline 118. In such embodiments, the formulated liquefied waste plastic stream 161 may be converted into pyrolysis oil in the pyrolysis facility 60 and then recycled back to the liquefaction system 40, as described above.

[0283] Figure 5 It shows what can be used as Figure 1 An exemplary melting tank system of the liquefaction system 40 in the example. It should be understood that... Figure 5 An exemplary embodiment of a liquefaction system is described. Figure 5 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 5 The system described herein. It should be noted that, unless otherwise stated, Figure 5 All components described above can be used in conjunction with the above. Figure 1 and Figure 4 The same components described operate in the same way.

[0284] like Figure 5 As shown, the waste plastic feed, such as the PO-enriched waste plastic stream 114, can be derived from the waste plastic source 20, such as the pretreatment facility 20 described herein. The waste plastic feed, such as the PO-enriched waste plastic stream 114, can be introduced into the liquefaction system 40. Figure 5It is described as comprising at least one melting tank 312, at least one external heat exchanger 340, at least one stripping tower 330, and at least one phase separation vessel 320. These various exemplary components in the liquefaction system 40 and their functions are discussed in more detail below.

[0285] In one embodiment or in combination with any of the embodiments mentioned herein, the liquefaction system 40 includes a melting tank 312 and a heater, such as Figure 5 As shown. Melting tank 312 receives waste plastic feed, such as PO enriched waste plastic stream 114, and heaters heat the waste plastic.

[0286] In one embodiment or in combination with any of the embodiments mentioned herein, the melting tank 312 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 system 40, such rheology modifiers may be added to and / or mixed with PO-rich plastics in or before the melting tank 312 via line 141 and / or line 143.

[0287] In one embodiment or in combination with any of the embodiments mentioned herein, the heater of the liquefaction system 40 ( Figure 5 (Not shown) can take the form of an internal heat exchange coil located within the melting tank 312, a jacket on the outside of the melting tank 312, heat tracing on the outside of the melting tank 312, and / or an electric heating element on the outside of the melting tank 312. Additionally or alternatively, such as Figure 5 As shown, the heater of the liquefaction system 40 may include an external heat exchanger 340 that receives the liquefied plastic stream 171 from the melting tank 312, heats it, and returns at least a portion of the heated liquefied plastic stream 173 to the melting tank 312.

[0288] The external heat exchanger 340 may include any conventional heat exchanger known and used in the art. In one embodiment or in combination with any of the embodiments mentioned herein, the external heat exchanger 340 may include a single-pass or multi-pass vertical heat exchanger. Figure 5 As shown, the external heat exchanger 340 receives liquefied plastic from the melting tank 312 via pipeline 171 and heats it for further processing.

[0289] like Figure 5As shown, when using an external heat exchanger 340 to provide heat to the liquefaction system 40, a circulation loop can be used to continuously add heat to the PO enriched material. In one embodiment or in combination with any of the embodiments mentioned herein, the circulation loop includes a melting tank 312, an external heat exchanger 340, piping (shown as lines 159, 171, 173, and 175) connecting the melting tank 312 and the external heat exchanger 340, and a pump 151 for circulating the liquefied waste plastic in the circulation loop. When using the circulation loop, the resulting liquefied PO enriched material can be distributed as part of the circulating PO enriched stream via... Figure 5 The pipe 161 shown is continuously drawn from the liquefaction system 40.

[0290] although Figure 5 A liquefaction system is described that includes only a single melting tank 312, a single heat exchanger 340, a single stripping tower 330, and a single phase separation vessel 320. However, within the scope of this application, the liquefaction system 40 may include multiple melting tanks 312, multiple external heat exchangers 340, multiple stripping towers 330, and / or multiple phase separation vessels 320.

[0291] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 5 As shown, when liquefied plastic is introduced and present in stripping tower 330, dehalogenation of the liquefied plastic stream can be promoted by injecting stripping gas (e.g., steam) into the liquefied plastic material via pipe 153. The stripping gas may include, for example, nitrogen, steam, methane, carbon monoxide, and / or hydrogen. In certain embodiments, the stripping gas may include steam.

[0292] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 5 As shown, the stripping tower 330 and the phase separation vessel 320 are provided in a circulation loop downstream of the external heat exchanger 340 and upstream of the melting tank 312. Figure 5 As shown, the stripping tower 330 can receive heated liquefied plastic from an external heat exchanger 340 and inject stripping gas flow 153 into the liquefied plastic. In some embodiments, injecting stripping gas into the liquefied plastic can create a two-phase medium in the stripping tower 330.

[0293] Then, the two-phase medium formed in stripping tower 330 can flow (e.g., by gravity) through phase separation vessel 320, where the halogen-rich gas phase 162 separates from the halogen-depleted liquid phase. Or, as Figure 5 As shown, a portion of the heated liquefied plastic from the external heat exchanger 340 can bypass the stripping tower 330 and be introduced directly into the phase separation vessel 320.

[0294] 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 phase-separated container may be returned to the melting tank 312 via line 159, while a second portion of the halogen-depleted liquid phase may be discharged from the liquefaction system as a dehalogenated liquefied plastic stream 161. The phase-separated halogen-enriched gaseous stream 162 may be removed from the liquefaction system 40 for further processing and / or disposal.

[0295] In one embodiment or in combination with any embodiment mentioned herein, the internal space of the melting tank 312 in which the plastic is heated is maintained at a temperature of at least 200, at least 210, at least 220, at least 230, at least 240, at least 250, at least 260, at least 270, at least 280, at least 290, at least 300, at least 310, at least 320, at least 330, at least 340, at least 350, at least 360, at least 370, at least 380, at least 390, or at least 400°C. Additionally or alternatively, the internal space of the melting tank 312 may be maintained at a temperature not exceeding 500, 475, 450, 425, 400, 390, 380, 370, 365, 360, 355, 350, or 345°C. Typically, in one or more embodiments, the internal space of the melting tank 312 can be maintained within a temperature range of 200 to 500°C, 240 to 425°C, 280 to 380°C, or 320 to 350°C.

[0296] In one embodiment or in combination with any of the embodiments mentioned herein, the residence time of the plastic fed into the melting tank 312 may be at least 1, at least 5, at least 10, at least 20, at least 30, at least 40, at least 50, or at least 60 minutes and / or no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, no more than 4, or no more than 3 hours. Typically, in one or more embodiments, the residence time of the plastic fed into the melting tank 312 may range from 1 minute to 10 hours, 30 minutes to 6 hours, or 60 minutes to 4 hours.

[0297] In one embodiment or in combination with any of the embodiments mentioned herein, the pressure within the melting vessel 312 can be maintained in the range of absolute vacuum to 100 Torr.

[0298] As described above, the external heat exchanger 340 can provide additional heating and can further heat the liquefied plastic from the melting tank 312. In one embodiment or in combination with any of the embodiments mentioned herein, the residence time of the liquefied plastic fed into the external heat exchanger 340 in the heat exchanger 340 can be at least 1, at least 2, at least 3, at least 4, or at least 5 minutes and / or no more than 30, no more than 25, no more than 20, no more than 15, or no more than 10 minutes. Typically, in one or more embodiments, at least 50%, at least 75%, at least 90%, at least 95%, or at least 99%, or substantially all of the heat used to form molten waste plastic in the melting tank 312 is provided by the external heat exchanger 340.

[0299] Back Figure 5 At least a portion of the molten plastic from an external heat exchanger 340 can be introduced into a stripping tower 330, which is configured to inject a stripping gas stream 153 into the liquefied waste plastic, thereby forming a multiphase mixture (e.g., a two-phase mixture) that may contain both gas and liquid phases. Typically, in one or more embodiments, the stripping tower 330 includes one or more injection tubes comprising a plurality of orifices configured to distribute stripping gas into the molten waste plastic.

[0300] In one embodiment or in combination with any embodiment mentioned herein, the residence time of the liquefied plastic in the stripping tower 330 may be at least 10 seconds, at least 30 seconds, at least 1 minute, at least 5 minutes, at least 10 minutes, at least 15 minutes, or at least 30 minutes and / or no more than 60 minutes, no more than 30 minutes, no more than 10 minutes, no more than 5 minutes, or no more than 1 minute. The residence time in the stripping tower 330 is primarily affected by the location and size of the stripping tower 330. Typically, when in the stripping tower 330, stripping gas may be introduced into the molten waste plastic at a ratio of at least 0.01:1, at least 0.05:1, or at least 0.1:1 and / or no more than 3:1, no more than 2:1, no more than 1:1, or no more than 0.9:1, by weight.

[0301] Furthermore, in one or more embodiments, the phase-separating container 320 may be configured to receive a multiphase mixture from a stripping tower 330 and separate the liquid and gas phases of the multiphase mixture, thereby providing halogen-enriched gaseous material and halogen-depleted molten waste plastic. In one embodiment or in combination with any of the embodiments mentioned herein, the phase-separating container 320 may include a gravity flow, multi-level, tray-containing container. Typically, in one or more embodiments, the residence time of the multiphase mixture in the phase-separating container 320 may be at least 10 seconds, at least 30 seconds, at least 1 minute, at least 5 minutes, at least 10 minutes, at least 15 minutes, or at least 30 minutes and / or no more than 2 hours, no more than 60 minutes, no more than 30 minutes, or no more than 10 minutes.

