Integrated system and method for producing polyamides from recycled components

Abstract

A method of producing a polyamide 66 polymer from at least one cyclic atomic component is disclosed. For example, the recycled atomic component may comprise a fluid obtained from biomass or from an industrial waste stream, such as an industrial gas stream that would otherwise be released into the environment. The produced polyamide 66 polymer not only contains a large number of cyclic atoms, but also has excellent mechanical and physical properties.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 664,516, filed June 26, 2024, the entire contents of which are expressly incorporated herein by reference. Background Technology

[0003] Nylon is a synthetic polymer and a special type of polyamide polymer. Nylon is known for its toughness, strength, and elasticity. It also possesses a high melting point, good abrasion resistance, and excellent chemical resistance. These properties make nylon suitable for a wide range of applications.

[0004] Two widely used nylons include nylon 6 and nylon 66. Nylon 6 is made from a single monomer unit called caprolactam. Nylon 66, on the other hand, is made from two different monomer units. These two different monomer units contain a diamine (e.g., hexamethylenediamine) and adipic acid.

[0005] Nylon 66 can be used alone or in combination with nylon 6. For example, nylon 66 is typically used in the textile industry to produce fibers. Nylon 66 fibers can be used to make fabrics, carpets, and clothing.

[0006] Nylon 66 is also used in engineering plastics because of its high tensile strength, stiffness, heat resistance, and chemical resistance. For example, Nylon 66 can be used to manufacture automotive components, electrical connectors, and industrial machinery.

[0007] Nylon 66 is also found in a wide variety of consumer products, including toothbrush bristles, kitchen utensils, and furniture components. Due to its toughness and barrier properties, it is also used to produce packaging materials such as films and pouches. Because of its chemical resistance, Nylon 66 is also used in industrial applications such as bearings, gears, rollers, and washers.

[0008] Nylon, particularly nylon 66, is conventionally made from fossil-based components. However, efforts are underway to reduce the use of fossil materials. In particular, businesses are actively seeking ways to decrease the use of fossil fuels and lower carbon emissions.

[0009] In light of the above, there is currently a need for methods capable of generating bio-based components for producing nylon polymers, particularly nylon 66 polymers. There is also a need for nylon 66 polymers with an inherently cyclic (e.g., renewable or recaptured) atomic content. Summary of the Invention

[0010] Generally, this disclosure relates to an industrial method for producing polyamides, particularly polyamide 66 polymers. Polyamide 66 polymers are made from recycled adipic acid and / or recycled diamines. One or both of these monomers can be produced from renewable feedstocks, such as renewable natural gas sources, to incorporate renewable or recycled atoms, such as carbon atoms, into the polymer structure.

[0011] In one aspect, for example, this disclosure relates to a method for producing polyamide 66. The method includes forming a polyamide 66 polymer from a first monomer and a second monomer. At least a portion of the first monomer is formed from a recycled feedstock component, such as a recycled carbon feedstock (e.g., recycled natural gas). As used herein, a recycled feedstock refers to a component containing renewable atoms (e.g., from sources that can be replenished over a relatively short timeframe, such as less than about 100 years) or from recaptured atoms (e.g., atoms that are typically discarded or released into the atmosphere). The feedstock can be a recycled carbon feedstock. Many recycled feedstocks can be naturally regenerated or grown through sustainable practices. Recycled feedstocks can be obtained from biomass, bio-based products, recycled materials, or atom capture processes, such as capturing carbon emissions from industrial processes. According to this disclosure, the recycled feedstock is used directly to produce other components that thus contain recycled atoms, or as an energy source in various process steps. The first monomer may contain a diamine. The second monomer may contain adipic acid. In one aspect, the recycled feedstock may contain recycled or renewable natural gas.

[0012] According to this disclosure, the resulting polyamide 66 polymer has a recycling atom content of at least about 10% by weight, for example, at least about 14% by weight, for example, at least about 18% by weight, for example, at least about 20% by weight, for example, at least about 25% by weight, for example, at least about 30% by weight, for example, at least about 35% by weight, for example, at least about 41% by weight. The recycling atom content can be determined according to a suitable recycling atom certification process. In one aspect, the recycling atom content can be determined according to the International Sustainability and Carbon Certification (ISCC) rule ISCC-PLUS v3.4.2, which is incorporated herein by reference. The ISCC certification process is a globally recognized sustainability certification system that certifies the chain of custody to track the sustainability characteristics of the supply chain. It covers various sectors, including agriculture, forestry, bioenergy, chemicals, and polymer processes. The ISCC certification rules ensure that the sourcing and processing of materials and products are sustainable, reducing environmental impact and promoting social responsibility. ISCC certification ensures the proper application of a quality balance approach, which can be used to track the sustainability of raw materials throughout the supply chain. This involves tracking the quantity of certified and non-certified materials and ensuring that claims regarding sustainability can be verified. For example, this method allows for the calculation of the proportion of certified renewable (or recycled) content in a mixed batch of materials. During the calculation, carbon and non-carbon atoms can be tracked and incorporated into the calculation. More information on the ISCC mass balance methodology is available from ISCC, such as ISCC EU System Document 202, 2024, https: / / www.iscc-system.org / process / certification-process / system-documents / , which is incorporated herein by reference.

[0013] In one respect, the recycled or renewable natural gas contains bio-based methane, which contains more than about 80% by weight, for example more than about 85% by weight, for example more than about 90% by weight, for example more than about 95% by weight.

[0014] The first monomer containing a diamine may include hexamethylenediamine, 2-methylpentane-1,5-diamine, or a mixture thereof.

[0015] In the formation of the first monomer, renewable natural gas can be steam reformed to produce hydrogen, which combines with nitrogen to form ammonia. Ammonia can then combine with an additional amount of renewable natural gas to form hydrogen cyanide. Hydrogen cyanide can be used to form adiponitrile, which can be hydrogenated to form the first monomer. Ammonia, as described above, can be produced according to either an endothermic or exothermic reaction. Adiponitrile can be formed via the hydrocyanation of 1,3-butadiene. In one aspect, 1,3-butadiene can also be formed from a recycled carbon fraction comprising recycled pyrolysis oil, recycled cooking oil, recycled diesel oil, or recycled naphtha.

[0016] In an alternative embodiment, renewable natural gas can be steam reformed to produce hydrogen, which combines with nitrogen to form ammonia. The ammonia then combines with oxygen and propylene to form adiponitrile. Adiponitrile can be hydrogenated to form a first monomer. In this embodiment, propylene can be formed from a recycled carbon component, such as renewable natural gas, recycled pyrolysis oil, recycled naphtha, recycled diesel, or another type of recycled oil.

[0017] In one aspect, the ammonia used in this method includes blue ammonia, green ammonia, and / or blue-green ammonia.

[0018] The polyamide 66 polymer prepared according to this disclosure can be blended to possess excellent physical properties and characteristics. When tested according to ASTM test D789 and / or D4878, the relative viscosity of the polyamide 66 polymer can be from about 2.3 to about 3.2. The polyamide 66 polymer can be blended with various other components to produce molded articles. For example, in one embodiment, the polyamide 66 polymer can be bonded to glass fibers. The glass fibers can be present in the polymer composition in an amount from about 5% by weight to about 65% by weight. The polymer composition may also contain lubricants or release agents, antioxidants, UV stabilizers, etc. This disclosure also relates to molded articles made of polyamide 66 polymer. In one aspect, the molded article comprises an electrical connector.

