Process for producing synthesis gas from a waste stream

Abstract

The invention relates to a process for manufacturing synthesis gas from a feedstock, wherein the feedstock is a sorted shredder residue SSR formed by sorting from an unsorted shredder residue NSR, such as automotive shredder residue (ASR), which comprises metal pieces and / or non-metal inorganic pieces and pieces of at least one polymer. The size of these metal pieces and / or non-metal inorganic pieces and pieces of at least one polymer is reduced, followed by separation of these metal pieces and inorganic pieces to obtain the sorted shredder residue SSR. The sorted shredder residue SSR is then subjected to a gasification reaction in at least one plasma gasification furnace. Thereby, the sorted shredder residue SSR is converted into synthesis gas, thereby producing less CO2 compared to prior art processes.

Description

Technical Field

[0001] This invention relates to a method for producing syngas by gasifying waste streams such as automobile crush residue. Background Technology

[0002] Waste streams containing shredded residue are widely produced and are typically incinerated to generate heat, etc. There is a growing demand for more sustainable use of this shredded residue, particularly automotive shredded residue (ASR).

[0003] Plasma gasification using at least one plasma torch is a suitable technique for converting such crushed residues, particularly automotive crushed residues, into syngas. The syngas contains CO and H2, which are suitable, for example, as reactants in the manufacture of polymers and other materials contained in automobiles and other vehicles. At least one plasma torch included in the plasma gasifier has a lower operating threshold (“mindestlast” in German). Therefore, a minimum amount of electrical power and a minimum amount of at least one (preferably) gaseous plasma source are required to operate the at least one plasma torch and thereby convert the crushed residue into syngas. When the at least one plasma torch operates below its operating threshold, an undesirable large amount of at least one plasma source is discharged from the plasma gasifier along with CO and H2 from the reaction product syngas. This is the case when there is insufficient crushed residue available and / or feed into the plasma gasifier. The undesirable large amount of at least one plasma source must then be separated from the syngas by energy-intensive methods using expensive equipment to obtain CO and H2 of the purity required for downstream processes. The large amount of at least one plasma source to be separated from the syngas may even prevent the sustainability of the entire process.

[0004] The object of this invention is to provide a method for converting a waste stream containing crushed residues, such as automotive crushed residues, into syngas, wherein the method has a reduced product carbon footprint and / or reduced CO2 emissions compared to prior art methods.

[0005] Another objective is to provide a method for producing syngas from crushed residue, wherein the method does not result in an increase in the amount of unwanted plasma source in the syngas when the amount of crushed residue fed into the plasma gasifier is below the operating boundary value of at least one plasma torch inside the plasma gasifier. Summary of the Invention

[0006] These problems are addressed by a method for producing syngas from feedstocks, the method comprising the following steps:

[0007] (i) A first raw material F1 is provided, wherein the first raw material F1 comprises sorted crushed residue SSR, the sorted crushed residue SSR being formed by sorting unsorted crushed residue NSR.

[0008] The unsorted fragmented residue (NSR) comprises metal fragments and / or non-metallic inorganic fragments, as well as fragments of at least one polymer selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins, and polyolefins.

[0009] The unsorted crushed residue NSR is pre-sorted to form the sorted crushed residue SSR, preferably pre-sorted in the following order and manner:

[0010] a) Optionally, further reduce the size of the metal fragments and / or non-metallic inorganic fragments and at least one polymer fragment, and

[0011] b) Separate the metal fragments and / or the non-metallic inorganic fragments.

[0012] Thus, through step b), the sorted crushed residue SSR consists of metal-poor fragments and / or non-metallic inorganic fragments.

[0013] (ii) Provide at least one additional raw material F2,

[0014] (iii) The first raw material F1 provided in step (i) is combined with at least one additional raw material F2 provided in step (ii) and converted into a gas stream GS1 in at least one plasma gasification furnace PG, the gas stream GS1 comprising syngas, wherein the syngas comprises H2, CO and CO2, and wherein the at least one plasma gasification furnace PG comprises at least one plasma torch, the at least one plasma torch being electrically operated, wherein the plasma in the at least one plasma gasification furnace PG is generated by at least one plasma source PS, and

[0015] (iv) At least a portion of the CO2 is removed from the gas stream GS1 formed in step (iii) in the syngas upgrade unit SUP, thereby forming a gas stream GS2.

[0016] These problems are addressed by plasma gasification in at least one plasma gasifier PG for converting sorted crushed residue SSR into syngas, the sorted crushed residue SSR being formed by sorting unsorted crushed residue NSR, wherein the unsorted crushed residue NSR comprises metal fragments and / or glass fragments, wherein the unsorted crushed residue NSR is pre-sorted to form the sorted crushed residue SSR, preferably in such a sequence as a) optionally further reducing the size of the unsorted crushed residue NSR and b) sorting out the metal fragments and / or glass fragments from the unsorted crushed residue NSR, wherein the sorted crushed residue SSR comprises at least one polymer selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins, and polyolefins.

[0017] These problems are further addressed by providing at least one second feedstock F2 and converting it together with the first feedstock F1, which includes sorted crushed residue SSR, in a plasma gasifier comprising at least one plasma torch, wherein the plasma in the at least one plasma gasifier PG is generated by at least one plasma source PS. This prevents unwanted large quantities of at least one plasma source PS from entering the syngas.

[0018] Further aspects of the invention will become apparent to those skilled in the art directly from the foregoing and the following description and examples. Detailed Implementation

[0019] definition:

[0020] In the context of this specification and the appended claims, the term "about" preferably means a deviation of ±10% from the value described therein. In the context of this invention, the term "combination thereof" includes one or more of the listed elements. In the context of this invention, the term "mixture thereof" includes one or more of the listed elements.

[0021] "Resettlement-derived fuel" (RDF) is defined in this paper as fuel derived from various types of waste, such as municipal solid waste (MSW), industrial waste, or commercial waste. RDF is primarily composed of combustible components of such waste, such as non-recyclable plastics (excluding PVC), cardboard, labels, and other corrugated materials. These fractions are separated through various processing steps, such as screening, air classification, ballistic sorting, sorting of ferrous and non-ferrous metals, glass, stone, and other foreign materials, and chopping into uniform particle sizes, or pelletizing to produce homogeneous materials that can be used as feedstock for gasification processes (Y. Yang et al., Gasification of refuse-derived fuel from municipal solid waste for energy production: a review, Environmental Chemistry Letters (2021) 19, 2127-2140 (https: / / doi.org / 10.1007 / s10311-020-01177-5).

[0022] The term "downstream of" is defined in this document with respect to a series of unit operations as located on one side immediately adjacent to the flow direction of the fluid passing through the series of unit operations.

[0023] The term “fluidly connected to” in relation to two or more units is defined herein as a fluid (such as particulate solids, liquids, gases, and mixtures thereof) that can flow from one such unit to another and through and / or along such analytical units. Two units that are “fluidly connected” to each other are connected, for example, by one or more pipes connected to each other, or by a screw conveyor, or by an extruder, or by a solid pump.

[0024] The method according to the present invention is described in detail below.

[0025] In step i) of the method according to the invention, a first raw material F1 is provided. The first raw material F1 comprises sorted crushed residue SSR, which is formed by sorting unsorted crushed residue NSR. The unsorted crushed residue NSR comprises metal fragments and / or glass fragments and fragments of at least one polymer selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins, and polyolefins.

[0026] Unsorted shredded waste (NSR) is or includes, for example, automotive shredded waste (ASR), shredded electrical and electronic equipment (WEEE), and other types of shredded waste. Shredded electrical and electronic equipment (WEEE) preferably contains epoxy resin derived from printed circuit boards, etc., contained therein.

[0027] The unsorted crushed residue NSR is sorted to form sorted crushed residue SSR, preferably in the following order: a) optionally further reducing the size of the unsorted crushed residue NSR and b) separating metal fragments and / or non-metallic inorganic fragments from the unsorted crushed residue NSR.

[0028] Unsorted shredded residue (NSR) and sorted shredded residue (SSR) preferably comprise parts of end-of-life vehicles and / or shredded waste electrical and electronic equipment. Particularly preferred first feedstock F1 comprising parts of end-of-life vehicles is automotive shredded residue (ASR), which is described in more detail below:

[0029] Automotive debris can be obtained, preferably, through the crushing of vehicles. More preferably, automotive debris can be obtained through vehicle decontamination, vehicle dismantling, vehicle crushing, and separation of metal particles from the crushed vehicle.