[0302] like Figure 5 As shown, at least a portion of the halogen-poor molten waste plastic from the phase separation container 320 may be reintroduced into the melting tank 312 via line 159 for further liquefaction, and / or at least a portion of the halogen-poor molten waste plastic may be removed from the liquefaction system 40 via line 161 at or near the outlet of the phase separation container 320 for further processing in downstream facilities, such as in the pyrolysis reactor at the pyrolysis facility 60 and / or in the POX vaporizer at the POX facility 50.

[0303] In one embodiment or in combination with any of the embodiments mentioned herein, recirculated and heated molten plastic from the phase separation container 320 (and the circulation loop) can be used to provide heat in the melting tank 312, and thus help heat and melt the solid waste plastic introduced into the melting tank 312. Typically, in one or more embodiments, the ratio of halogen-depleted molten waste plastic returned to the melting tank 312 via line 159 to halogen-depleted molten waste plastic removed from the liquefaction system is at least 0.1:1, at least 0.2:1, at least 0.5:1, or at least 0.8:1 and / or no more than 50:1, no more than 40:1, no more than 30:1, no more than 20:1, no more than 10:1, no more than 5:1, or no more than 1:1. Typically, in one or more embodiments, the ratio of halogen-poor molten plastic waste returned to the melting tank 312 via line 159 to halogen-poor molten plastic waste removed from the liquefaction system is 0.1:1 to 40:1, 0.2:1 to 20:1, or 0.8:1 to 10:1.

[0304] In one embodiment or in combination with any of the embodiments mentioned herein, at least 50%, at least 75%, at least 90%, at least 95%, or at least 99%, or substantially all of the heat used to form molten waste plastic in the melting tank 312, is provided by heated waste plastic returned from the phase separation container 320 to the melting tank 312.

[0305] like Figure 5 As shown, in one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the syngas flow 128 from POX facility 50 and / or at least a portion of the pyrolysis vapor from pyrolysis facility 60 may be delivered via line 178 to external heat exchanger 340 in order to recover heat from these flows back into the circulation loop of liquefaction system 40.

[0306] In one embodiment or in combination with any of the embodiments mentioned herein, no more than 50%, no more than 25%, no more than 10%, no more than 5%, or substantially none of the heat required to form molten waste plastic in the melting tank 312 is provided via indirect heat transfer through the surface or interior of the melting tank 312. Typically, in some embodiments, the melting tank 312 may not include internal heating elements or an external heat jacket. Therefore, in such embodiments, the heat required to form molten waste plastic may originate solely from the external heat exchanger 340 and / or from heated molten waste plastic returned to the melting tank 312 from the circulation loop.

[0307] Furthermore, in one or more embodiments, the halogen-enriched gaseous material stream 162 may be removed from the outlet of the phase separation vessel 320, which is typically located at or near the top of the phase separation vessel 320, and / or from the outlet of the melting vessel 312, which is located at or near the top of the phase separation vessel 320.

[0308] In one embodiment or in combination with any of the embodiments mentioned herein, halogen-depleted molten waste plastic is produced by liquefaction system 40 at a rate of at least 2,000, at least 10,000, at least 25,000, at least 50,000, or at least 100,000 pounds per hour.

[0309] Figure 6 Alternative embodiments of the melting tank system 310 and the circulation loop are depicted. It should be understood that... Figure 6 An exemplary embodiment of a liquefaction system 40 in the form of a melting tank system 310 is depicted. 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 herein. It should be noted that, unless otherwise stated, Figure 6 All components described above can be used in conjunction with the above. Figure 1 , 4 It operates in the same way as the same components described in 5.

[0310] Figure 6 An alternative melting tank structure is described, which does not include an external heat exchanger. Instead, in Figure 6 In its construction, an internal heating system 350 is provided in the melting tank 312 to provide the heat required to form molten waste plastic. In one embodiment or in combination with any of the embodiments mentioned herein, this internal heating system may take the form of one or more internal heat exchange coils located in the melting tank 312. Figure 6As shown, molten plastic from melting tank 312 can be transferred via a circulation loop to stripper 330 to form a two-phase mixture, which can then be separated in phase separation vessel 320. The resulting halogen-poor molten plastic can be reintroduced into melting tank via line 159 (for further processing and / or to provide supplemental heating) and / or conveyed downstream via line 161 for further processing in pyrolysis reactor 60 and / or POX vaporizer 50.

[0311] Figure 7 Alternative embodiments of the melting tank system 310 and the circulation loop are depicted. It should be understood that... Figure 7 An exemplary embodiment of a liquefaction system 40 in the form of a melting tank system 310 is depicted. 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 herein. It should be noted that, unless otherwise stated, Figure 7 All components described above can be used in conjunction with the above. Figure 1 and 4 -6 describes the same components that operate in the same way.

[0312] Figure 7 An alternative melting tank structure is described that does not use a phase-separating vessel. Instead, in Figure 7 In its construction, the melting tank system 310 includes two melting tank circulation loops (pipelines 171, 173, and 175) arranged in series, wherein each melting tank circulation loop includes a melting tank 312, an external heat exchanger 340, and a stripping tower 330. Halogen-deficient molten plastic can be formed by sequentially processing in each of these melting tank circulation loops. Figure 7 As shown, molten plastic from melting tank 312 can be transferred via a circulation loop to heat exchanger 340 to form heated molten plastic. The heated molten plastic can then be fed to stripping tower 330 to form a two-phase mixture. This two-phase mixture can then be reintroduced into melting tank 312, where it can be separated into a halogen-enriched gaseous byproduct stream 164 (and removed from the system) and a halogen-depleted molten liquid stream 171. The resulting halogen-depleted molten plastic can be recycled in the first circulation loop and / or sent via pipe 161 in the second melting tank circulation loop for further processing. After sufficient treatment in the second melting tank circulation loop, the resulting halogen-depleted molten waste plastic can be sent downstream for further processing in pyrolysis reactor 60 and / or POX vaporizer 50.

[0313] although Figure 7The liquefaction system is described as having only two melt tank circulation loops, but it is feasible for the system to include more melt tank circulation loops. For example, the liquefaction system may include at least three, at least four, at least five, at least six, at least seven, or at least eight melt tank circulation loops connected in parallel and / or in series.

[0314] Figure 8 Alternative embodiments of the melting tank system and circulation loop are described. It should be understood that... Figure 8 An exemplary embodiment of a liquefaction system 40 in the form of a melting tank system 310 is depicted. Figure 8 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 8 The system described herein. It should be noted that, unless otherwise stated, Figure 8 All components described above can be used in conjunction with the above. Figure 1 and 4 -7 describes the same components that operate in the same way.

[0315] Figure 8 An alternative melting tank construction is described, which does not use a phase-separating vessel and an external stripping tower. Instead, in Figure 8 In its construction, the melting tank configuration includes two melting tank circulation loops placed in series, wherein each melting tank circulation loop includes a melting tank 312 and an external heat exchanger 340. Furthermore, each of the melting tanks 312 includes an internal ejector 360 for introducing a stripping gas stream 153 into the molten waste plastic within the melting tank 312. Halogen-depleted molten plastic can be formed by sequential processing in each of these melting tank circulation loops.

[0316] like Figure 8 As shown, molten plastic from melting tank 312 can be transferred via a circulation loop to heat exchanger 340 to form heated molten plastic, which can then be returned to melting tank 312. While in melting tank 312, molten waste plastic can be ejected with a stripping gas stream 153 from an internal ejector 360 located in melting tank 312 to form a two-phase mixture. Subsequently, this two-phase mixture can be separated into a halogen-enriched gaseous byproduct stream 164 (and removed from the system) and a halogen-depleted molten liquid. The resulting halogen-depleted molten plastic can be recycled in a first circulation loop and / or sent to a second melting tank circulation loop for further processing. After sufficient treatment in the second melting tank circulation loop, the resulting halogen-depleted molten waste plastic can be sent downstream via pipe 161 for further processing in pyrolysis reactor 60 and / or POX vaporizer 50.

[0317] although Figure 8The liquefaction system is described as having only two melt tank circulation loops, but it is feasible for the system to include more melt tank circulation loops. For example, the liquefaction system may include at least three, at least four, at least five, at least six, at least seven, or at least eight melt tank circulation loops connected in parallel and / or in series.

[0318] Figure 9 Alternative embodiments of the melting tank system and circulation loop are described. It should be understood that... Figure 9 An exemplary embodiment of a liquefaction system 40 in the form of a melting tank system 310 is depicted. Figure 9 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 9 The system described herein. It should be noted that, unless otherwise stated, Figure 9 All components described above can be used in conjunction with the above. Figure 1 and 4 -8 describes the same components that operate in the same way.