[0019] In another aspect, this disclosure relates to a method for producing a polyamide 66 polymer, the method comprising the step of forming the polyamide 66 polymer from a first monomer and a second monomer, wherein the first monomer comprises a diamine, and wherein at least a portion of the second monomer is formed from a recycled carbon component. The recycled carbon component may comprise recycled or renewable natural gas. The second monomer may comprise adipic acid. The renewable natural gas may be steam reformed to produce hydrogen, which combines with nitrogen to form ammonia. Ammonia may be identified as blue ammonia, green ammonia, or blue-green ammonia, which can combine with water and oxygen to form nitric acid. Nitric acid may be used to oxidize ketol oil to form adipic acid.

[0020] In yet another embodiment, this disclosure relates to the production of polyamide 66 polymers, wherein at least a portion of the first monomer and at least a portion of the second monomer are formed from the same recycled atomic component. For example, the recycled atomic component may comprise recycled natural gas, such as renewable natural gas.

[0021] Other features and aspects of the invention will be discussed in detail below. Attached Figure Description

[0022] The full and practical disclosure of this invention is set forth in more detail in the remainder of the specification, including with reference to the accompanying drawings, in which:

[0023] Figure 1This is a flowchart of one embodiment of a method for producing polyamide 66 according to the present disclosure;

[0024] Figure 2 yes Figure 1 A flowchart of a portion of the method shown;

[0025] Figure 3 This is another alternative embodiment of the flowchart for generating diamine monomers according to this disclosure;

[0026] Figure 4 This shows the production of adipic acid monomers. Figure 1 A portion of the flowchart;

[0027] Figure 5 This is one embodiment of an electrical connector that can be fabricated according to this disclosure; and

[0028] Figure 6 This is another embodiment of an electrical connector that can be manufactured according to this disclosure.

[0029] Reference numerals used repeatedly in this specification and accompanying drawings are intended to indicate the same or similar features or elements of the invention. Detailed Implementation

[0030] Those skilled in the art will understand that the detailed description herein is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the invention.

[0031] As used herein, the term "approximately" when used to modify a quantity or value refers to an approximate value that is greater than or less than the precisely specified quantity or value. The exact value of the approximation is determined in a manner that is deemed appropriate by those skilled in the art. The use of the term "approximately" conveys the idea that similar values ​​can produce equivalent results or effects.

[0032] For the sake of brevity and clarity, any numerical ranges listed in this disclosure refer to all values ​​within that range and are to be interpreted as support for claims of any listed subranges, the endpoints of which are integer values ​​within the specified range under discussion. As a hypothetical example, a disclosure of the range 1 to 5 should be considered to support claims of any of the following ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to 3; 3 to 5; 3 to 4; and 4 to 5.

[0033] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​listed. Rather, unless otherwise stated, each such dimension is intended to refer to the listed value and the functional equivalent range around that value. For example, a dimension disclosed as “40%” is intended to mean “approximately 40%”.

[0034] Generally, this disclosure relates to the production of polyamide polymers, particularly polyamide 66 polymers, in a more sustainable manner. According to this disclosure, recycled carbon components are used directly or indirectly to generate intermediate components and / or monomers for the production of polyamide 66 polymers. More specifically, according to this disclosure, a single recycled carbon component can be used in multiple methods for generating chemical components, which are then combined to form diamine monomers and / or adipic acid monomers in the production of polyamide polymers.

[0035] For example, the chemical synthesis of monomers used to produce polyamide 66 is somewhat complex and involves numerous steps in generating precursor chemicals. According to this disclosure, one or more cyclic carbon components can be used to generate a variety of precursor chemicals for monomer production. In one aspect, a single cyclic atomic component, such as a cyclic carbon component, can also be used to generate both diamine monomers and adipic acid monomers. In this way, this disclosure relates to an integrated method for producing polyamide polymers with the highest cyclic atomic content using cyclic atomic components from multiple pathways.

[0036] The polyamide polymers prepared according to this disclosure, particularly polyamide 66 polymers, can meet the sustainability needs of many manufacturers and customers. Polyamide 66 polymers can be used to produce all different types of products and articles in all different fields. For example, polyamide 66 polymers can be used to produce molded components and articles for the medical, automotive, electrical, food processing, and other industries. Manufacturers can incorporate polyamide 66 polymers into their products to meet renewable or bio-based content targets. Overall, polyamide 66 polymers prepared according to this disclosure can help manufacturers reduce their use of fossil fuels and lower their carbon emissions without sacrificing quality or mechanical properties in any way.

[0037] In one specific application, for example, polyamide 66 polymer can be used in electric vehicles that are not powered by fossil fuels. For instance, polyamide 66 polymer can be used to manufacture electrical connectors, battery housings, and other components for the vehicle interior.

[0038] The amount of cyclic atoms, such as renewable atoms (carbon and non-carbon), contained in the polyamide 66 polymer disclosed herein can be determined by any suitable method. For example, in one method, the polyamide 66 polymer can be certified according to the International Sustainability and Carbon Certification (ISCC). ISCC is a globally applicable sustainability certification system that covers a wide range of sustainable raw materials, including agricultural and forestry biomass, circular and bio-based materials and renewable energy, as well as materials with a carbon footprint below the industry average. ISCC can certify the quality balance method, which allows verification of the polymer's renewable components. In quality balance, renewable raw materials are attributed to selected products based on their respective chemical composition and formulation, taking into account all yields and losses. Key criteria for applying the quality balance method include raw material identification, chain of custody, and product declaration.

[0039] The quality balance approach enables the tracking of the quantity and sustainability characteristics of circular raw materials (e.g., renewable raw materials) in the value chain and their verifiable attribution to the final product. In one aspect, for example, the polyamide 66 polymer prepared according to this disclosure can have a circular atom content of at least about 10% by weight (e.g., renewable, recycled, etc.). For example, the circular atom content of the polyamide 66 polymer can be greater than about 14% by weight, for example, greater than about 18% by weight, for example, greater than about 22% by weight, for example, greater than about 30% by weight, for example, greater than about 35% by weight, for example, greater than about 40% by weight, for example, greater than about 45% by weight, for example, greater than about 50% by weight, for example, greater than about 55% by weight, for example, greater than about 60% by weight, for example, greater than about 65% by weight, for example, greater than about 70% by weight, for example, greater than about 75% by weight. The circular atom content of the polyamide 66 polymer is generally less than about 99% by weight, for example, less than about 90% by weight, for example, less than about 80% by weight. Due to the complex manner in which polyamide 66 monomers are formed, it has historically been difficult to obtain polyamide 66 polymers with any significant circular atom content. However, the methods disclosed herein allow for the incorporation of larger quantities of recycled atomic contents into polymers in an integrated, efficient, and elegant manner.

[0040] As described above, the chemical precursors of the monomers used to produce polyamide 66 are at least partially derived from the recycled atomic component. The recycled atomic component can vary depending on the specific application. For example, the recycled atomic component can contain a fluid, such as biogas. Biogas is, for example, a gas produced from biomass. For example, biogas is produced from solid waste landfills and anaerobic digester plants. Alternatively, the recycled atomic component can contain a recycled gas. For example, the recycled gas can be a gas obtained from industrial processes. For example, the recycled gas can be a gas that is collected rather than released into the atmosphere.

[0041] The recycled atomic component may comprise a gas or liquid, such as a hydrocarbon, as described above. In one aspect, the recycled atomic component comprises recycled natural gas. For example, the natural gas may be derived from biomass, such as plant by-products, animal by-products, cellulose by-products, etc. Alternatively, the natural gas may be a recycled gas from industrial processes, etc., that would otherwise be released into the environment. In one embodiment, as will be described in more detail below, the recycled carbon component, such as recycled natural gas, may be used in various methods to produce a chemical precursor, which is then used to produce monomers for the polyamide 66 polymer.