[0030] The method described for a) optionally further reducing the size of the metal fragments and / or non-metallic inorganic fragments and at least one polymer fragment, and b) sorting the metal fragments and / or non-metallic inorganic fragments in relation to the Automotive Crushed Residue (ASR) described below, can also be applied to other unsorted crushed residue NSR provided in step (i) to form a sorted crushed residue SSR that is depleted of metal fragments and / or non-metallic inorganic fragments compared to the unsorted crushed residue NSR by step b). Non-metallic inorganic fragments are, for example, glass fragments.

[0031] Vehicles in Automotive Shrapnel Residue (ASR) are typically end-of-life vehicles (also known as “ELVs”) that are at least 15 years old. Vehicles can be passenger cars, light or heavy-duty trucks, motorcycles, multi-purpose vehicles, agricultural vehicles, or recreational vehicles. Vehicles can be electric vehicles, such as pure electric vehicles or hybrid electric vehicles.

[0032] In vehicle decontamination, harmful liquids (such as fuel, lubricating oil, coolant, brake fluid) and batteries can be removed from the vehicle before crushing.

[0033] Vehicle dismantling can include the selective removal of parts such as engines, transmissions, tires, glass, and plastics for reuse as spare parts in the second-hand market. Dismantling can also include the removal of larger plastic components, such as bumpers, dashboards, and fluid containers, for individual recycling of the plastics.

[0034] ASR may include additional waste from other sources. For example, trash from a previous owner may remain in the trunk or interior of the vehicle. An advantage of the method of the present invention is that it can handle a wide variety of ASR compositions.

[0035] Crushing can be carried out using a vehicle crusher. Vehicle crushers are manufactured in various sizes. Typically, a vehicle crusher includes a heavy-duty, high-speed rotating rotor that can rotate in a vertical or horizontal plane and is usually equipped with a swing hammer. The vehicle crusher tears and crushes the vehicle wreckage until its parts are reduced to fragments. The fragments can then pass through a grating and exit the rotor housing. The vehicle crushing residue preferably accounts for 10 to 40 wt.% of the original vehicle weight, more preferably 15 to 35 wt.% and most preferably 20 to 30 wt.% of the original vehicle weight.

[0036] In step a), the size of the fragments may be further reduced to obtain a preferred fragment size, i.e., at least 90 wt.% of the crushed residue fragments formed in step a) are less than 5 cm, preferably at least 95 wt.% are less than 5 cm, and more preferably at least 95 wt.% are less than 3 cm. If the unsorted crushed residue NSR already has a preferred fragment size, i.e., at least 90 wt.% of the crushed residue fragments formed in step a) are less than 5 cm, preferably at least 95 wt.% are less than 5 cm, and more preferably at least 95 wt.% are less than 3 cm, then step a) may preferably be omitted.

[0037] The method used in step a) is selected from the group consisting of crushing, grinding, milling, sieving, grading, and combinations thereof. Optionally, step a) may further include optical and / or manual sorting to remove excessively large fragments. Such methods are known to those skilled in the art and can be applied to the given unsorted crushed residue NSR provided in step (i).

[0038] Following optional step a), after crushing and further reducing in size, metal fragments such as ferrous and nonferrous metal fragments and nonmetallic inorganic materials (“inert materials”) such as glass or sand can be separated from the crushed vehicle in step b). Step b) includes at least removing metal fragments and / or glass fragments from the unsorted crushed residue NSR. Metal fragments typically, but not always, include ferrous and nonferrous metal fragments.

[0039] Ferrous metal fragments can be removed using magnetic separators. Magnetic separators typically utilize the magnetic properties of ferrous metals to attract and separate them from non-magnetic materials. Generally, the material is fed onto a conveyor belt or vibrating feeder, and as the material moves along the conveyor belt, the magnetic separator generates a strong magnetic field (e.g., a magnetic field is generated by passing an electric current through a coil, which produces a magnetic force). When the material passes through the magnetic field, the magnetically charged ferrous metals can be attracted to the magnetic separator. Once the ferrous metals are attracted to the magnetic separator, they can be separated from the remaining waste and collected separately. This can be accomplished using separate chutes or conveyor belts to guide the separated ferrous metals to a designated collection area.

[0040] Non-ferrous metal fragments can be separated from broken vehicles using eddy current separators, density separation methods (e.g., heavy medium sinking / floating units), manual sorting, and combinations thereof. Suitable eddy current separators utilize the principle of electromagnetic induction to generate eddy currents, which in turn generate magnetic fields that repel non-ferrous metals. Typically, material is fed onto a conveyor belt or vibrating feeder, and as the material moves along the conveyor belt, the eddy current separator generates an alternating magnetic field. When this alternating magnetic field interacts with a conductive non-ferrous metal (such as aluminum or copper), eddy currents can be induced within the conductive non-ferrous metal due to electromagnetic induction. These eddy currents typically generate their own magnetic fields, which produce repulsive forces against the magnetic field of the eddy current separator. This repulsion can cause the non-ferrous metals to be pushed away from the separator, thus separating them from the rest of the material.

[0041] The automotive debris preferably contains up to 15 wt.-%, more preferably up to 10 wt.-%, and most preferably up to 5 wt.-%, of metal fragments, such as ferrous and nonferrous metal particles.

[0042] Typically, 60 to 90 wt.% of a vehicle's weight is metal, which can be separated from a broken vehicle.

[0043] Non-metallic inorganic materials (“inert materials”) such as glass or sand are preferably separated by density separation. Suitable methods for density separation include cyclone separation, jigging, air separation, or sedimentation-flotation separation. Automotive debris may preferably contain up to 15 wt.% of glass fragments, more preferably up to 10 wt.% of glass fragments, and most preferably up to 5 wt.% of glass fragments, such as broken window glass fragments.

[0044] Cyclone separation is a method commonly used to separate materials based on their density and size using a device called a cyclone separator. A cyclone separator typically consists of a cylindrical body with a conical base and an inlet and outlet at the top. The inlet can be tangentially connected to the body, which creates vortex motion inside the cyclone separator. As the material rotates inside the cyclone separator, centrifugal force is generated, causing denser and larger particles to move towards the outer wall of the cyclone separator, while lighter and smaller particles tend to remain near the center.

[0045] Jigging is a method of separating materials based on their density using a device called a jig, which typically consists of a rectangular or circular container with a screen or mesh at the bottom. This container can be mounted on a frame with mechanisms that move it up and down. The jig can be filled with water, and a pulsating flow of water is introduced from the bottom of the container. This pulsation causes the material to move up and down within the container. More dense particles may tend to settle faster and move towards the bottom of the container, while lighter particles tend to remain near the top.

[0046] Air separation is typically based on airflow, as seen in air classifier structures, which are typically vertical chambers with an inlet at the bottom and an outlet at the top. This chamber may contain a series of guide vanes or blades that generate centrifugal forces that separate the materials. Airflow is usually introduced from the bottom of the chamber, and this airflow causes the materials to move upwards and separate based on their density. Denser particles generally tend to move towards the outer walls of the chamber, while lighter particles tend to remain near the center. The separated material can be collected at different locations within the air classifier.

[0047] Sinking-float separation is generally based on the principle that materials of different densities will behave differently when placed in a fluid medium: denser materials typically sink, while less dense materials float. The fluid medium can be a heavy liquid, such as water or a specially formulated solution, or a finely ground powder. The liquid is usually chosen to have a density between that of the materials to be separated.

[0048] Automotive debris comprises fragments of various polymer vehicle parts, which contain at least one polymer selected from polyamides, polyisocyanate addition polymers, rubbers, and polyolefins. The fragments are selected from the following: bumpers, interior trim panels, dashboards, cable insulation, electrical insulation materials, flexible foam seats, foam insulation boards, automotive suspension bushings, electrical potting compounds, body parts, pillar covers, spoiler polymer parts coated with automotive paint, wheel covers, gears, bushings, cams, bearings, weather-resistant coatings, interior and exterior trim, fuel systems, gear housings, headlight retainers, engine hoods, connector housings, door handles, carburetor components, exterior rearview mirror components, windshield wiper components, windshield wiper protective housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna covers, headlights and taillights, radiator grilles and exterior body parts, engine hoods, cylinder head covers, intake manifolds, cylinder head covers, engine hoods, supercharger cooler housings, supercharger cooler valves, preferably at least one of which is included in the sorted crushed residue SSR.

[0049] The automotive debris preferably contains at least 30 wt.-%, more preferably at least 40 wt.-%, and most preferably at least 50 wt.-%, of polymeric vehicle parts (referred herein as "fragments containing at least one polymer"), wherein the at least one polymer is selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, and polyolefins. Such fragments containing at least one polymer are particularly suitable for conversion into syngas in at least one plasma gasifier PG in step (iii).