[0319] Figure 9 An alternative melting tank structure is described that does not use a phase-separated vessel, external heat exchanger, or external stripping tower. Instead, in Figure 9 In the configuration, two melting tanks 312 are placed in series, each of which includes an internal heating system 350 and an internal ejector 360 for introducing a stripping gas stream 153 into the molten waste plastic within the melting tank 312. Halogen-deficient molten plastic can be formed by sequential processing in each of these melting tanks 312. When in each of the melting tanks 312, the molten waste plastic can be ejected with a stripping gas stream 153 from the internal ejector 360 located in the melting tank 312 to form a two-phase mixture. Subsequently, this two-phase mixture can be separated into a halogen-enriched gaseous byproduct stream 164 (and removed from the system) and a halogen-deficient molten liquid. After sufficient treatment in the second melting tank 312, the resulting halogen-deficient molten waste plastic can be sent downstream via pipe 161 for further processing in a pyrolysis reactor 60 and / or a POX vaporizer 50.

[0320] although Figure 9 A liquefaction system can be described as consisting of only two melting tanks connected in series, but it is feasible for the system to include more melting tanks connected in series. For example, a liquefaction system may include at least three, at least four, at least five, at least six, at least seven, or at least eight melting tank circulation loops connected in parallel and / or in series.

[0321] Figure 10 Alternative embodiments of the melting tank system and circulation loop are described. It should be understood that... Figure 10 An exemplary embodiment of a liquefaction system 40 in the form of a melting tank system 310 is depicted. Figure 10Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 10 The system described herein. It should be noted that, unless otherwise stated, Figure 10 All components described above can be used in conjunction with the above. Figure 1 and 4 -9 describes the same components that operate in the same way.

[0322] Figure 10 An alternative melting tank construction is described, which does not use a phase-separating vessel, stripping tower, and ejector. Instead, in Figure 10 In its construction, the melting tank configuration includes four melting tank circulation loops arranged in series, each melting tank circulation loop comprising a melting tank 312 and an external heat exchanger 340. Halogen-depleted molten plastic can be formed by sequentially processing in each of these melting tank circulation loops. Figure 10 As shown, molten plastic from melting tank 312 can be transferred via a circulation loop to heat exchanger 340 to form heated molten plastic, which can then be returned to melting tank 312. In each melting tank circulation loop, a halogen-enriched gaseous byproduct stream 164 can be formed (and removed from the system) and separated from the molten plastic. The resulting halogen-depleted molten plastic can be recycled in the circulation loop and / or sent to the next melting tank circulation loop for further processing. After sufficient treatment in the fourth melting tank circulation loop, the resulting halogen-depleted molten waste plastic can be sent downstream via pipe 161 for further processing in pyrolysis reactor 60 and / or POX gasifier 50.

[0323] As described above, in one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the synthesis gas stream 128 from POX facility 50 and / or at least a portion of the pyrolysis vapor from pyrolysis facility 60 may be delivered via line 178 to any of the external heat exchangers 340 in order to recover heat from these streams back into the circulation loop of liquefaction system 40.

[0324] although Figure 10 The system is described as having only four molten tank circulation loops, but it is feasible for the system to include more molten tank circulation loops. For example, a liquefaction system may include at least three, at least four, at least five, at least six, at least seven, or at least eight molten tank circulation loops connected in parallel and / or in series.

[0325] Figure 11 and 12 An exemplary external stripping tower 330 that can be used in the liquefaction system 40 is depicted, particularly in the melting tank system 310 described herein. It should be understood that... Figure 11 and 12An exemplary embodiment of the stripping tower 330 is depicted. Figure 11 and 12 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 11 and 12 The external stripping tower 330 is described above. It should also be noted that this external stripping tower 330 can be configured in accordance with the above-mentioned... Figure 4-10 The stripping tower 330 described herein shall operate in the same manner unless otherwise stated.

[0326] Figure 11 An exemplary stripping tower 330 that can be used in the liquefaction system 40, such as the melting tank system 310 described herein, is depicted. Figure 12 Depicting Figure 11 The image depicts a cross-sectional view of the stripping tower 330. (See image for reference.) Figure 11 As shown, molten plastic can be introduced into stripping tower 330 via pipes in the circulation loop. In stripping tower 330, stripping gas can be introduced into the molten plastic via injection pipe 360 ​​including multiple gas distribution holes 362. For example... Figure 11 and 12 As shown, the liquid level of the molten plastic is maintained above the injection pipe 360 ​​to facilitate the distribution of stripping gas into the molten plastic.

[0327] like Figure 11 and 12 As shown, injecting stripping gas into the molten liquid results in the formation of a two-phase mixture comprising a gas phase and a liquid phase. Furthermore, the outlet of the stripping tower may include a contraction section 332 (e.g., Figure 11 (As shown), thereby regulating the flow of the two-phase mixture from the stripping tower. Alternatively, in Figure 11 As not shown in the diagram, the contraction section 332 can be in the form of a weir.

[0328] like Figure 12 As shown, the spray nozzle 362 can be positioned at a defined angle below the transverse axis of the spray tube 360 ​​relative to the transverse axis of the spray tube. For example, the spray nozzle 362 can be positioned below the transverse axis of the spray tube 360 ​​at an angle of at least 10 degrees, at least 20 degrees, at least 30 degrees, or at least 40 degrees and / or no more than 90 degrees, no more than 80 degrees, no more than 70 degrees, no more than 60 degrees, or no more than 50 degrees relative to the horizontal axis. Typically, in some embodiments, the spray nozzle 362 can be positioned below the transverse axis of the spray tube 360 ​​at an angle of 10 to 90 degrees, 20 to 80 degrees, 30 to 70 degrees, or 40 to 60 degrees.

[0329] Switch to phase separation container 320. Figure 13An exemplary configuration including a stripping tower 330 and a multi-stage phase separation vessel 420 is depicted, which can be used in a liquefaction system 40, such as the melting tank system 310 described herein. It should be understood that... Figure 13 An exemplary embodiment of the construction of the stripping tower 330 and the phase separation vessel 420 that can be used is described. (The following can be omitted.) Figure 13 Some of the features shown herein and / or other features described elsewhere in this document may be added to Figure 13 The stripping tower 330 and phase separation vessel structure 430 are shown. It should also be noted that the phase separation vessel 420 and stripping tower 330 can be configured in accordance with the above-mentioned... Figure 4-12 The phase separation vessel 320 and stripping tower 330 described herein operate in the same manner unless otherwise stated.

[0330] like Figure 13 As shown, a two-phase mixture from a stripping tower can be introduced into a multi-stage phase-separated container 420, which is described as a gravity-flow, multi-level, tray-containing vessel. The two-phase medium formed in the stripping tower 330 can flow (e.g., by gravity) through multiple levels of the phase-separated container 420 defined by separated trays 422, such as... Figure 13 As shown, when flowing between multiple tray levels 422 in the phase separation vessel 420, the halogen-rich gas phase (G) can be separated from the halogen-depleted molten plastic phase (L). The flow of the two-phase mixture can be controlled by using a weir 424 on each tray 422, as... Figure 13 As shown.

[0331] like Figure 13 As shown, the halogen-enriched gas phase (G) can exit from the top of the phase separation vessel 420, while the halogen-depleted molten plastic phase (L) can be collected at the bottom of the vessel via an alternative piping structure. Figure 13 As shown, the conduit from the bottom of the phase separation vessel 420 can be configured to introduce at least a portion of the liquefied plastic through conduit 428 to the top of the melting tank 312 and / or through conduit 430 to the bottom of the melting tank 312. Therefore, the halogen-depleted molten plastic phase can be reintroduced into the melting tank 312. Additionally or alternatively, at least a portion of the halogen-depleted molten plastic phase can be sent downstream for treatment via conduit 427 to the pyrolysis reactor and / or POX vaporizer.

[0332] although Figure 13The multistage phase-separating container 420 is described as having five individual stages or trays 422, but the multistage phase-separating container 420 may have a different number of stages or trays 422. For example, the multistage phase-separating container 420 may include at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least or 8 and / or no more than 30, no more than 25, no more than 20, no more than 15, or no more than 10 stages or trays 422. Typically, in some embodiments, the multistage phase-separating container 420 may contain 2 to 30 trays, 4 to 25 trays, 5 to 20 trays, or 8 to 15 trays.

[0333] Figure 14 Alternative embodiments of the phase separation vessel 320 that can be used in the liquefaction system 40 are depicted, such as the melting tank system 310 described herein. It should be understood that... Figure 14 An exemplary embodiment of the phase separation container 520 is depicted. Figure 14 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 14 The container 520 is depicted in the diagram. It should also be noted that the phase-separating container 520 can be configured in accordance with the above-mentioned... Figure 4-12 The phase-separating container 320 described herein operates in the same manner as otherwise noted.

[0334] like Figure 14 As shown, the phase separation vessel 520 can be in the form of a finger-shaped vessel, which is another type of gravity-flow, multi-level vessel containing trays. Figure 14 The finger-shaped container 520 can be used with Figure 13 The phase-separating container 420 shown works in a similar manner. For example... Figure 14 As shown, molten plastic is introduced into the top level (or "finger") 522 of container 520 and is allowed (e.g., by gravity) to flow through multiple levels (i.e., fingers) 522 of container 520. As it flows between the multiple levels 522 in container 520, a halogen-rich gas phase (G) can separate from the halogen-depleted molten plastic phase (L). The flow of the two-phase mixture can be controlled by using a weir 524 on each finger 522, as... Figure 14 As shown.