[0042] As described above, in one aspect, the recycled carbon component used to produce the polyamide 66 polymer may comprise recycled carbon gas, particularly recycled natural gas. Using recycled natural gas as a starting component in the methods of this disclosure to generate numerous chemical precursors offers many advantages and benefits. For example, the recycled gas, particularly recycled natural gas, may contain very little or no impurities, which prevents impurities from appearing in the final product and interfering with the physical properties of the polymer. For example, in one aspect, the recycled carbon component comprises recycled natural gas containing methane in an amount greater than about 80% by weight, for example, greater than about 85% by weight, for example, greater than about 90% by weight, for example, greater than about 93% by weight, for example, greater than about 95% by weight, for example, greater than about 97% by weight, for example, even greater than about 99% by weight.

[0043] refer to Figure 1 and Figure 2 This document illustrates one embodiment of a method for producing polyamide 66 polymer 10 from a recycled atomic component. As shown, the polyamide 66 polymer 10 is produced from two monomers, including a diamine monomer 12 in combination with adipic acid 14. The diamine monomer 12 may comprise, for example, hexamethylenediamine, 2-methylpentane-1,5-diamine, or mixtures thereof. According to this disclosure, both monomers 12 and 14 are at least partially formed from or derived from the recycled atomic component. Figure 1 and Figure 2 In the illustrated embodiment, the cyclic atomic component comprises cyclic methane 20. As shown, the cyclic methane 20 is used to generate hydrogen to produce ammonia, the ammonia is used to produce hydrogen cyanide, and the ammonia is used to produce nitric acid. In this way, the cyclic atomic component is inserted into at least three different pathways for forming two monomers 12 and 14 to maximize the amount of cyclic atoms contained in the polyamide polymer 10.

[0044] refer to Figure 2 ,Will Figure 1 The illustrated process flow diagram is used solely to generate diamine monomer 12, which may contain hexamethylenediamine. As shown, the method includes combining recycled methane 20 according to this disclosure with water 22 to form hydrogen gas 24. In this way, recycled hydrogen gas 24 is formed.

[0045] A common method for converting methane to hydrogen is steam reforming. In steam reforming, methane and steam combine in the presence of a catalyst to produce hydrogen and carbon monoxide. Carbon monoxide can react with the steam to produce more hydrogen, as described in detail in U.S. Patent No. 3,361,534, which is incorporated herein by reference. The steam and methane used for steam reforming can be maintained at high temperatures in the reaction chamber, such as greater than 400 degrees Fahrenheit, greater than 500 degrees Fahrenheit, greater than 600 degrees Fahrenheit, greater than 700 degrees Fahrenheit, or greater than 800 degrees Fahrenheit. Furthermore, the pressure can be increased to approximately atmospheric pressure, such as greater than 5 atmospheres, greater than 10 atmospheres, greater than 15 atmospheres, greater than 20 atmospheres, greater than 25 atmospheres, or greater than 30 atmospheres. Steam reforming can be carried out in the presence of a catalyst such as a nickel catalyst. However, it should be understood that the methods and process conditions described above are merely exemplary and do not limit the methods and products of this disclosure in any way.

[0046] As shown, circulating hydrogen 24 is then combined with nitrogen 26 to produce ammonia 28. In one aspect, ammonia 28 can be produced exothermically.

[0047] A method for producing recycled ammonia from hydrogen derived from recycled methane can be the Haber-Bosch process. The Haber-Bosch process is a reaction that can be carried out at high temperatures and pressures. Suitable temperatures can be greater than 750 degrees Fahrenheit, for example, greater than 900 degrees Fahrenheit, for example, greater than 1000 degrees Fahrenheit, for example, greater than 1150 degrees Fahrenheit. Furthermore, the method can be carried out at pressures greater than 200 atmospheres, for example, greater than 300 atmospheres, for example, greater than 400 atmospheres. The method can also use catalysts, including osmium or iron catalysts, but other metals such as ruthenium can also be included. In addition to the presence of a catalyst, promoters can be used, such as, but not limited to, molybdenum, potassium oxide, or potassium hydroxide. When using catalysts, high purity ammonia and recycled methane are advantageous when they are free from impurities such as sulfur, phosphorus, arsenic, or chlorine. It should be understood that the above methods and process conditions are merely exemplary and do not in any way limit the methods and products of this disclosure.

[0048] Alternatively, ammonia 28 can be generated by electrolysis. For example, in one embodiment, recycled hydrogen 24 and nitrogen 26 are introduced into an electrochemical cell. Within this cell, the nitrogen undergoes a reduction reaction, promoted by an electric current and possibly a catalyst, to produce ammonia.

[0049] The ammonia produced can be separated from the electrolyte and other byproducts. Separation techniques can include, for example, distillation or absorption. Any unreacted nitrogen or hydrogen can be recycled back into the electrochemical cell to improve efficiency and reduce waste. Exothermic methods for ammonia production can offer advantages over the Haber-Bosch process, such as the ability to operate under milder conditions and potentially lower energy requirements. However, the Haber-Bosch process may be better suited for large-scale scaling.

[0050] The ammonia produced according to this disclosure may be blue ammonia, green ammonia, and / or blue-green ammonia.

[0051] As used in this article, blue ammonia is ammonia produced using a method that significantly reduces carbon emissions compared to conventional methods. The production of blue ammonia involves generating hydrogen, which, compared to conventional methods, combines the hydrogen with nitrogen from the air, and synthesizes ammonia via the Haber-Bosch process. This method can incorporate carbon capture to ensure it remains low-carbon, making blue ammonia an environmentally friendly alternative to traditional ammonia production methods.

[0052] In the first step, hydrogen is produced. For example, steam methane reforming (SMR) can be used. During SMR, recycled natural gas (methane) is mixed with steam and heated to produce hydrogen (H2) and carbon monoxide (CO). By adding air and reacting over a catalyst, this H2, CO, and CH4 stream from SMR can be further converted via autothermal reforming (ATR) into a stream primarily containing H2, CO2, and N2. In other cases of producing blue hydrogen and blue ammonia, ATR is the primary reaction for producing the H2, CO2, and N2 stream. After CO2 removal, the H2 and N2 stream can be used for ammonia synthesis. In the case of blue ammonia, the CO2 generated during the process is captured and stored or utilized; this method is called carbon capture and storage (CCS) or carbon capture, utilization, and storage (CCUS). Most blue hydrogen and blue ammonia processes focus on capturing CO2 from within the reactor, where its concentration increases before being removed from the process. In one instance, blue hydrogen and blue ammonia can be produced from fossil natural gas. Capturing a portion of the CO2 from this method reduces the product's carbon footprint without altering its renewable content. Alternatively, renewable natural gas can be used to replace fossil natural gas to further reduce the carbon footprint of products and provide renewable content for downstream products.

[0053] Alternatively, hydrogen can be produced using electrolysis, where electricity is used to split water into hydrogen and oxygen. In one aspect, the electricity used for electrolysis can come from renewable or low-carbon sources (such as wind, solar, or hydropower), ensuring the electrolysis method is low-carbon. As described below, this method is generally referred to as green hydrogen.

[0054] Alternatively, renewable hydrogen can be produced by the pyrolysis of renewable methane to generate hydrogen and carbon black. This renewable hydrogen can be used to produce renewable ammonia with lower carbon emissions compared to conventional ammonia production methods. This method produces turquois hydrogen and turquois ammonia.

[0055] The method also involves obtaining a nitrogen source. Nitrogen (N2) is typically obtained from the air through a process known as air separation, in which atmospheric air is cooled and distilled to separate nitrogen from other components such as oxygen and argon.

[0056] Then, the Haber-Bosch process is used to combine hydrogen and nitrogen to produce blue ammonia. This involves reacting the gases under high temperature and pressure, with the aid of a catalyst, to produce ammonia (NH3).