[0050] Epoxy resins are typically found in shredded waste electrical and electronic equipment, and can also be found in automotive shredded waste.

[0051] The polyamides that may be included in the sorted crushed residue SSR are selected from the group consisting of polyamide 6 (PA6), polyamide 66 (PA66), and mixtures thereof. These polyamides may contain fillers.

[0052] Polyisocyanate addition polymers that may be included in the sorted crushed residue SSR are selected from the group consisting of polyurethane (PU), thermoplastic polyurethane (TPU), polyurea, polyisocyanurate (PIR), and mixtures thereof. These polyisocyanate addition polymers may contain fillers.

[0053] The rubber that may be included in the sorted crushed residue SSR is selected from the group consisting of: natural rubber, styrene-butadiene rubber, butyl rubber, ethylene propylene diene monomer rubber, chloroprene rubber, nitrile rubber and silicone rubber.

[0054] Polyolefins that may be included in the sorted crushed residue SSR are selected from the group consisting of: low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene (PE), polypropylene (PP), and mixtures thereof. These polyolefins may contain fillers.

[0055] The sorted crushed residue SSR more preferably comprises at least two different polymers from the group consisting of: polyamides, polyisocyanate addition polymers, rubbers, epoxy resins, and polyolefins.

[0056] The automotive debris may contain up to preferably 15 wt.% of wood and cardboard, more preferably up to 10 wt.% of wood, and most preferably up to 5 wt.% of cardboard. Such components may be retained in the first feedstock F1 used in the gasification process in step (iii) because they can be converted into syngas.

[0057] Preferably, the unsorted crushed residue NSR and / or the sorted crushed residue SSR are dried before step (iii).

[0058] In step (ii), at least one additional raw material F2 is provided and subjected to a gasification process in step (iii), wherein the gasification process includes at least one plasma gasifier PG, and wherein the additional raw material F2 is injected "together" with the sorted and crushed residue SSR provided in step (i) into at least one plasma gasifier PG. The meaning of "together" depends on the type of the at least one additional raw material F2 and the type of plasma gasifier PG used in step (iii), and is explained in detail below.

[0059] Preferably, the at least one additional feedstock F2 provided in step (ii) is selected from the group consisting of or including: biomass, waste-derived fuel (RDF), pyrolysis oil derived from plastic waste, pyrolysis oil derived from scrap tires, pyrolysis oil derived from biomass, heating oil, vacuum residue, preferably vacuum distillation residue, crude oil residue, heavy crude oil, extra-heavy crude oil, tar sands asphalt, viscosity-reducing cracking bottom residue, deasphalting bottom residue, C5 asphaltene fraction, high-viscosity residue, fuel oil, pyrolytic gasoline, tire pyrolysis oil (TPO), waste oil, used oil, municipal solid waste (MSW), coal, tar, natural gas, contaminated vehicle parts and mixtures thereof.

[0060] The term "biomass" includes, but is not limited to, wood, wood pellets, sawdust, straw, lignocellulosic biomass, energy crops, algae, bio-based oils and bio-based fats (preferably hydrated).

[0061] The biomass is preferably roasted or converted into pyrolysis oil via pyrolysis, and then used as at least one additional feedstock F2 in step (iii). Municipal solid waste (MSW) is optionally pretreated by methods such as drying, crushing, sorting, and inert matter removal, and is preferably used in step (iii) in the form of waste-derived fuel (RDF). Preferably, the roasted biomass is preheated to a temperature such as 200°C, and then fed into the at least one plasma gasification furnace PG as at least one additional feedstock F2 in step (iii).

[0062] "Contaminated vehicle parts" are suitable as an additional raw material F2. Such contaminated vehicle parts are made of plastic materials and are contaminated by contaminants such as gasoline or diesel fuel due to physical and chemical contact between the vehicle parts and the corresponding contaminants for up to one year. Contaminated vehicle parts are, for example, gas cylinders (made of plastic materials such as polyethylene) contaminated with gasoline or diesel fuel (=contaminants). Preferably, the contaminated vehicle parts are removed from the respective vehicle before the vehicle is crushed. Crushed vehicle parts are defined as automotive slag residue (ASR), which is the first raw material F1 in the method according to the invention. Therefore, such contaminated vehicle parts are preferably not included in the automotive slag residue (ASR). The dismantling of contaminated vehicle parts can be carried out manually by humans and / or automatically by robots.

[0063] Optionally, at least one additional raw material F2 provided in step (ii) is preferably selected from the group consisting of or including: biomass, waste-derived fuel (RDF), pyrolysis oil made from plastic waste, pyrolysis oil made from scrap tires, pyrolysis oil made from biomass, municipal solid waste (MSW), coal, contaminated vehicle parts and mixtures thereof.

[0064] At least one additional raw material F2 is preferably pretreated prior to step (ii) by a method selected from or consisting of the following: sorting, sieving, milling, grinding, pyrolysis, roasting, metal sorting and combinations thereof.

[0065] The weight ratio of "first raw material F1 : other raw material F2" preferably ranges from 10 : 1 to 1 : 10, more preferably from 1 : 2 to 1 : 10, and most preferably from 1 : 5 to 1 : 10. Preferably, "other raw material F2" means all the other raw materials F2 combined when more than one other raw material F2 is used.

[0066] Preferably, the additional liquid feedstock F2 (such as bio-based oil and pyrolysis oil) is preheated and / or pressurized to >1 bar (absolute value), more preferably >2 bar (absolute value), and most preferably about 4 bar (absolute value), before being fed into at least one plasma gasifier PG. Suitable devices for preheating and / or pressurizing the liquid feedstock for feeding into the at least one plasma gasifier PG are known in the art, including, for example, flap valves and locks, as well as annual gaps, pressure nozzles and pressure atomizers, and can be adapted by a technician to the given additional feedstock F2. The at least one plasma gasifier PG is most preferably a fixed-bed plasma gasifier PG.

[0067] An overview of the plasma gasifier (PG) is provided, for example, in James G. Speight, Handbook of Gasification Technology, Scrivener Publishing and Wiley, 2020, Chapter 8.4.2, pages 259-262.

[0068] At least one plasma gasifier PG has at least one inlet and at least one outlet, through which a first feedstock F1 and at least one additional feedstock F2 are fed into the at least one plasma gasifier PG, and through which syngas is discharged from the at least one plasma gasifier PG. Preferably, the at least one plasma gasifier PG has more than one inlet. Thus, at least one additional feedstock F2 and the first feedstock F1 can be fed separately into the at least one plasma gasifier PG through separate inlets. The term "inlet" includes openings in the at least one plasma gasifier PG, such as flap valves and locks, as well as annual gaps (as in a dual-fluid atomizer), pressure nozzles, and pressure atomizers that are part of the burner. The plasma is formed by at least one plasma torch and at least one plasma source PS.

[0069] A plasma gasifier PG is preferred for a first feedstock F1 along with at least one additional feedstock F2 because the types of feedstocks with different calorific values ​​and availability can be better balanced in such a plasma gasifier PG to achieve consistent syngas production (e.g., yield, molar ratio H2:CO). Furthermore, less CO2 is produced in the plasma gasifier PG by the gasification of the first feedstock F1, particularly when steam is used as the plasma source PS and when at least one plasma torch is operated using electricity from a renewable source. Thus, less CO2 is formed compared to all gasifier types that rely on generating heat through (partial) oxidation.

[0070] Plasma gasification is a high-temperature waste treatment process that uses plasma (a gas composed of highly charged particles) to decompose organic matter into gas. In this process, a first feedstock F1 and at least one additional feedstock F2 are fed into a plasma gasification furnace PG. Preferably, the first feedstock F1 and at least one additional feedstock F2 are fed into the plasma gasification furnace PG, where they are exposed to at least one plasma torch, which ionizes the first feedstock F1 and at least one additional feedstock F2 and generates plasma. The plasma is generated by means of at least one plasma torch, more preferably, by means of at least two plasma torches. Most preferably, the plasma gasification furnace comprises three or more plasma torches. Preferably, at least one plasma torch is installed in the portion of the plasma gasification furnace PG where the first feedstock F1 and / or at least one additional feedstock F2 is fed into the plasma gasification furnace PG, and one or two plasma torches are installed in the portion of the plasma gasification furnace PG where the syngas exits the plasma gasification furnace PG (most preferably in an arrangement that forces the syngas through the one or two plasma torches). The high temperature inside the plasma gasifier PG (which can reach up to about 10,000 K) causes the first feedstock F1 and at least one other feedstock F2 to evaporate and decompose into constituent components, including hydrogen, carbon monoxide and methane.