[0335] like Figure 14 As shown, the halogen-enriched gas phase (G) can exit from the top of the finger container 520, while the halogen-depleted molten plastic phase (L) can be collected at the bottom of the container. The halogen-depleted molten plastic phase can then be reintroduced into the melting tank and / or sent downstream to the pyrolysis reactor and / or POX gasifier for further processing.

[0336] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 14As depicted, each of the fingers 522 in container 520 may include an optional ejector 560 to distribute stripping gas into the molten plastic, thereby increasing the formation of a two-phase mixture in the container. It is conceivable that only a single finger 522 may include an ejector 560, some of the fingers 522 may include an ejector 560, or all of the fingers 522 may include an ejector 560. The ejector 560 may be associated with... Figure 11 and 12 The injector 360 described herein operates in the same manner as otherwise noted.

[0337] Exemplary finger containers and systems are described in U.S. Patent 7,872,089, the entire disclosure of which is incorporated herein by reference without conflict with the present disclosure.

[0338] although Figure 14 The finger container 520 is depicted as having four individual levels or fingers 522, but the finger container 520 may have a different number of levels or fingers 522. For example, the finger container 520 may include at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8 and / or no more than 30, no more than 25, no more than 20, no more than 15, or no more than 10 levels or fingers 522. Typically, in some embodiments, the finger container 520 may include 2 to 30, 3 to 25, 4 to 20, 5 to 15, or 6 to 10 levels or fingers 522.

[0339] In one embodiment or in combination with any of the embodiments mentioned herein, the viscosity of the liquefied molten plastic stream leaving the liquefaction system 40, such as the melting tank system 310, can 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 40, less than 30, less than 25, less than 20, less than 10, less than 5, less than 4, less than 3, less than 2 or less than 1 poise and / or at least 0.1, at least 0.2 or at least 0.5 poise, were measured using a Borelfeld R / S rheometer with a V80-40 paddle rotor, which operated at a shear rate of 10 rad / s and a temperature of 350°C. For example, the viscosity of the liquefied molten plastic stream leaving the liquefaction system 40 (e.g., melting tank system 310) can be 0.1 to 3,000 poise, 0.1 to 800 poise, 0.1 to 500 poise, 0.1 to 250 poise, 0.1 to 75 poise, 0.1 to 50 poise, 0.1 to 10 poise, 0.1 to 5 poise, or 0.1 to 1 poise, and is 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.

[0340] In one embodiment or in combination with any embodiment mentioned herein, the viscosity of the liquefied plastic stream leaving the liquefaction system 40 (e.g., melting tank system 310) (measured at 350°C and 10 rad / s and expressed in poise) is no more than 95%, no more than 90%, no more than 75%, no more than 50%, no more than 25%, no more than 10%, no more than 5%, or no more than 1% of the viscosity of the waste plastic stream introduced into the liquefaction system 40.

[0341] In one embodiment or in combination with any of the embodiments mentioned herein, the halogen content of the halogen-depleted molten waste plastic leaving the liquefaction system 40 (e.g., melting tank system 310) can 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.

[0342] In one embodiment or in combination with any embodiment mentioned herein, the halogen content of the liquefied plastic stream leaving the liquefaction system 40 (e.g., melting tank system 310) 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 waste plastic stream introduced into the liquefaction system 40.

[0343] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream from liquefaction system 40 to one or more downstream chemical recovery facilities such as melting tank system 310 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, based on the total weight of the feed streams introduced into one or more downstream processing facilities. For example, feed streams 116, 118, 120, and 122 of each of POX facility 50, pyrolysis facility 60, cracking facility 70, energy recovery facility 80, and / or any other facility 90 of chemical recovery facility 10 may include PO enriched waste plastics and a quantity of one or more solvent decomposition byproducts described herein.

[0344] Additionally or alternatively, the feed stream to the pyrolysis facility 60, POX facility 50, cracking facility 70, energy recovery facility 80 and / or any other facility 90 may contain no more than 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 2 or 1 wt% of one or more solvent decomposition byproduct streams, based on the total weight of the feed streams introduced into one or more downstream processing facilities.

[0345] Alternatively or additionally, the liquefied (or reduced viscosity) plastic stream drawn from the liquefaction system 40 (e.g., melting tank system 310) 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 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 35, not exceeding 30, not exceeding 25, not exceeding 20, not exceeding 15, not exceeding 10, not exceeding 5, not exceeding 2 or not exceeding 1 wt% of polyolefin, based on the total weight of the stream, or the amount of polyolefin may be in the range of 1 wt%-95 wt%, 5 wt%-90 wt%, or 10 wt%-85 wt%, based on the total weight of the stream.

[0346] like Figure 1As shown, at least a portion (alone or in combination with one or more solvent decomposition byproduct streams) of the PO-enriched plastic stream from the pretreatment facility 20 and / or from the liquefaction system 40 may be introduced into one or more downstream treatment facilities, including, for example, a pyrolysis facility 60, a cracking facility 70, a POX gasification facility 50, an energy recovery facility 80, and any other optional facilities 90 discussed in detail herein.

[0347] like Figure 4-11 As shown, at least a portion of halogen-depleted liquefied waste plastics from a liquefaction system (e.g., a melting tank system) can be introduced into a downstream POX gasifier at a POX gasification facility to produce a syngas composition and / or into a downstream pyrolysis reactor at a pyrolysis facility to produce pyrolysis vapors (i.e., pyrolysis gas and pyrolysis oil) and pyrolysis residues. These methods will be described in more detail below.

[0348] pyrolysis

[0349] In one embodiment or in combination with any of the embodiments mentioned herein Figure 1 The chemical recycling facility 10, as generally described herein, 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., essentially oxygen-free) atmosphere. A "pyrolysis facility" includes all the equipment, piping, and control devices necessary for carrying out the pyrolysis of waste plastics and raw materials derived therefrom.

[0350] Figure 15 An exemplary pyrolysis facility is described for converting waste plastics, such as liquefied waste plastics from liquefaction zone 40, into pyrolysis gas, pyrolysis oil, and pyrolysis residues. It should be understood that... Figure 15 An exemplary embodiment of the present technology is depicted. Therefore, Figure 15 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 15 The system described in the text.

[0351] Usually, such as Figure 15 As shown, the pyrolysis facility includes a pyrolysis membrane reactor 600, a solids separator 630 (e.g., a filtration system, a multistage separator, a condenser, and / or a quench tower), and a gas separation unit 640 (e.g., a filtration system, a multistage separator, a condenser, and / or a quench tower) for separating the pyrolysis effluent 170 into a pyrolysis residue stream 180, a pyrolysis oil stream 174, and a pyrolysis gas stream 172. When in the pyrolysis reactor 600, at least a portion of the feed stream 161 from the liquefaction system 40 can undergo a pyrolysis reaction, producing a pyrolysis effluent 170 comprising pyrolysis oil, pyrolysis gas, and pyrolysis residue.

[0352] As used herein, the term "pyrolysis gas" refers to a composition obtained by pyrolysis that is gaseous at 25°C and 1 atm. 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 carbon-containing composition obtained by pyrolysis that is solid at 200°C and 1 atm. As used herein, the term "pyrolysis heavy wax" refers to C20+ hydrocarbons obtained by pyrolysis that are not pyrolysis coke, pyrolysis gas, or pyrolysis oil.

[0353] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 161 of the pyrolysis facility may comprise at least one of one or more solvent decomposition byproduct streams, PO enriched waste plastic streams, and combinations thereof as described above. Additionally or alternatively, one or more of these streams may be introduced into the pyrolysis facility continuously, or one or more of these streams may be introduced intermittently. When multiple types of feed streams are present, each may be introduced individually, or all or part of the streams may be combined, such that a combined stream may be introduced into the pyrolysis facility. When this is done, the combination may be carried out continuously or intermittently. The feed introduced into the pyrolysis facility may be in the form of liquefied plastics (e.g., liquefied, plasticized, depolymerized, or combinations thereof), plastic pellets or granules, or a slurry thereof.

[0354] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 15 As shown, the feed stream 161 of the pyrolysis facility may be derived from the liquefaction system 40 described herein. For example, the feed stream 161 of the pyrolysis facility may include or consist of a liquefied plastic feed stream, such as halogen-depleted molten waste plastic, which has been derived from the liquefaction system 40 described herein. Therefore, any plastic feed processed and described above with respect to the liquefaction system 40, including the melting tank system 310, can be introduced into the pyrolysis facility.

[0355] In addition, such as Figure 15 As shown, at least a portion of the pyrolysis oil stream 174 formed by the pyrolysis membrane reactor 600 can be introduced into the liquefaction system 40 via line 143 to serve as a dissolving solvent, as previously discussed. Additionally or alternatively, at least a portion of the pyrolysis residue streams 176 and 180 and / or the pyrolysis oil stream 174 can be introduced via line 143 into the feed stream 161 fed into the pyrolysis membrane reactor 600, allowing these streams to undergo additional conversion.

[0356] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 161 to the pyrolysis facility comprises halogen-depleted molten waste plastics with a halogen content of 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.