[0057] As used in this article, green ammonia is produced using renewable energy, resulting in minimal carbon emissions throughout the production process. More specifically, green ammonia is produced by electrolyzing water with renewable electricity to generate hydrogen, obtaining nitrogen from the air, and synthesizing ammonia via the Haber-Bosch process, all powered by renewable energy. This reliance on renewable energy throughout the production process ensures that green ammonia has a minimal carbon footprint, making it a sustainable alternative to conventionally produced ammonia.

[0058] For example, hydrogen is initially produced through the electrolysis of water. Electricity is used in the electrolyzer to break down water (H2O) into hydrogen (H2) and oxygen (O2). For green ammonia, the electricity used in this process can come from renewable energy sources such as wind, solar, and hydropower, or by using recycled methane as a fuel source.

[0059] Nitrogen is also produced sustainably using air separation. Nitrogen (N2) is separated from atmospheric air. This is typically done via cryogenic distillation, in which air is cooled to very low temperatures and then distilled to separate nitrogen from other components such as oxygen and argon. The energy required for this method can also be derived from renewable energy sources to maintain green ammonia production standards.

[0060] The Haber-Bosch process is then used to produce green ammonia. Hydrogen and nitrogen are fed into the Haber-Bosch reactor. Under high temperature and pressure, in the presence of a catalyst, the gases react to produce ammonia (NH3). The energy required for this method can again be derived from renewable energy sources to ensure that the production chain remains low-carbon.

[0061] like Figure 2 As shown, the generated recycled ammonia 28 is then combined with a larger amount of recycled methane 20 to produce hydrogen cyanide 30 and possibly more hydrogen 32.

[0062] Methods for producing hydrogen cyanide can include the Andrussow process. In the Andrussow process, ammonia, methane, and oxygen react over a catalyst to form at least HCN. The catalyst may contain platinum and / or rhodium. Furthermore, the Andrussow process is carried out at temperatures above room temperature, such as above 1800 degrees Fahrenheit, above 1900 degrees Fahrenheit, above 2000 degrees Fahrenheit, or above 2100 degrees Fahrenheit. The reaction pressure can be atmospheric pressure or close to atmospheric pressure, such as less than 1 atmosphere or greater than 1 atmosphere. Pressures greater than atmospheric pressure can be greater than 2 atmospheres or greater than 3 atmospheres. Additionally, pressures can be less than 3 atmospheres, such as less than 2 atmospheres, less than 1 atmosphere, or less than 0.75 atmospheres. While there are no particular limitations on the reaction chamber, a preferred reaction chamber can be a series of tubes. This series of tubes may contain a catalyst bed, such as platinum or rhodium. The reaction chamber can be a conventional reactor. However, it should be understood that the above methods and method conditions are merely exemplary and do not limit the methods and products of this disclosure in any way.

[0063] Another method for producing hydrogen cyanide is the Degussa process, or the BMA method. The BMA method also uses methane and ammonia. The BMA method can be carried out at high temperatures, such as above 1900 degrees Fahrenheit, above 2000 degrees Fahrenheit, above 2100 degrees Fahrenheit, or above 2200 degrees Fahrenheit. Furthermore, the method can be carried out in the presence of a catalyst bed containing platinum. While the reaction chamber for the BMA method can be a conventional reactor, a specific reactor that can be used is a pipe internally coated with a platinum catalyst. In embodiments where the reaction chamber is a pipe, ammonia and methane are passed through the pipe. Ammonia and methane can be at atmospheric pressure, above atmospheric pressure, or below atmospheric pressure, such as above 1 atmosphere, above 2 atmospheres, or above 3 atmospheres. Additionally, the pressure can be less than 3 atmospheres, such as less than 2 atmospheres, less than 1 atmosphere, or less than 0.75 atmospheres. However, it should be understood that the above methods and method conditions are merely exemplary and do not in any way limit the methods and products of this disclosure.

[0064] Whether using the Andruse process or the BMA process, the hydrogen cyanide 30 produced according to this disclosure contains a large number of recycled atoms, including recycled carbon. For example, in one embodiment, all the carbon contained in the hydrogen cyanide 30 may comprise recycled carbon.

[0065] As shown, in one embodiment, hydrogen cyanide 30 is combined with butadiene 34 to produce adiponitrile 36.

[0066] Adiponitrile can be prepared by the hydrocyanation of 1,3-butadiene. In this type of reaction, hydrogen cyanide reacts with 1,3-butadiene to first form 3-pentenonitrile. As a byproduct of this reaction, 2-methyl-3-butenonitrile is produced. 2-methyl-2-butenonitrile isomerizes to 3-pentenonitrile. Finally, 3-pentenonitrile undergoes hydrocyanation to form adiponitrile. This method can be carried out at atmospheric pressure, above atmospheric pressure, or below atmospheric pressure, for example, greater than 1 atmosphere, for example, greater than 2 atmospheres, or greater than 3 atmospheres. Furthermore, the pressure can be less than 3 atmospheres, for example, less than 2 atmospheres, for example, less than 1 atmosphere, for example, less than 0.75 atmospheres. This method can be carried out in the presence of a catalyst. Additionally, elevated temperatures can be used, for example, greater than 300 degrees Fahrenheit, for example, greater than 400 degrees Fahrenheit, for example, greater than 500 degrees Fahrenheit, for example, greater than 600 degrees Fahrenheit, for example, greater than 700 degrees Fahrenheit. However, it should be understood that the above methods and method conditions are merely exemplary and do not limit the methods and products of this disclosure in any way.

[0067] In one aspect, butadiene 34 used to produce adiponitrile 36 can also have a cyclic atom content. For example, butadiene 34 can be produced from, for example, Figure 2 The circulating naphtha or circulating pyrolysis oil 38 shown is produced.

[0068] In one aspect, for example, butadiene 34 is produced from recycled naphtha. Recycled naphtha can be produced from biomass sources such as vegetable oils, animal fats, etc. The recycled naphtha is then subjected to steam cracking. In this method, the recycled naphtha is heated to a high temperature, for example, about 850°C to about 900°C, in the presence of steam. This causes larger hydrocarbon molecules to break down into smaller molecules. The products of steam cracking contain a mixture of various hydrocarbons, including butadiene 34. Butadiene can be separated from the resulting mixture through a series of purification steps, typically involving distillation, and sometimes other methods such as extraction or adsorption.

[0069] The isolated butadiene can undergo further purification to remove any residual impurities, ensuring the high purity of the final product. In this way, butadiene 34 can contain a majority of recycled atoms. In one aspect, for example, 100% of the carbon in the butadiene can contain recycled carbon.

[0070] Alternatively, such as Figure 2 As shown, butadiene 34 can be produced from recycled oil. Recycled oil can be cooking oil or pyrolysis oil.

[0071] In one aspect, biomass, such as wood, agricultural residues, or algae, undergoes pyrolysis. Pyrolysis involves heating biomass under anaerobic conditions, breaking it down into smaller molecules. This method typically occurs in the temperature range of approximately 400°C to approximately 700°C.

[0072] The steam produced during biomass pyrolysis is cooled, causing it to condense into a liquid mixture known as pyrolysis oil. This oil contains a variety of organic compounds, including butadiene precursors.

[0073] The pyrolysis oil is then subjected to separation and upgrading processes to isolate desired compounds, including butadiene. Fractionation techniques, such as distillation or solvent extraction, can be used to separate butadiene from other components in the pyrolysis oil. Depending on the composition of the pyrolysis oil, additional steps, such as hydrogenation or dehydration, can be used to convert certain compounds into butadiene. Hydrogenation can saturate double bonds in the molecule, while dehydration removes water molecules to promote butadiene formation.

[0074] The butadiene fraction obtained by the above method can undergo further purification to remove any residual impurities and contaminants.