[0071] Most preferably, at least one plasma gasifier PG is a fixed-bed plasma gasifier. Fixed-bed plasma gasifier PGs are better suited for the first feedstock F1 because the non-metallic inorganic fragments they contain cause less clogging and associated undesirable effects compared to other types of plasma gasifier PGs (such as fluidized-bed and entrained-flow plasma gasifier PGs).

[0072] Preferably, the power for operating at least one plasma torch of at least one plasma gasifier PG is generated from a renewable source. More preferably, the power for operating at least one plasma torch of at least one plasma gasifier PG is generated from at least one source selected from the group consisting of: solar energy, wind energy, tidal energy, nuclear energy, geothermal energy, and combinations thereof.

[0073] The plasma in at least one plasma gasifier PG is generated by at least one plasma source PS, which is selected from the group consisting of steam, oxygen, CO2, air, and combinations thereof. In the case of syngas with a desired molar ratio of H2:CO > 1, steam is most preferred as the plasma source PS. The syngas exiting the plasma gasifier PG also contains at least one plasma source PS or a portion thereof.

[0074] In step (iii), at least one plasma source is co-fed into at least one plasma gasifier PG. Most preferably, in step (iii), steam is co-fed into at least one plasma gasifier PG. The weight ratio of "(combined first feedstock F1 and optional additional feedstock F2) : steam" is preferably in the range of 1:1 to 10:1, more preferably 2:1 to 10:1, and most preferably 5:1 to 10:1 or higher.

[0075] Preferably, the ratio of "electrical power applied to one or more plasma torches: mass of the generated gas stream GS1" is preferably in the range of 0.1 to 15 kW / h: kg, more preferably 0.5 to 10 kW / h: kg, and most preferably 1 to 8 kW / h: kg. This ratio is preferred when using a first feedstock F1 to maintain the desired process conditions inside at least one plasma gasifier PG.

[0076] Preferably, the first raw material F1 and at least one other raw material F2 are compressed to a maximum of 4 bar (absolute value) and then fed into at least one plasma gasification furnace PG.

[0077] The temperature of the gas exiting the plasma gasifier PG is preferably in the range of 1100°C to 1400°C, and most preferably about 1300°C. The pressure of the syngas exiting the plasma gasifier PG is preferably at least 0.7 bar (absolute value), and more preferably at least 1 bar (absolute value). The residence time of the reactants inside the plasma gasifier PG is at least 2 to 3 s. The plasma is preferably generated by a gas (plasma source PS) selected from the group consisting of CO2, steam, O2, air, and mixtures thereof. More preferably, the plasma is generated by CO2, steam, or a mixture of CO2 and steam.

[0078] Preferably, the first feedstock F1 is fed into the plasma gasifier PG through an opening independent of the opening for feeding at least one other feedstock F2. Preferably, steam is fed into the plasma gasifier through another opening.

[0079] The gas stream GS1 then exits at least one plasma gasifier PG. The gas stream GS1 contains CO and H2 (“syngas”), byproducts of the gasification reaction such as CO2, CH4, and ash, and at least one plasma source PS or a portion thereof. The syngas formed in step (iii) preferably contains < 15 Vol.-% CO2, more preferably < 10 Vol.-% CO2, and most preferably < 8 Vol.-% CO2.

[0080] The method includes an additional step (iv), in which impurities and other unwanted components, such as at least one plasma source PS or a portion thereof, are removed from the gas stream GS1 formed in step (iii) within a gas processing unit GTU. This yields a gas stream GS2 having a first molar ratio of H2:CO.

[0081] Typical impurities in gas stream GS1 include chlorides, sulfur-containing organic compounds such as sulfur dioxide, trace heavy metals (e.g., as corresponding salts), tar / condensable hydrocarbons, particulate residues, and at least one plasma source PS or a portion thereof. Various chemical and / or physical methods for removing such impurities from gas stream GS1, such as filtration, washing, condensation, and absorption / adsorption, are known and can be selected and tailored according to the type and corresponding concentration of impurities in gas stream GS1 and the tolerance for such impurities in another process FP1. Some selected methods for removing impurities from gas stream GS1 will be discussed in more detail. One or more of these methods can also be implemented in a gas handling unit GTU. However, the choice of method does not limit the scope of the invention.

[0082] Other gaseous substances such as HCl and H2S are formed, and / or these substances are separated from gas stream GS1 in the gas processing unit GTU. Impurities are removed from gas stream GS1, and gas stream GS2 with a first molar ratio of H2:CO is obtained.

[0083] Particulate impurities can be removed from gas stream GS1 by cyclone separators and / or filters; chlorides are removed by wet scrubbing; trace heavy metals are removed by catalytic hydrolysis to convert sulfur-containing organic compounds into H2S; and acid gas removal is used to extract sulfur-containing gases such as H2S. Large and (fine) particles (such as dust) in gas stream GS1 can also be removed by quenching in the soot water scrubbing unit.

[0084] After the gas stream GS1 leaves the gasifier, particulate impurities can optionally be removed directly from the gas stream GS1 via a cyclone separator and / or filter. Therefore, particle removal from the gas stream GS1 can be part of the gasifier and / or part of a gas processing unit GTU fluidly connected to at least one plasma gasifier PG.

[0085] After the gas stream GS1 exits at least one plasma gasifier PG, fine particles can optionally be removed directly from the crude syngas using a filter. Therefore, the removal of fine particles from the gas stream GS1 can be part of at least one plasma gasifier PG and / or part of a gas processing unit GTU fluidly connected to at least one plasma gasifier PG.

[0086] The optional gas treatment unit (GTU) preferably includes a unit for removing at least a portion of CO2 from the gas stream GS1 in step (iv) by a method selected from or comprising the group consisting of: absorption, adsorption, membrane separation, cryogenic separation, and combinations thereof. Most preferably, the unit is a washing unit, such as "amine washing" or "methanol washing," which uses one or more amine compounds, such as alkanolamines or methanol, to absorb CO2. Such units are known in the art and can be adapted by a person skilled in the art to remove at least a portion of CO2 from the gas stream GS1.

[0087] Optionally, CO and / or H2 can be separated from the gas stream GS1. CO can be separated from the gas stream GS1 in a syngas separation unit, which is optionally downstream of and fluidly connected to at least one gasifier G. CO can be separated from the gas stream GS1 by cryogenic separation methods, often referred to as "cold boxes," which utilize the different boiling points of CO and H2. H2 can be separated using H2-selective membranes, which permeate through the membranes and are thus separated from the GS1 stream.

[0088] Gas stream GS1 has a first molar ratio of H2:CO. Optionally, gas stream GS1 is then preferably subjected to a water-gas shift reaction in a water-gas shift unit. This increases the H2 content in gas stream GS1 by causing a portion of the CO in gas stream GS1 to react with water to form additional H2 and CO2, thereby forming gas stream GS2 with a second molar ratio of H2:CO, which exits the water-gas shift unit. The H2 content in gas stream GS2, exiting the water-gas shift unit and having the second molar ratio of H2:CO, is higher than the content in gas stream GS1, exiting at least one gasifier and having the first molar ratio of H2:CO. The hydrogen content in gas stream GS1 can also be increased, for example, by adding hydrogen supplied from another source, such as by preferably using hydrogen formed by electrolyzing water with electricity from a renewable source (such as solar and / or wind power).

[0089] The water-gas shift reaction will be carried out in a temperature range of approximately 200°C to approximately 480°C using a variety of catalysts (such as copper-zinc-aluminum catalysts and chromium or copper-promoted iron-based catalysts).

[0090] Optionally, the gas stream GS2 can be compressed to a pressure in the range of 1.5 to 4 bar (absolute value).

[0091] Optionally, at least a portion of the CO2 separated from the gas stream GS1 in step (iv) is co-fed with a first feedstock F1 and optionally an additional feedstock F2 into at least one plasma gasifier PG, thereby converting it into syngas. Such CO2 is not considered additional feedstock F2. The weight ratio of CO2 to the combined feedstocks F1 and F2 fed into the at least one plasma gasifier ranges from 0 to 2, preferably from 0 to 1.5, and more preferably from 0 to 1. Thus, unwanted CO2 formed during the gasification process of the first feedstock F1 and at least one additional feedstock F2, or supplied as a plasma source PS, can be used as an additional feedstock for the production of syngas.

[0092] Furthermore, CO2 from other sources (such as other chemical processes) can optionally be co-fed with a first feedstock F1 and at least one additional feedstock F2 into at least one plasma gasifier PG, thereby being converted into syngas. Thus, unwanted CO2 from other sources can be used as an additional feedstock for the production of syngas.