[0357] In one embodiment or in combination with any embodiment mentioned herein, the liquefied plastic feed stream 161 to the pyrolysis facility comprises at least 10, at least 15, at least 25, at least 50, at least 75, or at least 90 and / or no more than 99, no more than 98, 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, or no more than 30 wt% of one or more polyolefins. Additionally or alternatively, the liquefied plastic feed stream to the pyrolysis facility comprises no more than 20, no more than 15, 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 0.1, or no more than 0.01 wt% of PET and / or PVC.

[0358] 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.

[0359] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reactor 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.

[0360] In one embodiment or in combination with any of the embodiments mentioned herein, and as Figure 15 As shown, the pyrolysis reactor includes a membrane reactor 600, such as a falling film reactor, a wiped film reactor, a structured packing reactor, a parallel wires reactor, a parallel wires reactor, a vacuum film reactor, a perforated plate reactor, and / or an upstream tubular reactor.

[0361] The membrane reactor 600 can be configured to receive a liquefied plastic feed stream 161 (e.g., molten waste plastic) and allow the liquefied plastic feed to flow in a fixed direction (e.g., upward or downward) along a fixed membrane formation structure within the reactor 600 under certain temperature and pressure conditions, thereby pyrolyzing the liquefied waste plastic and forming a pyrolysis effluent stream 170 containing pyrolysis gas and pyrolysis oil. During the pyrolysis reaction, the flowing liquefied plastic feed can at least partially coat the fixed membrane formation structure, thereby forming membranes, bubbles, and / or particles on these structures. The flow rate of the liquefied plastic feed to each membrane formation structure (e.g., a tube) can be at least 0.1, at least 0.5, at least 1, at least 2, at least 3, or at least 5 and / or no more than 500, no more than 400, no more than 300, no more than 200, no more than 100, or no more than 50 L / h, or 0.1 to 500, 0.5 to 400, or 5 to 200 L / h. Typically, the feed rate of the liquefied plastic can be maintained to promote film formation on the film-forming structure. Excessively high feed rates may negatively impact film formation on the fixed film-forming structure.

[0362] In one embodiment or in combination with any of the embodiments mentioned herein, the fixed membrane generation structure includes tubes, lines, plates (e.g., parallel plates), rings, saddles, sheets, grids, screens, and / or meshes. Additionally or alternatively, in one or more embodiments, the fixed membrane generation structure includes plates and / or tubes with geometrically perturbed structures. It should be noted that the geometry of these perturbed structures is not limited and may include, for example, triangular, square, and / or rectangular perturbed structures.

[0363] The advantage of membrane reactor 600 is that it typically does not require moving mechanical parts (e.g., agitators) to form a membrane on a fixed membrane-forming structure. Instead, membrane reactors are generally designed to promote the formation of passive surface regions of the membrane on the fixed membrane-forming structure, thereby facilitating the pyrolysis reaction.

[0364] The pyrolysis membrane reactor 600 may include only a single falling film reactor, or alternatively, it may include two or more pyrolysis membrane reactors connected in series or in parallel.

[0365] Exemplary falling film reactors that can be used in pyrolysis reactors are described in Chinese Patent No. CN203582812U, U.S. Patent Application Publication No. 2009 / 0093600, U.S. Patent Application Publication No. 2006 / 0251547, and U.S. Patent No. 7,453,393, the entire disclosures of which are incorporated herein by reference without conflict with the present disclosure.

[0366] Figure 16An exemplary falling film pyrolysis reactor 600 that can be used as a pyrolysis membrane reactor is depicted. It should be understood that... Figure 16 An exemplary embodiment of a falling film reactor is described. Figure 16 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 16 The reactor described above. It should also be noted that the falling film reactor 600 can be compared with the above-mentioned... Figure 15 The falling film reactor described herein shall operate in the same manner unless otherwise stated.

[0367] like Figure 16 As shown, the falling film reactor includes a reaction section located between a top feed section 602 and a bottom collection section 604. The top feed section 602 and the bottom collection section 604 are separated from the reaction section via an orifice plate 606. The orifice plate 606 may include a plurality of orifices 608. The geometry of the orifices 608 is not particularly limited, and the orifices 608 can have any geometry (e.g., circular, rectangular, elliptical, etc.). The feed section 602 also includes an inlet 610 for liquefied plastic feed and an outlet 612 for pyrolysis vapors, including pyrolysis gas and vaporized pyrolysis oil. Similarly, the bottom collection section 604 includes an outlet 614 for pyrolysis residues.

[0368] The reaction section may include one or more membrane-forming structures 616, which in Figure 16 The orifice plate 606 is depicted as a plurality of tubes 616, which may be located at and between the orifices 608 within the orifice plate 606. As described above, the orifice plate 606 may include a plurality of orifices 608, and each of these orifices 608 may be associated with the membrane formation structure 616. Although in Figure 16 The tube 616 is depicted, but it is conceivable that other membrane-forming structures 616 could be used as alternatives.

[0369] Furthermore, in one embodiment or in combination with any of the embodiments mentioned herein, the falling film reactor 60 may include three or more tubes 616, such as Figure 16 As shown in the diagram. For example, the falling film reactor 600 may include 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, at least 15, at least 16, at least 17, at least 18, at least 19 or at least 20 and / or no more than 500, no more than 400, no more than 300, no more than 200 or no more than 100 membrane formation structures 616, or 2 to 500, 3 to 400, 5 to 200 or 10 to 100 membrane formation structures 616.

[0370] The size and length of the tube 616 are not particularly limited, and any size and length can be used as needed. For example, the vertical length of the tube 616 can be in the range of 0.5 to 50 m, 1 to 40 m, or 2 to 30 m.

[0371] like Figure 16 As shown, liquefied plastic (e.g., molten waste plastic) can be introduced into the top feed section 602 of reactor 600 and allowed to flow downwards along the inside of pipe 616 (by gravity or by pressurized flow via a pump). As it falls along pipe 616, the liquefied plastic feed is free-falling and forms films, bubbles, or particles along the inner wall of pipe 616. Due to the temperature and pressure conditions within reactor 600, these formed films, bubbles, and / or particles can be effectively pyrolyzed. During the pyrolysis of the liquefied waste plastic, the resulting pyrolysis vapors (formed primarily from non-condensable pyrolysis gas and vaporized pyrolysis oil) exit at the top of the falling film reactor, while the pyrolysis residue flows along the pipe to the bottom collection section, where it can be removed.

[0372] The heat supplied to the falling film reactor can be provided by external or internal sources, such as internal or external heating coils, heating jackets, and / or the injection of a heating medium (e.g., steam) into the reactor. An exemplary external source may include placing the falling film reactor 600 inside a furnace vessel.

[0373] The rate at which liquefied plastic feed is introduced into reactor 600 can be adjusted by overflow outlet 618, such as Figure 16 As shown, the bottom of the overflow outlet 618 can be aligned with the desired height for maintaining the plastic feed level within the unit. Excess plastic feed can exit the reactor 600 via the overflow outlet 618 and be sent to an external feed tank (not shown), where it can be recycled back to the reactor's feed inlet.

[0374] Additionally or alternatively, the reactor may include an optional level control (LC) device. Typically, the flow rate of the liquefied plastic feed into the falling film reactor 600 is regulated to maintain a constant mass flow rate and to promote effective surface area formation (i.e., film formation) in a manner that avoids overflow of the film-forming structure 616 (e.g., a tube). It is important to maintain the feed rate into the pyrolysis reactor 600 at a specific, designated rate, as introducing too much feed into the feed section 602 at once can negatively impact film formation within the tube 616. The flow rate can be significantly influenced by the number and shape of the fixed film-forming structure 616, the size of the orifices 608 in the orifice plate 606, the size of the reactor 600, and the viscosity of the liquefied plastic feed. The flow rate of the liquefied plastic feed to each membrane formation structure 616 (e.g., tube) may be at least 0.1, at least 0.5, at least 1, at least 2, at least 3 or at least 5 and / or not more than 500, not more than 400, not more than 300, not more than 200, not more than 100 or not more than 50 liters per hour, or 0.1 to 500, 0.5 to 400, 1 to 300, or 3 to 100 liters per hour.

[0375] The flow rate of the liquefied plastic feed can also be controlled at least in part by the disturbance structure 620 located at the top of the tube 616. Figure 17 and 18 Different types of perturbation structure 620 configurations that can be used for membrane generation structure 616 are depicted.

[0376] Figure 17 Depicting from Figure 16 A close-up cross-sectional view of the top of tube 616. (See image.) Figure 17 As shown, the tube 616 includes a plurality of triangular perturbation structures 620 at its top, which help regulate the flow of liquefied plastic feed into the tube 616. Therefore, these triangular perturbation structures 620 can promote the formation of a film in the tube 616 based on the controlled flow of liquefied plastic feed.

[0377] Figure 18 Alternative embodiments of the perturbation structure 624 are depicted. For example... Figure 18 As shown, the disturbance structure 624 is not located at the top of the tube 616; instead, the disturbance structure 624 takes the form of a hole formed within the wall of the tube 616. These holes 624 can have any geometry, although... Figure 18 Describe them as having a rectangular shape. For example... Figure 18 As shown, these perforated structures 624 can help regulate the flow of liquefied plastic feed into pipe 616 to facilitate film formation.