[0075] During the production of butadiene using any of the methods described above, any other hydrocarbons produced during the process, such as C4 or C5 hydrocarbons, may be used as an energy source for the production of butadiene or for any other purpose within the process.

[0076] like Figure 2 As shown, adiponitrile produced from hydrogen cyanide 30 and butadiene 34 can combine with recycled hydrogen to produce diamine monomer 12.

[0077] For example, adiponitrile can be hydrogenated to form a diamine monomer. The diamine monomer may contain hexamethylenediamine or 2-methylpentane-1,5-diamine, although those skilled in the art will recognize that adiponitrile can be used to produce more diamines.

[0078] A method for hydrogenating adiponitrile to hexamethylenediamine may include reacting adiponitrile with hydrogen gas. The hydrogen gas used in the adiponitrile hydrogenation may be recycled hydrogen produced by the steam reforming method described above. This method is typically carried out at high temperatures, such as greater than 500 degrees Fahrenheit, greater than 600 degrees Fahrenheit, greater than 700 degrees Fahrenheit, greater than 800 degrees Fahrenheit, greater than 900 degrees Fahrenheit, greater than 1000 degrees Fahrenheit, or greater than 1100 degrees Fahrenheit. Furthermore, the pressure can be increased to approximately atmospheric pressure, such as greater than 5 atmospheres, greater than 10 atmospheres, greater than 15 atmospheres, greater than 20 atmospheres, greater than 25 atmospheres, or greater than 30 atmospheres. A catalyst, such as iron, nickel, or rhodium, may be used in the hydrogenation method. However, it should be understood that the above methods and method conditions are merely exemplary and do not limit the methods and products of this disclosure in any way.

[0079] Alternatively, the Androusso process and the BMA process described above can produce hydrogen as a byproduct in the formation of hydrogen cyanide. The hydrogen can contain a renewable component derived from the use of recycled natural gas and recycled ammonia in the process. Figure 1 As shown, renewable hydrogen byproducts can be captured. For example, a method for capturing hydrogen is described in WO2014099607A1, "Integrated Method for the Production of Hexamethylenediamine," which is incorporated herein by reference. By capturing and utilizing renewable hydrogen byproducts produced from the Androusso or BMA process using recycled natural gas or recycled ammonia feedstock, up to 7% by weight of recycled content can be introduced into hexamethylenediamine, and up to 3% by weight of recycled content can be introduced into polyamide 66 polymer. (Stoichiometry indicates that the hydrogen generated as a byproduct is 50% more than the hydrogen required for the hydrogenation of adiponitrile.)

[0080] In another embodiment, the diamine can be 2-methylpentane-1,5-diamine, also known as Dytek® A. 2-Methylpentane-1,5-diamine can be synthesized by hydrogenating 2-methylglutaronitrile.

[0081] The diamine monomer 12 prepared according to this disclosure may contain a large amount of recycled atoms, including carbon and non-carbon atoms. For example, the diamine monomer 12 may contain recycled carbon in an amount greater than about 30% by weight, for example greater than about 40% by weight, for example greater than about 45% by weight, for example greater than about 55% by weight, for example greater than about 65% by weight, for example greater than about 75% by weight, for example greater than about 80% by weight, for example greater than about 85% by weight, for example greater than about 90% by weight. For example, in various embodiments, the recycled atom content of the diamine monomer 12 may be between about 47% by weight and about 93% by weight.

[0082] like Figure 1 As shown, to produce polyamide 66 polymer, diamine monomer 12 reacts with adipic acid 14. (Reference) Figure 4 , showing Figure 1 This is part of an explanation of a pathway for producing adipic acid 14 from the cyclic carbon components of this disclosure.

[0083] As shown and described above, recycled methane 20 is steam reformed using water 22 to produce hydrogen 24. Hydrogen 24 is combined with nitrogen 26 to produce ammonia 28 as described above; ammonia 28 can be blue ammonia, green ammonia, or blue-green ammonia. Recycled ammonia 28 is then combined with oxygen 42 and water 44 to produce nitric acid 46. Oxygen 42, water 44, and recycled ammonia 28 are combined at high temperature in the presence of a catalyst to produce nitric acid 46.

[0084] Common reaction schemes are as follows:

[0085] (1)

[0086] Typically, this reaction is carried out at temperatures above 1000 degrees Fahrenheit, such as above 1200 degrees Fahrenheit, above 1400 degrees Fahrenheit, or above 1600 degrees Fahrenheit. Furthermore, the reaction is usually carried out in the presence of a rhodium and platinum mesh catalyst. Then, nitric oxide undergoes the reaction shown below:

[0087] (2)

[0088] Finally, nitrogen dioxide reacts with water according to the following reaction:

[0089] (3)

[0090] Typically, the first reaction is carried out at low pressure, while the second and third reactions are carried out at high pressure. The low pressure of the first reaction can be below 10 atmospheres, for example, below 5 atmospheres, for example, below 1 atmosphere, for example, below 0.5 atmospheres. The high pressure of the second and third reactions can be above 1 atmosphere, for example, above 5 atmospheres, for example, above 10 atmospheres, for example, above 15 atmospheres, for example, above 20 atmospheres. Subsequently, nitric acid is typically distilled by extractive distillation using sulfuric acid and a dehydrating agent. However, it should be understood that the above methods and process conditions are merely exemplary and do not limit the methods and products of this disclosure in any way.

[0091] like Figure 4 As shown, nitric acid 46 combines with ketol oil 48 to form adipic acid 14. Ketone oil 48 can be formed from recycled oil or recycled naphtha 50. For example, the recycled oil or naphtha can be derived from the aforementioned biomass. Figure 2 As shown, recycled oil or naphtha can be converted into benzene 51 or phenol 52. Benzene 51 then combines with hydrogen 54 to form cyclohexane 56. Alternatively, phenol 52 can combine with hydrogen 54 to form ketol oil 48. In one aspect, hydrogen 54 can be derived from recycled methane 20. Cyclohexane 56 combines with oxygen 58 to form ketol oil 48.

[0092] Nitric acid 46 then combines with ketol oil 48 to produce a second monomer 14, or adipic acid. Adipic acid can be formed by oxidizing ketol oil with nitric acid. Ketone oil is a mixture containing ketones and alcohols, particularly cyclohexanol and / or cyclohexanone. In the oxidation of ketol oil, nitric acid in concentrations ranging from 50% to 60% can be used. The reaction is carried out in the presence of a catalyst, typically a copper / ammonium metavanadate catalyst. This method typically produces byproducts, including nitrous oxide and hydrogen, which can optionally be reused or recycled. The reaction is typically carried out at temperatures above 150 degrees Fahrenheit, for example, above 250 degrees Fahrenheit, above 350 degrees Fahrenheit, or above 450 degrees Fahrenheit. Furthermore, the synthesis of adipic acid from ketol oil and nitric acid is typically carried out at pressures greater than atmospheric pressure, for example, greater than 5 atmospheres, greater than 10 atmospheres, greater than 15 atmospheres, or greater than 20 atmospheres.

[0093] like Figure 4 As shown, the adipic acid 14 prepared according to this disclosure can have a cyclic atom content greater than about 20%, for example greater than about 25%, for example greater than about 30%, for example greater than about 35%, for example greater than about 40%. The cyclic atom content of adipic acid is typically less than about 99%, for example less than about 80%.

[0094] refer to Figure 3 Alternative embodiments for generating diamine monomer 12 are shown. Similar reference numerals are used to indicate similar elements. Figure 3 In the implementation method, similar to Figure 2 In this embodiment, recycled methane 20 is steam reformed with water 22 to form hydrogen 24. Hydrogen 24 is combined with nitrogen 26 to produce ammonia 28.