[0093] Optionally, the gas stream GS2 is then subjected to an additional process FP1 selected from the group consisting of methanation, alcohol synthesis (preferably methanol synthesis), and Fischer-Tropsch synthesis, thereby forming at least one first product stream PS1. The gas stream GS2 can also be used as fuel gas, and the optional additional process FP1 is briefly described below:

[0094] Optionally, gas stream GS2 can be converted to methane via a methanation reaction. The methanation reaction is described by chemical reaction schemes (1) and (2):

[0095] CO + 3H2 CH4 + H2O(1)

[0096] CO2 + 4H2 CH4 + 2H2O(2)

[0097] Methanation reactions and suitable methanation units are described, for example, in S. Rönsch, J. Schneider, S. Matthischke, M. Schlüter, M. Götz, J. Lefebvre, P. Prabhakaran, S. Bajohr: Review on methanation - From fundamentals to current projects; Fuel 166 (2016) 276-296 and can be selected and adapted by a person skilled in the art.

[0098] The methanation reaction is a catalytic reaction, for example, using an alumina-supported nickel catalyst, preferably a honeycomb catalyst, at 1 to 70 bar and 200°C to 700°C, preferably 5 to 60 bar, more preferably 10 to 45 bar and preferably 200°C to 550°C, more preferably 10 to 45 bar.

[0099] Alcohols such as methanol are another chemical product that can be produced from gas stream GS2 via an optional additional process FP1. Most preferably, methanol is produced from syngas in a low-pressure methanol process in, for example, an adiabatic reactor or a quasi-isothermal reactor, by a catalytic gas-phase reaction using a catalyst at a temperature of about 200°C to about 300°C. The catalyst is, for example, a mixture of copper and zinc oxides supported on alumina. Methanol synthesis suitable for combination with the production system according to the invention and various alternatives thereof are disclosed in Ullmann's Encyclopedia of Industrial Chemistry (2012), chapter “Methanol”, pages 3 to 12.

[0100] The gas stream GS2 can also optionally be converted to hydrocarbons such as light synthetic crude oil via an FT process in an optional Fischer-Tropsch (FT) reactor unit. These hydrocarbons are also referred to as "Fischer-Tropsch hydrocarbons". The light synthetic oil can be further converted to naphtha, light olefins, or diesel fuel via hydrocracking and / or isomerization. For the production of gasoline and light olefins, the FT process operates at a temperature range of approximately 330°C to approximately 350°C and a pressure of approximately 2.5 MPa (high-temperature FT process); for the production of waxes and / or diesel fuels, the process operates at a temperature range of approximately 220°C to approximately 250°C and a pressure of approximately 2.5 MPa to approximately 4.4 MPa (low-temperature FT process). Suitable reactors for the low-temperature FT process include tubular fixed-bed reactors and slurry-bed reactors. Suitable reactors for the high-temperature FT process include circulating fluidized-bed reactors and SAS (Sasol advanced synthol) reactors. Iron-based and / or cobalt-based catalysts are used in the FT process. Suitable combinations of Fischer-Tropsch synthesis with the production system according to the invention and various alternatives thereof are disclosed in Ullmann's Encyclopedia of Industrial Chemistry (2012), chapter “Coal Liquefaction”, pages 20-33.

[0101] The invention is further illustrated by the following set of embodiments and combinations of embodiments derived from the dependent relationships and reverse references shown. In particular, it should be noted that in each instance in which a series of embodiments is mentioned, for example in the context of the term "method as described in any one of Embodiments 1 to 3," each embodiment in this series is intended to clearly disclose to those skilled in the art that the wording of the term should be understood by those skilled in the art to be synonymous with "method as described in any one of Embodiments 1, 2, and 3." Furthermore, it should be clearly noted that the following set of embodiments represents a suitable structural portion of the general description of preferred aspects of the invention.

[0102] 1. A method for producing syngas from raw materials, the method comprising the following steps:

[0103] (i) A first raw material F1 is provided, wherein the first raw material F1 comprises sorted crushed residue SSR, the sorted crushed residue SSR being formed by sorting unsorted crushed residue NSR.

[0104] The unsorted fragmented residue (NSR) comprises metal fragments and / or non-metallic inorganic fragments, as well as fragments of at least one polymer selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins, and polyolefins.

[0105] The unsorted crushed residue NSR is pre-sorted to form the sorted crushed residue SSR, preferably pre-sorted in the following order and manner:

[0106] a) Optionally, further reduce the size of the metal fragments and / or non-metallic inorganic fragments and at least one polymer fragment, and

[0107] b) Separate the metal fragments and / or the non-metallic inorganic fragments.

[0108] Thus, through step b), the sorted crushed residue SSR consists of metal-poor fragments and / or non-metallic inorganic fragments.

[0109] (ii) Provide at least one additional raw material F2,

[0110] (iii) The first raw material F1 provided in step (i) is combined with at least one additional raw material F2 provided in step (ii) and converted into a gas stream GS1 in at least one plasma gasification furnace PG, the gas stream GS1 comprising syngas, wherein the syngas comprises H2, CO and CO2, and wherein the at least one plasma gasification furnace PG comprises at least one plasma torch, the at least one plasma torch being electrically operated, wherein the plasma in the at least one plasma gasification furnace PG is generated by at least one plasma source PS, and

[0111] (iv) At least a portion of the CO2 is removed from the gas stream GS1 formed in step (iii) in the syngas upgrade unit SUP, thereby forming a gas stream GS2.

[0112] 2. The method according to Example 1, wherein the unsorted crushed residue NSR and the sorted crushed residue SSR include parts of the scrapped vehicle.

[0113] 3. The method according to Example 1 or 2, wherein the fragments of the at least one polymer are selected from at least one component, which is selected from the group consisting of: bumpers, interior trim panels, dashboards, cable insulation layers, electrical insulation materials, flexible foam seats, foam insulation boards, automotive suspension bushings, electrical potting compounds, body parts, pillar covers, spoiler polymer parts coated with automotive paint, wheel covers, gears, bushings, cams, bearings, weather-resistant coatings, interior and exterior trim, fuel systems, gear housings, headlight retainers, engine hoods, connector housings, door handles, carburetor components, exterior rearview mirror components, windshield wiper components, windshield wiper protection housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna covers, headlights and taillights, radiator grilles and exterior body parts, engine hoods, cylinder head covers, intake manifolds, cylinder head covers, engine hoods, turbocharger housings, and turbocharger valves.

[0114] 4. The method according to any one of Examples 1 to 3, wherein step a) is selected from the group consisting of or including the following: crushing, grinding, milling, sieving, grading and combinations thereof.

[0115] 5. The method according to any one of Examples 1 to 4, wherein at least 90 wt.% of the broken residue fragments formed in step a) are less than 5 cm, preferably at least 95 wt.% are less than 5 cm, and more preferably at least 95 wt.% are less than 3 cm.

[0116] 6. The method according to any one of Examples 1 to 5, wherein step b) includes at least removing metal fragments and / or non-metallic inorganic fragments from the unsorted crushed residue NSR.

[0117] 7. The method according to any one of Examples 1 to 6, wherein step b) is selected from the group consisting of or including: magnetic separation, eddy current separation, density separation, manual sorting and combinations thereof.

[0118] 8. The method according to Example 7, wherein the density separation is a method selected from the group consisting of or preferably the group consisting of: cyclone separation, jigging, air separation, sinking-floating separation and combinations thereof.

[0119] 9. The method according to any one of Examples 1 to 8, wherein the unsorted crushed residue NSR preferably contains up to 15 wt.-%, more preferably up to 10 wt.-%, and most preferably up to 5 wt.-%, of metal fragments, and / or preferably up to 15 wt.-%, more preferably up to 10 wt.-%, and most preferably up to 5 wt.-%, of glass fragments.

[0120] 10. The method according to any one of Examples 1 to 9, wherein the unsorted crushed residue NSR and / or the sorted crushed residue SSR are dried prior to step (iii).

[0121] 11. The method according to any one of Examples 1 to 10, wherein the polyamides are selected from the group consisting of PA 6, PA 66 and mixtures thereof.

[0122] 12. The method according to any one of Examples 1 to 11, wherein the polyisocyanate addition polymers are selected from the group consisting of polyurethane (PU), thermoplastic polyurethane (TPU), polyurea, polyisocyanurate (PIR), and mixtures thereof.

[0123] 13. The method according to any one of Examples 1 to 12, wherein the rubber is selected from the group consisting of: natural rubber, styrene-butadiene rubber, butyl rubber, ethylene propylene diene monomer rubber, chloroprene rubber, nitrile rubber, and silicone rubber.