[0378] Alternatively, in one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis membrane reactor 600 may comprise an upflow membrane reactor 700. Figure 19An exemplary upflow membrane pyrolysis reactor 700 that can be used as a pyrolysis membrane reactor 600 is depicted. It should be understood that... Figure 19 An exemplary embodiment of an upflow membrane reactor 700 is depicted. Figure 19 Some features described herein may be omitted and / or additional features described elsewhere in this document may be added. Figure 19 The reactor 700 is depicted in the image.

[0379] like Figure 19 As shown, the upflow membrane reactor 700 includes a phase-separation section 702, which allows pyrolysis vapors (mainly formed by pyrolysis gas and vaporized pyrolysis oil) to separate from the pyrolysis residues. Figure 19 As shown, the upflow membrane reactor 700 includes a reaction section 704 located between a bottom feed section 706 and a top section 708. The bottom feed section 706 and the top section 708 can be separated from the reaction section 704 via an orifice plate 710, which may include a plurality of orifices 712. The geometry of the orifices 712 is not particularly restricted, and the orifices 712 can have any geometry (e.g., circular, rectangular, elliptical, etc.). The feed section 706 also includes an inlet 714 for feeding liquefied plastic, and the top section 708 includes an outlet 716 leading to a phase separation vessel 702.

[0380] Reaction section 704 may include one or more membrane formation structures 718, which in Figure 19 The orifice plate 710 is depicted as a plurality of tubes 718, which can be positioned at and between holes 712 within the orifice plate 710. As described above, the orifice plate 710 may include a plurality of holes 712, and each of these holes 712 may be associated with a membrane formation structure 718. Although in Figure 19 The tube 718 is depicted, but it is conceivable that other membrane generation structures 718 could be used as alternatives.

[0381] Furthermore, in one embodiment or in combination with any of the embodiments mentioned herein, the upflow membrane reactor 700 may include more than four tubes 718, for example... Figure 19 As shown in the diagram. For example, the upflow membrane reactor 700 may include 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, at least 15, at least 16, at least 17, at least 18, at least 19 or at least 20 and / or no more than 500, no more than 400, no more than 300, no more than 200 or no more than 100 membrane generation structures 718, or 2 to 500, 3 to 400, 4 to 300 or 10 to 100 membrane generation structures 718.

[0382] The size and length of the tube 718 are not particularly limited, and any size and length can be used as needed. For example, the vertical length of the tube 718 can be in the range of 0.5 to 50m, 1 to 40m, or 2 to 30m.

[0383] like Figure 19 As shown, liquefied plastic (e.g., molten waste plastic) can be introduced into the bottom feed section 706 of reactor 700 and allowed to flow upwards within the tube via pump 720. As it flows upwards along tube 718, the liquefied plastic feed undergoes pyrolysis conditions, leading to bubble formation. The bubbles travel upwards along the tube and form a film on the inner wall of tube 718 as they expand. This thus provides high heat transfer with a boiling effect. The resulting pyrolysis effluent generated within tube 718 can then be introduced into a horizontal phase-separating section 702 to separate the pyrolysis residue from the pyrolysis vapor, which is primarily composed of vaporized pyrolysis oil and non-condensable pyrolysis gas. The pyrolysis residue can be recovered from outlet 722 back to the bottom of the pyrolysis reactor or removed from the system. The pyrolysis vapor is removed from the top of the horizontal phase-separating section through outlet 724. Although in Figure 16 It is not shown in the figure, but this horizontal phase separation vessel can also be used in conjunction with the falling film reactor 600, with the same capacity as that used in the upflow film reactor 700.

[0384] The heat supplied to the upflow membrane reactor 700 can be provided by an external or internal source, such as internal or external heating coils, heating jackets, and / or the injection of a heating medium (e.g., steam) into the reactor. An exemplary external source may include placing the upflow membrane reactor 700 within a furnace vessel.

[0385] Exemplary upstream containers and systems are described in U.S. Patent 7,531,618, the entire disclosure of which is incorporated herein by reference without conflict with the present disclosure.

[0386] 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, the atmosphere within the pyrolysis reactor may contain no more than 5%, 4%, 3%, 2%, 1%, or 0.5% oxygen based on the internal volume of reactor 8.

[0387] 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 the feedstock into the pyrolysis reactor and / or to promote various reactions within the pyrolysis reactor. For example, the riser gas and / or feed gas may comprise 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 with the waste plastics prior to introduction into the pyrolysis reactor and / or may be added directly to the pyrolysis reactor. The riser gas and / or feed gas may include steam and / or reducing gases, such as hydrogen, carbon monoxide, and combinations thereof.

[0388] Furthermore, the temperature in the pyrolysis reactor 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, including the pyrolysis membrane reactor, 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.

[0389] Additionally or alternatively, the pyrolysis temperature in a pyrolysis reactor, including a pyrolysis membrane 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 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.

[0390] In one embodiment or in combination with any embodiment mentioned herein, the residence time of the feedstock in the pyrolysis reactor (including a pyrolysis membrane 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 0.1 to 10 seconds, 0.5 to 10 seconds, 30 minutes to 4 hours, or 30 minutes to 3 hours, or 1 hour to 3 hours, or 1 hour to 2 hours.

[0391] In one embodiment or in combination with any of the embodiments mentioned herein, the residence time of the feedstock in the pyrolysis membrane reactor may be 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 seconds. Additionally or alternatively, the residence time of the feedstock in the pyrolysis membrane reactor may be no more than 300, no more than 250, no more than 200, no more than 150, no more than 100, 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, or no more than 15 seconds. More particularly, in one or more embodiments, the residence time of the feedstock in the pyrolysis membrane reactor may be in the range of 2 to 300 seconds, 3 to 250 seconds, or 4 to 40 seconds.

[0392] 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.

[0393] In one embodiment or in combination with any of the embodiments mentioned herein, the pressure within the pyrolysis membrane reactor can be maintained at less than 70, less than 60, less than 50, less than 40, less than 30, or less than 20 Torr. As used herein, unless otherwise stated, “Torr” refers to gauge pressure.

[0394] In one embodiment, or in combination with any of the embodiments mentioned herein, a pyrolysis catalyst may be introduced into the feed stream 116 prior to and / or directly into the pyrolysis reactor 500. 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 reactor 510 to facilitate heat transfer. Such a catalyst-free pyrolysis process may be referred to as “thermal pyrolysis”.

[0395] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reaction in the pyrolysis reactor 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.

[0396] 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. The pyrolysis effluent or pyrolysis vapor may contain pyrolysis oil in the range of 20wt%-99wt%, 25wt%-80wt%, 30wt%-85wt%, 30wt%-80wt%, 30wt%-75wt%, 30wt%-70wt%, or 30wt%-65wt%, based on the total weight of the pyrolysis effluent or pyrolysis vapor.

[0397] 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. The pyrolysis effluent or pyrolysis vapor 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, based on the total weight of the stream.

[0398] 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. 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% based on the total weight of the stream.

[0399] 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 (as a liquid or vapor) pre-added to the pyrolysis unit and water generated in the pyrolysis unit.

[0400] The pyrolysis system described herein can produce pyrolysis effluents, which 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 although all the following characteristics and properties may 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 may exist in any combination.

[0401] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may primarily comprise hydrocarbons (e.g., C4 to 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 includes 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”. 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%, based on the total weight of the pyrolysis oil stream 174.

[0402] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may primarily comprise C5-C30 hydrocarbons, C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons. For example, 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-C30 hydrocarbons, C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons, based on the total weight of the pyrolysis oil.

[0403] In one embodiment or in combination with any embodiment mentioned herein, 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%, based on the total weight of the pyrolysis oil. 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%. The C5-C12 hydrocarbon content of the pyrolysis oil may be in the range of 10 wt%-95 wt%, 20 wt%-80 wt%, or 35 wt%-80 wt%, based on the total weight of the stream.

[0404] 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.

[0405] 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%.

[0406] 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.

[0407] 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.

[0408] The methane content of the pyrolysis gas can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, or at least 15 and / or no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, or no more than 20 wt%, based on the total weight of the pyrolysis gas. In one embodiment or in combination with any embodiment mentioned herein, the methane content of the pyrolysis gas can be 1 wt%-50 wt%, 5 wt%-50 wt%, or 15 wt%-45 wt%.

[0409] In one embodiment or in combination with any embodiment mentioned herein, the C3 and / or C4 hydrocarbon content (including all hydrocarbons having 3 or 4 carbon atoms per molecule) of the pyrolysis gas 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, or at least 60 and / or not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, or not more than 65 wt%, based on the total weight of the pyrolysis gas. The C3 hydrocarbon content, C4 hydrocarbon content, or combined C3 and C4 hydrocarbon content of the pyrolysis gas may be in the range of 10 wt%-90 wt%, 25 wt%-90 wt%, or 25 wt%-80 wt%.

[0410] In one embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas may comprise at least 10, at least 20, at least 30, at least 40, or at least 50 wt% of the total effluent from the pyrolysis reactor, and the 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%.