[0095] However, in Figure 3 In the embodiment shown, acrylonitrile 70 containing recycled carbon is produced, and acrylonitrile 70 is then combined with hydrogen 72 to produce adiponitrile 36.

[0096] To form acrylonitrile 70, recycled methane 20 is first used to produce propylene 74. To produce propylene (propylene, C3H6) from methane (CH4), a series of chemical processes can be employed. For example, in one embodiment, the first step is to convert methane into syngas, a mixture of hydrogen (H2) and carbon monoxide (CO). This can be achieved via steam methane reforming (SMR).

[0097] CH4 + H2O → CO + 3H2

[0098] Subsequently, the syngas can be converted into methanol (CH3OH) via catalytic methods:

[0099] CO + 2H₂ → CH₃OH

[0100] Methanol can be converted into light olefins, such as ethylene (C2H4) and propylene, via a methanol-to-olefins (MTO) process. The MTO process is disclosed in U.S. Patent Nos. 10,011,541 and 11,001,542, both of which are incorporated herein by reference. Any other hydrocarbons produced during this process, such as C4 or C5 hydrocarbons, can be used as an energy source to improve the efficiency of propylene production. The method may include dehydration and cracking reactions:

[0101] 2CH3OH→C2H4+2H2O

[0102] as well as

[0103] 3CH3OH→C3H6+3H2O

[0104] Alternatively, specific methanol-to-propylene (MTP) processes have been developed to maximize propylene yield.

[0105] In another embodiment, oxidative coupling (OCM) of methane can be used to directly convert methane into ethylene, which is then oligomerized and cracked to produce propylene. This method involves the oxidative coupling of methane molecules, typically using oxygen (O2) as the oxidant. This method requires a catalyst to facilitate the reaction. Common catalysts include metal oxides, such as oxides of lithium, magnesium, and lanthanum. These catalysts help lower the activation energy required for the reaction and improve selectivity for the desired product. The basic mechanism involves the activation of methane and oxygen on the catalyst surface to form methyl radicals (CH3•) and other active intermediates. These intermediates are then coupled to form C2 hydrocarbons. The initial steps can be represented as follows:

[0106] 2CH4 + O2 → C2H4 + 2H2O

[0107] Subsequently, ethylene can be converted into propylene via methods such as olefin metathesis:

[0108] C2H4 + C4H8 → 2C3H6

[0109] In another embodiment, methane pyrolysis can be used to form propylene. Methane can be directly decomposed into hydrogen and acetylene at high temperatures. Acetylene can then be converted into ethylene, and further into propylene.

[0110] Another route involves directly converting syngas into hydrocarbons via the Fischer-Tropsch process, producing a series of hydrocarbons that can be further refined and cracked to obtain propylene.

[0111] Propylene 74 containing recycled carbon is then combined with oxygen 76 and ammonia 28 formed from recycled methane 20.

[0112] For example, in one aspect, acrylonitrile 70 can be produced from ammonia 28, oxygen 76, and propylene 74 in a process known as the SOHIO process. During this process, ammonia, propylene, and oxygen are combined in a single reactor to convert into acrylonitrile 70 and hydrogen cyanide. The reaction can be carried out in a fluidized bed in the presence of a catalyst. Acrylonitrile 70 contains recycled carbon and / or other recycled atoms.

[0113] like Figure 3 As shown, acrylonitrile 70 is then combined with hydrogen 72 to form adiponitrile 36. For example, hydrogen 72 can be obtained from recycled methane 20 by steam reforming.

[0114] The production of adiponitrile from acrylonitrile and hydrogen involves a catalytic hydrogenation reaction. This reaction occurs in the presence of a catalyst, such as a nickel-based catalyst. During this process, acrylonitrile 70 is converted to adiponitrile 36. Adiponitrile 36 can then combine with an additional amount of hydrogen 32 to produce a diamine monomer 12.

[0115] exist Figure 3 In the reaction scheme shown, the diamine monomer 12 may contain a recycled oxygen amount greater than about 20% by weight, for example greater than about 25% by weight, for example greater than about 30% by weight, for example greater than about 35% by weight, for example greater than about 40% by weight, for example greater than about 45% by weight, for example greater than about 50% by weight, and less than about 90% by weight, for example less than about 85% by weight, for example less than about 80% by weight. For example, in one aspect, depending on the reuse of recycled methane 20, the diamine monomer 12 may contain recycled atoms in an amount from about 29% by weight to about 72% by weight.

[0116] Subsequently, the diamine monomer 12 and adipic acid 14 prepared according to this disclosure are combined to form a polyamide polymer, particularly as shown in the figure. Figure 1 Polyamide 66 polymer 10 is shown. For example, polyamide 66 polymer 10 can be produced by a polycondensation reaction between adipic acid and diamine.

[0117] The polyamide 66 polymer prepared according to this disclosure can have excellent physical and mechanical properties and can contain very few or no impurities.

[0118] For example, when tested according to ASTM test D789 and / or D4878, the relative viscosity of the polyamide 66 polymer prepared according to this disclosure can be greater than about 2.3, for example greater than about 2.4, for example greater than about 2.5, and less than about 3.2, for example less than about 3, for example less than about 2.9, for example less than about 2.8, for example less than about 2.7.

[0119] Once generated, polyamide 66 polymer can be combined with various additives and ingredients to produce compounded polymer compositions. These compounded polymer compositions are then well-suited for producing various articles by molding methods such as injection molding.

[0120] For example, in one embodiment, the polyamide 66 polymer can be combined with reinforcing fibers (e.g., inorganic fibers).

[0121] Inorganic fibers typically possess high tensile strength relative to their mass. For example, the ultimate tensile strength of fibers (as determined according to ASTM D2101) is typically from about 1,000 MPa to about 15,000 MPa, in some embodiments from about 2,000 MPa to about 10,000 MPa, and in some embodiments from about 3,000 MPa to about 6,000 MPa. High-strength fibers can be formed from materials that are also electrically insulating in nature, such as glass, ceramics (e.g., alumina or silica), and mixtures thereof. Glass fibers are particularly suitable, such as E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S1-glass, S2-glass, and mixtures thereof. Inorganic fibers can have a relatively small median diameter, for example, about 50 micrometers or less, from about 0.1 micrometers to about 40 micrometers in some embodiments, and from about 2 micrometers to about 20 micrometers in some embodiments, as determined, for example, using laser diffraction techniques (e.g., using a Horiba LA-960 particle size analyzer) according to ISO 13320:2009. It is believed that the small diameter of such fibers makes it easier to reduce their length during melt blending, which can further improve surface appearance and mechanical properties. For example, after forming the polymer composition, the average length of the inorganic fibers can be relatively small, for example, from about 10 micrometers to about 800 micrometers, from about 100 micrometers to about 700 micrometers in some embodiments, and from about 200 micrometers to about 600 micrometers in some embodiments. Inorganic fibers can also have a relatively high aspect ratio (average length divided by nominal diameter), for example, from about 1 to about 100, from about 10 to about 60 in some embodiments, and from about 30 to about 50 in some embodiments.

[0122] In one aspect, glass fibers may be present in the polymer composition in an amount of about 5% by weight to about 65% by weight. For example, glass fibers may be present in an amount greater than about 15% by weight, such as greater than about 20% by weight, such as greater than about 25% by weight, and less than about 63% by weight, such as less than about 50% by weight.