[0124] 14. The method according to any one of Examples 1 to 13, wherein the polyolefins are selected from the group consisting of: low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene (PE), polypropylene (PP), and mixtures thereof.

[0125] 15. The method according to any one of Examples 1 to 14, wherein the sorted crushed residue SSR comprises at least two different polymers from the group consisting of polyamides, polyisocyanate addition polymers, and polyolefins.

[0126] 16. The method according to any one of Examples 1 to 15, wherein in step (ii) at least one feedstock F2 is provided, said at least one additional feedstock F2 being selected from the group consisting of or composed of: biomass, waste-derived fuel (RDF), pyrolysis oil derived from plastic waste, pyrolysis oil derived from scrap tires, pyrolysis oil derived from biomass, heating oil, vacuum residue, preferably vacuum distillation residue, crude oil residue, heavy crude oil, extra-heavy crude oil, tar sands bitumen, viscosity-reducing cracking bottom residue, deasphalting bottom residue, C5 asphaltene fraction, high-viscosity residue, fuel oil, pyrolytic gasoline, tire pyrolysis oil (TPO), waste oil, used oil, municipal solid waste (MSW), coal, tar, natural gas, contaminated vehicle parts and mixtures thereof.

[0127] 17. The method according to any one of Examples 1 to 16, wherein, optionally, the at least one additional raw material F2 provided in step (ii) is selected from the group consisting of or composed of: biomass, waste-derived fuel (RDF), pyrolysis oil made from plastic waste, pyrolysis oil made from scrap tires, pyrolysis oil made from biomass, municipal solid waste (MSW), coal, contaminated vehicle parts and mixtures thereof.

[0128] 18. The method according to any one of Examples 1 to 17, wherein the optional at least one additional raw material F2 is pretreated prior to step (ii) by a method selected from the group consisting of: sorting, sieving, milling, grinding, pyrolysis, calcination, metal sorting and combinations thereof.

[0129] 19. The method according to any one of Examples 1 to 18, wherein the weight ratio of "first raw material F1 : other raw material F2" is preferably in the range of 10 : 1 to 1 : 10, more preferably 1 : 2 to 1 : 10 and most preferably 1 : 5 to 1 : 10.

[0130] 20. The method according to any one of Examples 1 to 19, wherein the at least one plasma gasification furnace PG comprises at least three plasma torches.

[0131] 21. The method according to any one of Examples 1 to 20, wherein the power for operating the at least one plasma torch of the at least one plasma gasifier PG is generated from a renewable source.

[0132] 22. The method according to any one of Examples 1 to 21, wherein the electricity for operating the at least one plasma torch of the at least one plasma gasifier PG is generated from at least one source selected from the group consisting of: solar energy, wind energy, tidal energy, nuclear energy, geothermal energy, and combinations thereof.

[0133] 23. The method according to any one of Examples 1 to 22, wherein the plasma in the at least one plasma gasification furnace PG is generated by at least one plasma source PS, the at least one plasma source being selected from the group consisting of or including steam, oxygen, CO2, air, and combinations thereof.

[0134] 24. The method according to any one of Examples 1 to 23, wherein the ratio “electrical power applied to the one or more plasma torches: mass of the generated gas stream GS1” is preferably in the range of 0.1 to 15 kW / h: kg, more preferably 0.5 to 10 kW / h: kg and most preferably 1 to 8 kW / h: kg.

[0135] 25. The method according to any one of Examples 1 to 24, wherein the at least one plasma gasifier PG is a fixed-bed plasma gasifier.

[0136] 26. The method according to any one of Examples 1 to 25, wherein in step (iii), steam is co-fed into the at least one plasma gasification furnace PG.

[0137] 27. The method according to any one of Examples 1 to 26, wherein in step (iii), steam is co-fed into the at least one plasma gasifier PG, and wherein the weight ratio of "(combined first feedstock F1 and optional additional feedstock F2) : steam" is preferably in the range of 1:1 to 10:1, more preferably 2:1 to 10:1, and most preferably 5:1 to 10:1 or higher.

[0138] 28. The method according to any one of Examples 1 to 27, wherein the synthesis gas formed in step (iii) preferably contains < 15 Vol.-% CO2, more preferably < 10 Vol.-% CO2 and most preferably < 8 Vol.-% CO2.

[0139] 29. The method according to any one of Examples 1 to 28, wherein in step (iv) at least a portion of CO2 is removed by a method selected from the group consisting of: absorption, adsorption, membrane separation, cryogenic separation, and combinations thereof.

[0140] 30. The method according to any one of Examples 1 to 29, wherein the weight ratio of "CO2 : combined raw materials F1 and F2" fed into the at least one plasma gasifier in step (v) ranges from 0 to 2, preferably from 0 to 1.5 and more preferably from 0 to 1.

[0141] 31. The method according to any one of Examples 1 to 30, wherein the method includes an additional step (v) selected from the group consisting of: separating H2 and CO from each other in the gas stream GS2, compressing the gas stream GS2 and / or the H2 and / or the CO, the combination thereof, subjecting the gas stream GS2 to a Fischer-Tropsch process, subjecting the gas stream GS2 to methanation, and subjecting the gas stream GS2 to methanol synthesis.

[0142] 32. The method according to any one of Examples 1 to 31, wherein the monomer of at least one polymer is produced by the synthesis gas formed in step (iii), said at least one polymer being selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins and polyolefins.

[0143] 33. The method according to any one of Examples 1 to 32, comprising the following steps:

[0144] - The gas stream GS2 or CO or H2 that can be obtained or acquired by the method according to any one of Examples 1 to 33, or the chemical material that can be obtained or acquired by the method according to any one of Examples 1 to 33, is converted to obtain the product.

[0145] 34. The method according to Example 33, wherein the product is selected from:

[0146] a) Building blocks or single units; or

[0147] b) A polymer, preferably polymer A, a polymer composition, preferably polymer composition A, or a polymer product, preferably polymer product A; or

[0148] c) Cleaning polymers, cleaning surfactants, descaling compounds, cleaning biocides, or combinations thereof; or

[0149] d) Agricultural chemical compositions, agricultural chemical formulations, adjuvants, or agricultural chemical active ingredients; or

[0150] e) Active pharmaceutical ingredients or intermediates thereof, pharmaceutical excipients, animal feed additives, human food additives, dietary supplements, aromatic chemicals or aromatic compositions; or

[0151] f) The aqueous polymer dispersion is preferably a polyurethane or polyurethane-poly(meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings, polyisocyanate, hyperbranched polyester polyol, polymer dispersant for inorganic binder compositions, unsaturated polyester polyol, or 100% curable composition; or

[0152] g) Cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, other cosmetic ingredients or combinations thereof; or

[0153] h) Polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.

[0154] 35. The use of plasma gasification in at least one plasma gasification furnace PG for converting sorted crushed residue SSR into syngas, said sorted crushed residue SSR being formed by sorting unsorted crushed residue NSR, said unsorted crushed residue NSR comprising metal fragments and / or non-metallic inorganic fragments, said unsorted crushed residue NSR being pre-sorted to form said sorted crushed residue SSR, preferably in such a sequence as a) reducing the size of said unsorted crushed residue NSR and b) sorting metal fragments and / or glass fragments from said unsorted crushed residue NSR being pre-sorted, said sorted crushed residue SSR comprising at least one polymer selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins and polyolefins.

[0155] 36. The use according to embodiment 35, wherein the at least one plasma gasification furnace PG includes at least one plasma torch.

[0156] 37. The use according to embodiment 35 or 36, wherein the at least one plasma gasifier PG is a fixed-bed plasma gasifier.

[0157] It should be clearly noted that the above set of embodiments represents appropriate structural portions of a general description of preferred aspects of the invention, and therefore appropriately supports but does not represent the claims of the invention.

[0158] The present invention further relates to a method according to any one of Examples 33 or 34, wherein the content of the gas stream GS2 formed in step (iv) or CO or H2 formed therefrom in the product is 1 wt.-% or more, preferably 2 wt.-% or more, more preferably 5 wt.-% or more, more preferably 15 wt.-% or more, more preferably 30 wt.-% or more, more preferably 40 wt.-% or more, more preferably 60 wt.-% or more, more preferably 80 wt.-% or more, more preferably 90 wt.-% or more, more preferably 95 wt.-% or more; and / or wherein the content of the gas stream GS2 formed in step (iv) or CO or H2 formed therefrom in the product is 100 wt.-% or less, preferably 95 wt.-% or less, more preferably 90 wt.-% or less, more preferably 50 wt.-% or less, more preferably 25 wt.-% or less, more preferably 10 wt.-% or less. wt.-% or less; and preferably wherein the content is determined based on a source retention and / or separation and / or quality balance and / or certificate statement chain of custody model, preferably based on quality balance, preferably the International Sustainable Development and Carbon Certification (ISCC) standard.