[0411] 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 includes all alkenes, alkanes, and isomers having that number of carbon atoms.

[0412] In one embodiment or in combination with any embodiment mentioned herein, the pyrolysis residue comprises at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% carbon-containing solids, based on the total weight of the pyrolysis residue. Additionally or alternatively, the pyrolysis residue comprises no more than 99, no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, or no more than 4 wt% carbon-containing solids. As used herein, “carbon-containing solids” refers to a carbon-containing composition obtained from pyrolysis and is solid at 25°C and 1 atm. 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, based on the total weight of the carbon-containing solids.

[0413] 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 can 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 of the aforementioned other facilities 90, 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 can be introduced into the energy recovery facility 80, the cracking facility 70, the POX gasification facility 50, and combinations thereof, while the pyrolysis residue stream 176 can be introduced into the POX gasification facility 50 and / or the energy recovery facility 80. In some embodiments, at least a portion of the pyrolysis gas stream 172, the pyrolysis oil stream 174, and / or the pyrolysis residue stream 176 can be fed to one or more separation facilities (…). Figure 1 (Not shown in the text), thereby forming a purer stream of pyrolysis gas, pyrolysis oil, and / or pyrolysis residues, which can then be fed to energy recovery facility 80, cracking facility 70, and / or POX gasification facility 50. Additionally or alternatively, all or a portion of the pyrolysis oil stream 176 may be combined with the PO-enriched waste plastic stream 114 to provide a liquefied plastic stream as feed to one or more downstream facilities as described herein.

[0414] Cracking

[0415] In one embodiment or in combination with any of the embodiments mentioned herein, the material from pyrolysis facility 60 or from... Figure 1At least a portion of one or more streams from one or more other facilities shown is 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 an apparatus 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.

[0416] Turn now Figure 20 This illustration shows a cracking facility 70 configured according to one or more embodiments of the present technology. Typically, the cracking facility 70 includes a cracker 820 and a separation zone 740 downstream of the cracker 820 for separating the furnace effluent into various final products, such as a recoverable olefin (r-olefin) stream 130. Figure 20 As shown, at least a portion of the pyrolysis gas stream 172 and / or pyrolysis oil stream 174 from the pyrolysis facility 60 can be sent to the cracking facility 70. The pyrolysis oil stream 174 can be introduced into the inlet of the cracking furnace 820, while the pyrolysis gas stream 172 can be introduced into a location upstream or downstream of the furnace 820. Similarly... Figure 20 As shown, the stream of alkanes 132 (e.g., ethane and / or propane) can be withdrawn from the separation zone and may include recovered alkanes (r-alkanes). All or part of the alkanes can be recovered via stream 134 to the inlet of cracker 820, as well as... Figure 20 As shown. 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 820.

[0417] In one embodiment or in combination with any of the embodiments mentioned herein, the feed stream 119 to the cracking facility 70 may comprise at least one of the following: (i) one or more solvent decomposition byproduct streams 110 as described above, (ii) a PO-enriched waste plastic stream 114, 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 facility 70 continuously or intermittently. When multiple types of feed streams are present, each may be introduced individually or all or part of the streams may be combined, such that a combined stream may be introduced into the cracking facility 70. When performed, the combination may be carried out continuously or intermittently. One or more feed streams introduced into the cracking facility 70 may be in the form of a predominantly gaseous stream, a predominantly liquid stream, or a combination thereof.

[0418] like Figure 20As shown, the streams of pyrolysis gas 172 and / or pyrolysis oil 174 may be introduced into the cracking facility 70 together with or as part of the cracker feed stream 136. In some embodiments, 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, based on the total weight of the stream 119. Alternatively or additionally, the 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, based on the total weight of stream 119, or it may contain amounts of these components in the range of 1 wt%-95 wt%, 5 wt%-90 wt%, or 10 wt%-85 wt%, based on the total weight of stream 119.

[0419] In some embodiments, 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, based on the total weight of the cracker feed stream 119, or 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, based on the total weight of the cracker feed stream 119.

[0420] In one embodiment or in combination with any of the embodiments mentioned 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 no more than 100, or no more than 99, or no more than 95, or no more than 92, or no more than 90, or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60, in each case, as a weight percentage of C2-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.

[0421] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream 119 may comprise a composition primarily containing C5-C22 hydrocarbons. As used herein, “primarily containing C5-C22 hydrocarbons” means a feed stream or composition comprising at least 50 wt% C5-C22 hydrocarbon components. Examples include gasoline, naphtha, middle distillates, diesel, and kerosene.

[0422] In one embodiment or in combination with any embodiment mentioned herein, 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-C22 or C5-C20 hydrocarbons, based on the total weight of the stream, or may contain an amount of C5-C22 hydrocarbons in the range of 20wt%-100wt%, 25wt%-95wt%, or 30wt%-85wt%, based on the total weight of the stream.

[0423] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream 119 may have a C15 and heavier (C15+) content of 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 based on the total weight of the feed, or may be in the range of 0.5wt%-40wt%, 1wt%-35wt%, or 2wt%-30wt%, based on the total weight of the stream.

[0424] In one embodiment or in combination with any of the embodiments mentioned herein, the feed to the cracker may include vacuum gas oil (VGO), hydrogenated vacuum gas oil (HVGO), or atmospheric gas oil (AGO). 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 or at least 90 and / or not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55 or not more than 50 wt% of at least one gas oil, based on the total weight of the stream 119, or it may be present in an amount in the range of 5 wt%-99 wt%, 10 wt%-90 wt%, or 15 wt%-85 wt%, or 5 wt%-50 wt%, based on the total weight of the stream 119.

[0425] like Figure 20 As shown, the cracker feed stream 119 is introduced into the cracking furnace 820. Now turning... Figure 21 A schematic diagram of a cracker 820 suitable for the chemical recovery and / or cracking facilities described herein is shown. Figure 21 As shown, the cracking furnace 820 may include a convection section 846, a radiation section 848, and a cross section 850 located between the convection section 846 and the radiation section 848. The convection section 846 is part of the furnace that receives heat from the hot flue gas and includes a row of tubes or coils 852 through which the cracker flow passes. In the convection section 846, the cracker flow is heated by convection from the hot flue gas passing through it. Although in Figure 21The diagram shows a horizontally oriented convection section tube 852a and a vertically oriented radiation section tube 852b, but it should be understood that the tubes can be constructed in any suitable configuration. For example, the convection section tube 852a can be vertical, and the radiation section tube 852b can be horizontal. Additionally, although shown as a single tube, the cracker 820 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.

[0426] The radiant section 848 is a section of furnace 820 that primarily transfers heat to the heater tubes via radiation from the high-temperature gas. The radiant section 848 also includes multiple burners 856 for introducing heat into the lower part of furnace 820. Furnace 820 includes a firebox 854 that surrounds and houses the tubes 852b within the radiant section 848, and the burners 856 are oriented into this firebox. The cross section 850 includes conduits for connecting the convection section 846 and the radiant section 848, and can transfer heated cracker flow from one section to another, either inside or outside furnace 820.

[0427] As hot combustion gases rise through the furnace body, they can pass through convection section 846, where at least a portion of the waste heat can be extracted and used to heat the cracker stream passing through convection section 846. Cracking furnace 820 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 860 near the furnace body controls the flow of hot flue gas and the heating distribution through furnace 820, and one or more heat exchangers 861 are available for cooling the furnace effluent. In addition... Figure 21 The heat exchanger 861 at the furnace outlet shown (e.g., a delivery line heat exchanger or TLE), or alternatively with... Figure 21 Together with the exchanger 861 at the furnace outlet shown, the cracked olefin-containing effluent 125 can be cooled using liquid quenching (not shown).

[0428] In one embodiment or in combination with any of the embodiments mentioned herein, cracking facility 70 may include a single cracking furnace, or may have at least two, three, four, five, six, seven, eight or more cracking furnaces operating in parallel. Any one 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 weight of all cracker feeds to the furnace.

[0429] In one embodiment or in combination with any of the embodiments mentioned herein, the cracker 820 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.

[0430] 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% by weight of the feed is vapor) (“gas coil”) at a coil inlet at the convection zone inlet. The gas coil may receive a predominantly C2-C4 or predominantly C2-C3 feedstock to the coil inlet 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.

[0431] 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 vapor phase feed at its coil inlet at the inlet of the convection zone, in which at least 60 wt%, or at least 70 wt%, or at least 80 wt%, or at least 90 wt%, or at least 95 wt%, or at least 97 wt%, or at least 98 wt%, or at least 99 wt%, or at least 99.5 wt%, or at least 99.9 wt% of the feed is vapor.

[0432] 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 (greater than 50% of the feed weight is liquid) at its coil inlet at the convection zone inlet.

[0433] 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.

[0434] 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 862, such as... Figure 21 As shown.

[0435] In one embodiment or in combination with any of the embodiments mentioned herein, when from Figure 1 When two or more streams from the chemical recovery facility 10 are combined with another stream from facility 10 to form cracker feed stream 119, such combination can occur upstream of or within the cracker furnace 820. Alternatively, different feed streams can be introduced into furnace 820 individually and can pass through part or all of furnace 820 simultaneously, while being isolated from each other by feeding into separate tubes within the same furnace 820 (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 cracking facility downstream of the cracker but upstream of one or more facilities in the separation facility.