[0123] The polyamide composition may also contain a wide variety of other additives, such as impact modifiers, compatibilizers, particulate fillers (e.g., mineral fillers), lubricants, pigments, antioxidants, light stabilizers, heat stabilizers, and / or other materials added to enhance properties and processability. For example, in some embodiments, the composition may contain a UV stabilizer. Suitable UV stabilizers may include, for example, benzophenone, benzotriazoles (e.g., 2-(2-hydroxy-3,5-di-α-cumylphenyl)-2H-benzotriazole (TINUVIN® 234), 2-(2-hydroxy-5-tert-octylphenyl)-2H-benzotriazole (TINUVIN® 329), 2-(2-hydroxy-3-α-cumyl-5-tert-octylphenyl)-2H-benzotriazole (TINUVIN® 928), etc.), triazines (e.g., 2,4-diphenyl-6-(2-hydroxy-4-hexyloxyphenyl)-s-triazine (TINUVIN® 1577), sterically hindered amines (e.g., bis(2,2,6,6-tetramethyl-4-piperidinyl) sebacate (TINUVIN® 770) or a polymer of dimethyl succinate and 1-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethyl-4-piperidine (TINUVIN® 622), and mixtures thereof. When used, such UV stabilizers typically constitute about 0.05 wt.% to about 2 wt.% of the composition, in some embodiments about 0.1 wt.% to about 1.5 wt.%, and in some embodiments about 0.2 wt.% to 1.0 wt.%.

[0124] In one embodiment, the polymer composition contains a heat stabilizer. For example, the heat stabilizer may comprise dipentaerythritol. The heat stabilizer may be present in the polymer composition in an amount greater than about 0.3% by weight, such as greater than about 0.5% by weight, such as greater than about 0.7% by weight, such as greater than about 1% by weight, such as greater than about 1.2% by weight, such as greater than about 1.4% by weight, and less than about 5% by weight, such as less than about 3% by weight, such as less than about 2% by weight, such as less than about 1.8% by weight.

[0125] Generally, other additives and fillers, processing stabilizers, lubricants, etc., may be present in the polymer composition in amounts from about 0.01% by weight to about 60% by weight.

[0126] Molded components can be formed from polyamide compositions using a variety of different techniques. Suitable techniques may include, for example, injection molding, low-pressure injection molding, extrusion compression molding, gas injection molding, foam injection molding, low-pressure gas injection molding, low-pressure foam injection molding, gas extrusion compression molding, foam extrusion compression molding, extrusion molding, foam extrusion molding, compression molding, foam compression molding, gas compression molding, etc. For example, an injection molding system comprising a mold in which the polyamide composition can be injected can be used. The injection timing can be controlled and optimized so that the polymer matrix does not pre-cure. When the cycle time is reached and the barrel is full for discharge, the composition can be injected into the mold cavity using a piston. Compression molding systems can also be used. As with injection molding, the molding of the polyamide composition into the desired article also occurs within a mold. The composition can be placed into the compression mold using any known technique, such as by being picked up by an automated robotic arm. The temperature of the mold can be maintained at or above the curing temperature of the polymer matrix for the desired period of time to allow curing. The molded product can then be cured by keeping its temperature below the melting temperature. The resulting product can be demolded. The cycle time for each molding method can be adjusted to suit the polymer matrix to achieve adequate adhesion and improve overall process productivity.

[0127] The nylon 66 disclosed herein can be used to produce all different types of products and components. For example, nylon 66 can be used to manufacture all different types of automotive components, including engine components (e.g., gears, bearings) and other mechanical parts, as well as interior components (e.g., seat belts, airbag containers, and interior trim). Nylon 66 can also be used in industrial applications to produce mechanical parts such as gears, bearings, and bushings; electrical components such as cable ties, electrical insulators, and connectors; and filtration systems such as filters and screens in industrial applications. Nylon 66 can be used in medical applications to produce surgical sutures and medical devices. Nylon 66 can also be used to produce packaging such as food packaging films and bags. Nylon 66 is used to produce textiles and clothing. Nylon 66 is also used to produce a wide variety of consumer goods, such as sporting goods, kitchen utensils, brushes, zippers, and toys.

[0128] Specific products and components that can be made from the Nylon 66 disclosed herein include vibration damping and suspension systems, traction motors, clamps, jigs, body plugs, grommets, cable ties, end caps, propulsion cooling systems, air management systems, cockpit components, high-speed data and low-voltage connectors, wires and cables, oil management systems, exterior trim and components, engine components, closures and fasteners, power electronics, rail and train systems, steering systems, charging plug and socket assemblies, injection equipment assemblies, traction motor assemblies, circuit breakers and contactors, tanks and containers, solar photovoltaic modules, furniture assemblies, braking system assemblies, transmission assemblies, wheeled motion assemblies, switches, pedals and shifting systems, door assemblies, fluid management components, pipes, hoses and conduits, oil management components, plugs, etc. Seats, piping hardware, relays, fuses and switches, filaments, fibers and fabrics, fuel cell components, military, weapons and ammunition components, sensors, tools, motorcycle parts, safety restraint systems, coil frames and transformer components, front and rear module components, conveyor chains and belts, relays, fuel supply system components, seats and seating system components, ADAS (Advanced Driver Assistance Systems) components, agricultural and mining components, footwear, medical packaging, server components, air conditioning components, ropes, rigging, nets, lithium-ion battery components, water management (irrigation and drainage) components, windshield wiper and washer system components, 5G base station components, desktop computer components, automation and robotics (drones, AMRs, AGVs) system components and assemblies, etc.

[0129] Nylon 66 is particularly suitable for electric vehicles to manufacture battery packs and housings, electrical connectors, terminal blocks and other electrical components.

[0130] For example, the inventors have found that polyamide compositions are particularly suitable for use in electrical connectors, such as those for electric vehicles and household appliances. The connector may include insertion channels configured to receive contact pins. These channels are defined by opposing walls, which may be formed from the polyamide compositions of the present invention. The width of the walls may be about 500 micrometers or less, in some embodiments about 100 micrometers to about 450 micrometers, and in some embodiments about 200 micrometers to about 400 micrometers.

[0131] refer to Figure 5 and Figure 6 The present invention illustrates an embodiment of an electrical connector that can be manufactured according to the present disclosure.

[0132] refer to Figure 5 This illustration shows one embodiment of a high-voltage connector 150 that can be manufactured according to the present disclosure. The electrical connector 150 includes a plurality of contact elements 156 extending from a base 154. The contact elements 156 are used for electrical connection to opposing connectors. Figure 5In the embodiment shown, contact element 156 is a male contact that is inserted into the opposite receiver.

[0133] like Figure 5 As shown, connector 150 also includes a gasket 158. Gasket 158 ​​provides a fluid-tight connection when the connector is engaged with a complementary receiver. The gasket can be made of any suitable elastomer or rubber. For example, in one aspect, gasket 158 ​​is made of a silicone elastomer.

[0134] refer to Figure 6 This illustrates another connector 160 prepared according to the present disclosure. Connector 160 is used for receiving and connecting to, for example... Figure 5 The connector 150 is shown. Connector 160 includes a base 162 surrounding a plurality of contact elements 166 and forming walls therearound. The contact elements 166 are female connectors for receiving, such as... Figure 5 The male contact 156 of connector 150 is shown. As shown, connector 160 also includes a similar... Figure 5 Washer 168 of the embodiment shown.

[0135] According to this disclosure, the base 154 of connector 150 and the base 162 of connector 160 can be made of the polymer composition of the present invention.

[0136] These and other modifications and variations of the invention can be implemented by those skilled in the art without departing from the spirit and scope of the invention. Furthermore, it should be understood that aspects of the various embodiments can be interchanged, in whole or in part. Moreover, those skilled in the art will understand that the foregoing description is merely exemplary and is not intended to limit the invention further described in the appended claims.

Claims

1. A method for producing polyamide 66, comprising: A polyamide 66 polymer is formed from a first monomer and a second monomer, wherein at least a portion of the first monomer is derived from a recycled atomic component, the first monomer contains a diamine, the second monomer contains adipic acid, the recycled atomic component contains a recycled carbon component, the recycled carbon component contains recycled natural gas, and wherein the resulting polyamide 66 polymer has a recycled atomic content of at least about 10% by weight.