[0159] Publication Prior Art Disclosure; Issue 684; Paragraphs

[1000] to

[8005] ; ISSN: 2198-4786; Publication date: February 12, 2024, shall be regarded as reference RF1, which is incorporated herein by reference in its entirety. Preferably, the product is the product as described in paragraphs

[1000] to

[8005] of reference RF1. Preferably, the method described herein is further a method for producing the product.

[0160] The conversion steps for obtaining the product preferably include one or more steps as described below, and can be carried out by conventional methods well known to those skilled in the art. The conversion steps preferably include one or more steps selected from: recycling, preferably depolymerization, gasification, pyrolysis and / or steam cracking; and / or purification, preferably crystallization, (solvent) extraction, distillation, evaporation, hydrogenation, absorption, adsorption and / or ion exchange; and / or assembling, preferably foaming, synthesis, chemical conversion, chemical transformation, polymerization and / or blending; and / or shaping, preferably foaming, extrusion and / or molding; and / or finishing, preferably coating and / or smoothing.

[0161] In addition, one or more of these steps are described in detail in paragraphs

[1000] to

[8005] of reference RF1.

[0162] As used herein, the term "building unit" includes compounds that are in a gaseous or liquid state under standard conditions of 0°C and 0.1 MPa. Building units are typically used in the chemical industry to form secondary products that offer greater structural complexity and / or higher molecular weight than the building unit on which the secondary products are based. Building units are preferably selected from the group consisting of free hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycol, syngas containing mixtures of hydrogen and carbon monoxide, alkanes, alkenes, alkynes, and aromatic compounds. Alkanes, alkenes, alkynes, and aromatic compounds particularly contain 1 to 12 carbon atoms, respectively.

[0163] As used herein, the term "monomer" includes molecules that can react with each other to form polymer chains through polymerization. Monomers are preferably selected from the group consisting of: (meth)acrylic acid, salts of (meth)acrylic acid; particularly sodium, potassium, and zinc salts; (meth)acrylaldehyde and (meth)acrylates. (Meth)acrylates containing 1 to 22 carbon atoms, particularly 1 to 8 carbon atoms, are preferred. The terms (meth)acrylic acid, (meth)acrylaldehyde, or (meth)acrylate refer to acrylic acid, acrolein, or acrylates, and where applicable, to methacrylic acid, methacrolein, or methacrylates. Furthermore, monomers may be selected from hexamethylenediamine (HMD) and adipic acid.

[0164] The building blocks may further be intermediate compounds. As used herein, the term "intermediate compound" includes organic reagents that are used to form compounds with higher molecular complexity. Intermediate compounds may, for example, be selected from the group consisting of phosgene, polyisocyanates, and propylene oxide. Polyisocyanates are particularly aromatic diisocyanates and polyisocyanates, preferably toluene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI).

[0165] The building blocks and monomers, as well as one or more typical transformation steps used to obtain the building blocks or monomers, are described in more detail in paragraphs

[1000] through

[1012] of reference RF1.

[0166] As used herein, the term “polymer A” includes thermoplastics (e.g., polyamides or thermoplastic polyurethanes), thermosettings (e.g., polyurethanes), elastomers (e.g., polybutadiene) or copolymers or mixtures thereof, and is defined in more detail in paragraphs

[2001] through

[2007] of reference RF1.

[0167] As used herein, the term “polymer composition A” includes all compositions comprising the polymers described above and one or more additives (e.g., reinforcing agents, colorants, modifiers and / or flame retardants), and is defined in more detail in paragraph

[2008] of reference RF1.

[0168] As used herein, the term “polymer product A” includes any product comprising polymer A and / or polymer composition A as described above, and is defined in more detail in paragraphs

[2009] and

[2010] of reference RF1.

[0169] One or more steps for obtaining a polymer (preferably polymer A), a polymer composition (preferably polymer composition A), or a polymer product (preferably polymer product A) are described in more detail in paragraph

[2011] of reference RF1.

[0170] As used herein, the term "industrial polymer" includes rheological polymers based on polycarboxylate, alkoxylated polyalkyleneamine, alkoxylated polyalkyleneimide, polyether, dye-inhibiting and dirt-releasing cleaning polymers, as defined in more detail in paragraphs

[3035] through

[3044] of reference RF1. As used herein, the term "industrial surfactant" includes nonionic, anionic, and amphoteric industrial surfactants, as defined in more detail in paragraphs

[3008] through

[3034] of reference RF1. As used herein, the term "industrial descaling compound" includes nonphosphate-based detergent builders (NPB) and phosphonates (CoP), as described in more detail in paragraphs

[3001] through

[3005] of reference RF1. As used herein, the term "industrial biocide" refers to compounds that kill or inhibit the growth or reproduction of microorganisms, as defined in more detail in paragraphs

[3006] through

[3007] of reference RF1. As used herein, the term “industrial solvent” includes alkylamides, alkyl lactamides, alkyl esters, lactates, alkyl diesters, cyclic alkyl diesters, cyclic carbonates, aromatic aldehydes, and aromatic esters, as defined in more detail in paragraphs

[3045] through

[3055] of reference RF1. As used herein, the term “industrial dispersant” includes anionic and nonionic industrial dispersants, as defined in more detail in paragraphs

[3056] through

[3058] of reference RF1. The term “composition and / or formulation thereof” with respect to industrial polymers, industrial surfactants, scale-removing compounds, and / or industrial biocides refers to industrial compositions and / or institutional products and / or textile and household care products and / or personal care products, as defined in more detail in paragraph

[3059] of reference RF1. One or more conversion steps for obtaining industrial polymers, industrial surfactants, scale-removing compounds, and / or industrial biocides are defined in more detail in paragraph

[3060] of reference RF1. The conversion steps for obtaining industrial compositions or formulations of industrial polymers, industrial surfactants, scale-removing compounds and / or industrial biocides are defined in more detail in paragraph

[3061] of reference RF1.

[0171] As used herein, the term "agricultural chemical composition" typically refers to a composition comprising an agricultural chemical active ingredient and at least one agricultural chemical formulation adjuvant. Examples of agricultural chemical compositions, active ingredients, and adjuvants are described in more detail in paragraph

[4001] of reference RF1.

[0172] Agricultural chemical compositions can be in any conventional formulation form. These agricultural chemical compositions are prepared in known ways, for example, as described in: Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. One or more conversion steps to obtain agricultural chemical active ingredients and adjuvants can be similar to one or more generation steps of their analogues based on petrochemicals or other precursors not obtained through recycling methods. Furthermore, the conversion of compounds mentioned in the sections “Polymers” and “Cosmetic Surfactants, Emollients, Waxes, Cosmetic Polymers, UV Filters, Other Cosmetic Ingredients or Combinations or Formulations thereof” can be carried out as described in those sections and the corresponding paragraphs in reference RF1.

[0173] As used herein, the terms active pharmaceutical ingredient and / or its intermediates include substances that provide pharmacological activity or other direct action or influence the structure or any function of the body in the diagnosis, cure, relief, treatment or prevention of a disease. Intermediates are isolated products generated during a multi-step synthetic route of the active pharmaceutical ingredient. As used herein, the term pharmaceutical excipient includes compounds or mixtures of compounds used in compositions for various pharmaceutical applications that are substantially non-pharmaceutical in themselves. Active pharmaceutical ingredients and / or their intermediates, as well as pharmaceutical excipients, are defined in more detail in paragraph

[5001] of reference RF1.

[0174] One or more conversion steps for obtaining an active pharmaceutical ingredient and / or its intermediates and pharmaceutical excipients may include one or more synthetic steps and may be carried out by conventional synthesis and techniques well known to those skilled in the art.

[0175] As used herein, the terms animal feed additives, human food additives, and dietary supplements include vitamins, provitamins, and their active metabolites, including intermediates and precursors, particularly vitamins A, B, E, D, and K, and their esters (such as acetates, propionates, and palmitates) or their alcohols (such as retinol) or their salts or any combination thereof; tetraterpenes, particularly isoprene-like compounds, such as carotenoids and lutein, including their intermediates and precursors, as well as mixtures and derivatives thereof, particularly β-carotene, canthaxanthin, hesperidin, astaxanthin, zeaxanthin, lutein, and tomato. Red pigments, apocarotenoids, and any combination thereof; organic acids, especially formic acid, propionic acid, and their salts (such as sodium, calcium, or ammonium salts) and any combination thereof, such as, but not limited to, formic acid and sodium formate, propionic acid and ammonium propionic acid, formic acid and propionic acid, formic acid and sodium formate, and mixtures of propionic acid, propionic acid and sodium propionic acid, and formic acid and sodium formate; glycerides of carboxylic acids and short- and medium-chain fatty acids, conjugated linoleic acid (such as omega-6 fatty acid (C18:2) methyl esters), and 1,2-propanediol; and beverage stabilizers such as polyvinylpyrrolidone polymers or polyvinylimazole / polyvinylpyrrolidone copolymers. Animal feed additives, human food additives, and dietary supplements are defined in more detail in paragraph

[5002] of reference RF1.