[0436] The heated cracker stream 119 then passes through the cracking furnace 820, 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 furnace 820 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 not more than 2, or not more than 1.75, or not more than 1.5, or not more than 1.25, or not more than 1, or not more than 0.9, or not more than 0.8, or not more than 0.75, or not more than 0.7, or not more than 0.65, or not more than 0.6, or not more than 0.5 seconds in each case, or it can be in the range of 0.15 to 2 seconds, 0.20 to 1.75 seconds, or 0.25 to 1.5 seconds.

[0437] The temperature of the cracked olefin effluent 125 withdrawn 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. 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 in °C, within the range of 730 to 900 °C, 750 to 875 °C, or 750 to 850 °C.

[0438] 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%. 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, based on the total weight of the effluent.

[0439] In one embodiment or in combination with any of the embodiments mentioned herein, the olefin-containing effluent 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. The effluent 125 may consist primarily of ethylene, primarily of propylene, or primarily of both ethylene and propylene, based on the total weight of the olefin-containing effluent 125. 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, not exceeding 2:1, not exceeding 1.7:1, not exceeding 1.5:1, or not exceeding 1.25:1.

[0440] Turn again Figure 20 In one embodiment or in combination with any of the embodiments mentioned herein, when introduced into the cracking facility 70, pyrolysis gas 172 may be introduced into the inlet of the cracking furnace 820, or all or part of the pyrolysis gas may be introduced downstream of the furnace outlet, upstream of or within the separation zone 840 of the cracking facility 70. When introduced into or upstream of the separation zone 840, 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 section of the separation zone 840.

[0441] Prior to entering the cracking unit 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. The pyrolysis gas stream 172 introduced into the cracking unit 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, based on the total weight of the pyrolysis gas stream 172.

[0442] In one embodiment or in combination with any embodiment mentioned herein, the total ethylene content of the pyrolysis gas 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 stream 172. Alternatively or additionally, the total propylene content of the pyrolysis gas 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 stream 172. The total amount of ethylene and propylene in the pyrolysis gas stream 172 may be at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40 or at least 45 wt% and / or not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50 or not more than 45 wt%, based on the total weight of the stream.

[0443] Upon exiting the cracker outlet, 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 scaling in downstream facilities. 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.

[0444] 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, optionally with 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, CO, 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-stripping tower configuration may be employed.

[0445] 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 of 20 to 50 barg, 25 to 45 barg, or 30 to 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 sent 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.

[0446] In one embodiment, or in combination with any of the embodiments mentioned herein, a feed stream from the quenching section may be introduced into at least one column within the fractionation section 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 apparatus and methods utilizing fractionation include, but are not limited to, distillation, rectification, stripping, and gas-liquid separation (single-stage).

[0447] In one embodiment or in combination with any of the embodiments mentioned herein, the fractionation section of a cracking 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.

[0448] 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, as well as additional streams, including, for example, methane and a lighter component and butane and a heavier component.

[0449] In one embodiment or in combination with any embodiment mentioned herein, 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, 99, 97, 95, 90, 85 or 80 wt% of olefins, based on the total weight of the olefin stream. The olefins may be primarily ethylene or primarily propylene. 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 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 olefins in 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, based on the total weight of the olefin stream, or it may be present in amounts of 20 wt%-80 wt%, 25 wt%-75 wt%, or 30 wt%-70 wt%, based on the total weight of the olefin stream.

[0450] Alternatively or additionally, 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, based on the total weight of the olefins in the olefin stream. In one embodiment or in combination with any embodiment mentioned herein, 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, based on the total weight of the olefin stream, or it may be present in amounts of 20 wt%-80 wt%, 25 wt%-75 wt%, or 30 wt%-70 wt%, based on the total weight of the olefin stream.

[0451] 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°C, or at least -142°C, or at least -140°C, or at least -135°C, in each case, and / or not exceeding -120°C, not exceeding -125°C, not exceeding -130°C, not exceeding -135°C. The bottom stream from the demethanizer 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, or at least 99 (in each case, a percentage of the total amount) of ethane and heavier components.

[0452] 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 C2 and lighter components introduced into the column in the overhead stream, as a percentage of the total amount in each case. 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, as a weight percentage in each case, based on the total weight of the overhead stream.

[0453] In one embodiment or in combination with any of the embodiments mentioned herein, the C2 and lighter overhead streams from the de-ethaner 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 taken 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.

[0454] 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, based on the total weight of the bottom stream. 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.

[0455] 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.

[0456] In one embodiment or in combination with any of the embodiments mentioned herein, the overhead stream from a propane stripper can be introduced into a propane-propylene fractionator (propylene fractionator or propylene splitter), 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...

Claims

1. A method for dehalogenating waste plastics, comprising: (a) Liquefying solid waste plastics to produce liquefied waste plastics; (b) Inject stripping gas into the liquefied waste plastic to produce a multiphase mixture; and (c) Separating the gas phase and liquid phase of the multiphase mixture to provide halogen-enriched gaseous materials and halogen-depleted liquefied waste plastics; The liquefaction includes liquefying at least a portion of the solid waste plastic in a melting tank in the presence of at least one dissolving solvent, wherein the dissolving solvent comprises pyrolysis oil; the total feed stream introduced into the liquefaction comprises 1 wt% to 50 wt% of the at least one dissolving solvent, based on the total weight of the feed stream; A heat exchanger is provided outside the melting tank; wherein the liquefaction includes: (i) circulating the liquefied waste plastic in a loop through the melting tank and the heat exchanger, and (ii) heating the liquefied waste plastic in the heat exchanger while circulating it in the loop; and The spraying is performed using an injector located downstream of the heat exchanger and upstream of the molten tank in the circulation loop. At least a portion of the halogen-depleted liquefied waste plastic is returned to the melting tank for further liquefaction, and at least a portion of the halogen-depleted liquefied waste plastic is removed for further processing in a downstream facility; the ratio of halogen-depleted liquefied waste plastic returned to the melting tank to the removed halogen-depleted molten waste plastic is from 0.1:1 to 40:

1. The heat used to form the liquefied waste plastic in the melting tank comes only from the heat exchanger and / or the heated liquefied waste plastic returned to the melting tank.

2. The method according to claim 1, wherein, The stripping gas includes nitrogen, steam, methane, carbon monoxide, hydrogen, or a combination thereof.

3. The method according to claim 1, wherein, The melting tank is maintained at a temperature of 200 to 500°C.

4. The method according to claim 1, wherein, The phase separation is performed using a phase separation container in the circulation loop, the phase separation container being located downstream of the ejector and upstream of the melting tank.

5. The method according to claim 1, wherein, The halogen content of the halogen-depleted liquefied waste plastic does not exceed 100 ppmw.

6. The method according to claim 1, wherein, The chemical recovery facility is in fluid communication with the heated halogen-depleted molten waste plastic, wherein the chemical recovery facility includes a partial oxidation (POX) gasification facility, a pyrolysis facility, a cracking facility, or a combination thereof.

7. A waste plastic dehalogenation system, comprising: (a) A liquefaction system for at least partially liquefying solid waste plastics into liquefied waste plastics in the presence of at least one dissolving solvent; wherein the dissolving solvent comprises pyrolysis oil; the total feed stream introduced into the liquefaction system comprises 1 wt% to 50 wt% of the at least one dissolving solvent, based on the total weight of the feed stream; the liquefaction system includes a melting tank and a heat exchanger disposed outside the melting tank; wherein the liquefaction comprises: (i) circulating the liquefied waste plastics in a loop through the melting tank and the heat exchanger, and (ii) heating the liquefied waste plastics in the heat exchanger while circulating them in the loop; (b) A halogen stripping tower configured to receive at least a portion of the liquefied waste plastic and inject stripping gas into the liquefied waste plastic to form a multiphase mixture; the halogen stripping tower is located downstream of the heat exchanger and upstream of the melting tank; and (c) A phase separation container configured to receive the multiphase mixture and separate the gaseous and liquid phases of the multiphase mixture, thereby providing halogen-enriched gaseous material and halogen-depleted molten waste plastic; At least a portion of the halogen-depleted molten plastic waste is returned to the melting tank for further liquefaction, and at least a portion of the halogen-depleted molten plastic waste is removed for further processing in a downstream facility; the ratio of halogen-depleted molten plastic waste returned to the melting tank to the removed halogen-depleted molten plastic waste is from 0.1:1 to 40:

1. The heat used to form molten waste plastic in the melting tank comes solely from the heat exchanger and / or from the halogen-depleted molten waste plastic returned to the melting tank.

8. The system according to claim 7, wherein, The phase-separating container includes a gravity flow, multi-level container with trays.

9. The system according to claim 7, wherein, The phase separation vessel is in fluid communication with a chemical recovery facility, which includes a partial oxidation (POX) gasification facility, a pyrolysis facility, a cracking facility, or a combination thereof.

10. The system according to claim 7, wherein, The melting tank includes a continuously stirred tank.

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