2. The method of claim 1, wherein the resulting polyamide 66 polymer has a recycled atom content of at least about 14% by weight, for example at least about 18% by weight, for example at least about 25% by weight, for example at least about 30% by weight, for example at least about 35% by weight, for example at least about 39% by weight.

3. The method according to claim 1 or 2, wherein the cyclic atomic content is determined based on cyclic certification.

4. The method according to claim 1, 2 or 3, wherein the cyclic atomic content is determined according to ISCC.

5. The method according to any one of the preceding claims, wherein the recycled natural gas comprises recycled methane, the recycled methane containing more than about 80% by weight, for example more than about 85% by weight, for example more than about 90% by weight, for example more than about 95% by weight of methane.

6. The method according to any one of the preceding claims, wherein the first monomer comprises hexamethylenediamine.

7. The method according to any one of claims 1 to 5, wherein the first monomer comprises 2-methylpentane-1,5-diamine.

8. The method according to any one of the preceding claims, wherein the recycled natural gas steam is reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is combined with an additional amount of the recycled natural gas to form hydrogen cyanide, the hydrogen cyanide is used to form adiponitrile, and the adiponitrile is hydrogenated to form the first monomer.

9. The method of claim 8, wherein the adiponitrile is hydrogenated using hydrogen captured during the generation of hydrogen cyanide.

10. The method of claim 8, wherein the ammonia comprises blue ammonia.

11. The method of claim 8, wherein the ammonia comprises green ammonia.

12. The method of claim 8, wherein the ammonia comprises blue-green ammonia.

13. The method according to any one of claims 8 to 12, wherein the adiponitrile is formed by hydrocyanation of 1,3-butadiene.

14. The method of claim 13, wherein the 1,3-butadiene is formed from a recycled carbon component comprising recycled oil.

15. The method of claim 13, wherein the 1,3-butadiene is formed from a recycled carbon component comprising recycled naphtha.

16. The method according to any one of claims 1 to 7, wherein the circulating natural gas steam is reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is combined with oxygen and propylene to form acrylonitrile, the acrylonitrile is converted to adiponitrile, and the adiponitrile is hydrogenated to form the first monomer.

17. The method of claim 16, wherein the propylene is derived from a recycled carbon component comprising recycled natural gas.

18. The method according to any one of the preceding claims, wherein the relative viscosity of the polyamide 66 polymer is about 2.3 to about 3.2 when tested according to ASTM test D789 and / or D4878.

19. The method according to any one of the preceding claims, wherein the relative viscosity of the polyamide 66 polymer is about 2.4 to about 2.7 when tested according to ASTM test D789 and / or D4878.

20. The method according to any one of the preceding claims, wherein the polyamide 66 polymer is combined with glass fibers, the glass fibers being present in the resulting polymer composition in an amount of about 5% to about 65% by weight.

21. The method according to any one of the preceding claims, wherein the polyamide 66 polymer is combined with a lubricant.

22. The method according to any one of the preceding claims, wherein the polyamide 66 polymer is molded into an article.

23. The method of claim 22, wherein the molded article comprises an electrical connector.

24. A method for producing polyamide 66, comprising: A polyamide 66 polymer is formed from a first monomer and a second monomer, wherein the first monomer comprises a diamine, and wherein at least a portion of the second monomer is derived from a recycled carbon component comprising recycled natural gas, the second monomer comprising adipic acid, and wherein the recycled natural gas is steam-reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is combined with water and oxygen to form nitric acid, and the nitric acid is used to oxidize ketol oil to form adipic acid.

25. The method of claim 24, wherein the resulting polyamide 66 polymer has a cycling atomic content of at least about 18% by weight, for example at least about 30% by weight, for example at least about 35% by weight, for example at least about 37% by weight, for example at least about 39% by weight, and wherein the cycling atomic content is determined according to ISCC.

26. The method according to any one of claims 24 to 25, wherein the recycled natural gas comprises recycled methane, the recycled methane containing more than about 80% by weight, for example more than about 85% by weight, for example more than about 90% by weight, for example more than about 95% by weight of methane.

27. The method according to any one of claims 24 to 26, wherein the first monomer comprises hexamethylenediamine and / or 2-methylpentane-1,5-diamine, and wherein at least a portion of the first monomer is also formed from the recycled natural gas.

28. The method of claim 27, wherein the circulating natural gas steam is reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is used to form adiponitrile, and the adiponitrile is hydrogenated to form the first monomer.

29. A method for producing polyamide 66, comprising: A polyamide 66 polymer is formed from a first monomer and a second monomer, wherein at least a portion of the first monomer and at least a portion of the second monomer are derived from the same recycled carbon component, the recycled carbon component comprising recycled natural gas, and wherein the resulting polyamide 66 polymer has a recycled atom content of at least about 10% by weight.

30. The method of claim 29, wherein the resulting polyamide 66 polymer has a recycled atom content of at least about 18% by weight, for example at least about 25% by weight, for example at least about 37% by weight, for example at least about 39% by weight.

31. The method according to claim 29 or 30, wherein the cyclic atomic content is determined according to ISCC.

32. The method according to any one of claims 29 to 31, wherein the recycled natural gas comprises recycled methane, the recycled methane containing more than about 80% by weight, for example more than about 85% by weight, for example more than about 90% by weight, for example more than about 95% by weight of methane.

33. The method according to any one of claims 29 to 32, wherein the first monomer comprises a diamine.

34. The method of claim 33, wherein the first monomer comprises hexamethylenediamine.

35. The method of claim 33, wherein the first monomer comprises 2-methylpentane-1,5-diamine.

36. The method according to any one of claims 29 to 35, wherein the recycled natural gas steam is reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is combined with an additional amount of the recycled natural gas to form hydrogen cyanide, the hydrogen cyanide is used to form adiponitrile, and the adiponitrile is hydrogenated to form the first monomer.

37. The method of claim 36, wherein the adiponitrile is formed by hydrocyanation of 1,3-butadiene.

38. The method of claim 37, wherein the 1,3-butadiene is formed from a recycled carbon component comprising recycled oil, recycled naphtha, or a mixture thereof.

39. The method according to any one of claims 29 to 35, wherein the circulating natural gas steam is reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is combined with oxygen and propylene to form adiponitrile, and the adiponitrile is hydrogenated to form the first monomer.

40. The method of claim 39, wherein the propylene is formed from a recycled carbon component comprising the recycled natural gas.

41. The method according to any one of claims 29 to 40, wherein the second monomer comprises adipic acid.

42. The method of claim 41, wherein the circulating natural gas steam is reformed to produce hydrogen, the hydrogen is combined with nitrogen to form ammonia, the ammonia is combined with water and oxygen to form nitric acid, and the nitric acid is used to oxidize ketol oil to form adipic acid.

43. The method according to any one of claims 29 to 42, wherein the relative viscosity of the polyamide 66 polymer is about 2.3 to about 3.2 when tested according to ASTM test D789 and / or D4878, and the relative viscosity of the polyamide 66 polymer is about 2.5 to about 2.7 when tested according to ASTM test D789 and / or D4878.

44. The method according to any one of claims 29 to 43, wherein the polyamide 66 polymer is combined with glass fibers, the glass fibers being present in the resulting polymer composition in an amount of about 5% to about 65% by weight.

45. The method according to any one of claims 29 to 44, wherein the polyamide 66 polymer is combined with a lubricant.

46. ​​The method according to any one of claims 29 to 45, wherein the polyamide 66 polymer is molded into an article.

47. The method of claim 46, wherein the molded article comprises an electrical connector.

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