[0176] One or more conversion steps used to obtain animal feed additives, human food additives, or dietary supplements may include one or more synthetic steps and may be carried out by conventional synthesis and techniques well known to those skilled in the art.

[0177] As used herein, aromatic chemicals and aromatic compositions include volatile organic compounds with a molecular weight between 70 and 250 g / mol, comprising a carbon skeleton of C5-C6. 16 Functional groups of carbon atoms, the carbon skeleton including straight chains, branches, and rings (e.g., rings with a size of C5-C). 18 Aromatic chemicals are bicyclic or tricyclic aliphatic chains, but do not necessarily contain one or more unsaturated structural elements such as double bonds, triple bonds, aromatic or heteroaromatic groups, and preferably, one or more additional functional groups are selected from alcohols, ethers, esters, ketones, aldehydes, acetals, carboxylic acids, nitriles, thiols, and amines. In one aspect, aromatic chemicals are terpenoid-based aromatic chemicals, such as those selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes, or tetraterpenes. Aromatic chemicals can be combined with other aromatic chemicals to obtain aromatic compositions. Aromatic chemicals and aromatic compositions are defined in more detail in paragraph

[5003] of reference RF1.

[0178] One or more conversion steps for obtaining aromatic chemicals and aromatic compositions may include one or more synthetic steps and may be carried out by conventional synthesis and techniques well known to those skilled in the art.

[0179] As used herein, the term "aqueous polymer dispersion" includes one or more aqueous compositions comprising one or more dispersed polymers, and is defined in more detail in the section entitled "Aqueous Polymer Dispersions" of reference RF1

[6001] . One or more dispersed polymers may be selected from one or more acrylic emulsion polymers, one or more styrene acrylic emulsion polymers, one or more styrene butadiene dispersions, one or more aqueous dispersions comprising composite particles, one or more acrylate-alkyd hybrid dispersions, one or more polyurethanes (including UV-curable polyurethanes), and one or more polyurethane-poly(meth)acrylate hybrid polymers. As used herein, the term "emulsion polymer" includes one or more polymers prepared by free radical emulsion polymerization. One or more aqueous polyurethane dispersions are defined in more detail in the section entitled "Polyurethane Dispersions" of reference RF1

[6002] . One or more UV-curable polyurethanes are defined in more detail in the section entitled "Polyurethane Dispersions" of reference RF1

[6017] . One or more polyurethane-poly(meth)acrylate hybrid polymers are defined in more detail in the section of reference RF1

[6016] .

[0180] As used herein, the term “polymer dispersant” preferably includes one or more polymers comprising polyether side chains, particularly one or more polycarboxylate ether polymers and one or more condensation products as defined in more detail in the paragraph entitled “Polymer Dispersants” in reference RF1

[6020] .

[0181] One or more conversion (polymerization) steps for obtaining one or more aqueous polymer dispersions comprising one or more emulsion polymers are defined in more detail in the section entitled “Emulsion Polymerization” in reference RF1

[6003] .

[0182] One or more conversion (polymerization) steps for obtaining one or more waterborne polyurethane dispersions are defined in more detail in the section entitled “Methods for preparing waterborne polyurethane dispersions”

[6014] and the section entitled “UV-curable waterborne polyurethane dispersions, their preparation and use and compositions containing them”

[6017] of reference RF1.

[0183] Compositions and uses of one or more aqueous polymer dispersions and one or more polymer dispersants are defined in more detail in the following sections of reference RF1:

[0184] The section titled "Applications of Aqueous Polymer Dispersions"

[6004]

[0185] The section titled "Adhesives for Building and Building Coatings"

[6005]

[0186] The section titled "Adhesives for Paper Coatings"

[6006]

[0187] The section titled "Adhesives for Fiber Bonding"

[6007]

[0188] The section titled "Adhesive Polymers and Adhesive Compositions"

[6008]

[0189] The section titled "Aqueous Polyurethane Dispersions Suitable for Coating Compositions"

[6015]

[0190] The section titled "Waterborne polyurethane-poly(meth)acrylate hybrid polymer dispersions suitable for coating compositions"

[6016]

[0191] The section titled "Waterborne UV-curable polyurethane dispersions, their preparation and uses, and compositions containing them"

[6017]

[0192] Section entitled “Inorganic binder compositions containing polymer dispersants and their uses”

[6018]

[6019] 100% curable coating compositions.

[0193] One or more UV-crosslinkable poly(meth)acrylates and their uses are defined in more detail in the section entitled “UV-crosslinkable poly(meth)acrylates for use in UV-curable solvent-free hot melt adhesives and their use in the preparation of pressure-sensitive self-adhesive products” in reference RF1

[6009] .

[0194] One or more polyisocyanates, one or more compositions comprising them, and their uses are defined in more detail in the section entitled “Polyisocyanates” in reference RF1

[6010] .

[0195] One or more hyperbranched polyester polyols and their uses are defined in more detail in the section entitled "Organic solvent-based hyperbranched polyester polyols suitable for coating compositions"

[6011] of reference RF1. One or more conversion steps for obtaining hyperbranched polyester polyols are defined in more detail in the section entitled "Preparation of organic solvent-based hyperbranched polyester polyols"

[6012] of reference RF1. One or more coating compositions comprising one or more hyperbranched polyester polyols, one or more polyisocyanates and one or more additives, and one or more substrates coated therewith are defined in more detail in the section entitled "Organic solvent-based two-component coating compositions comprising hyperbranched polyester polyols and polyisocyanates"

[6013] of reference RF1.

[0196] One or more unsaturated polyester polyols, one or more solvent-based coating compositions comprising said one or more unsaturated polyester polyols, and one or more substrates for coating with said one or more coating compositions are defined in more detail in the section entitled “Coating compositions comprising unsaturated polyester polyols” in reference RF1

[6018] .

[0197] One or more 100% curable coating compositions are defined in more detail in section

[6019] of reference RF1.

[0198] One or more polymeric dispersants for use in inorganic binder compositions are defined in more detail in section

[6020] of reference RF1. One or more inorganic binder compositions comprising polymeric dispersants and their uses are defined in more detail in section

[6021] of reference RF1. One or more conversion steps for obtaining one or more polymeric dispersants are defined in more detail in section

[6020] of reference RF1. As used herein, the term "inorganic binder composition" comprising one or more polymeric dispersants preferably includes, in particular, hydraulic coagulating compositions and compositions comprising calcium sulfate, and is defined in more detail in section

[6021] of reference RF1 entitled "Inorganic Binder Compositions Containing Polymer Dispersants and Their Uses". Specific one or more building material formulations comprising one or more polymeric dispersants, or one or more building products produced from building material formulations containing polymeric dispersants, are disclosed in more detail in section

[6021] of reference RF1.

[0199] As used herein, the term “cosmetic surfactant” includes nonionic, anionic, cationic, and amphoteric surfactants, and is defined in more detail in paragraph

[7002] of reference RF1. As used herein, the term “emollient” refers to a compound used to protect, moisturize, and / or lubricate the skin, and is defined in more detail in paragraph

[7003] of reference RF1. As used herein, the term “wax” includes pearlescent agents and opacifiers, and is defined in more detail in paragraph

[7004] of reference RF1. As used herein, the term “cosmetic polymer” includes any polymer that can be used as an ingredient in cosmetic formulations, and is defined in more detail in paragraph

[7005] of reference RF1. As used herein, the term “UV filter” refers to a compound that blocks or absorbs ultraviolet light, and is defined in more detail in paragraph

[7006] of reference RF1. As used herein, the term “additional cosmetic ingredient” includes any ingredient suitable for the preparation of cosmetic formulations. Several sources disclose ingredients acceptable for cosmetic use. For example, the Cosing database on the European Commission's website discloses cosmetic ingredients, as does the International Dictionary and Handbook of Cosmetic Ingredients edited by the Personal Care Products Association (PCPC). The term "compositions and / or formulations thereof" in relation to cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, and / or other cosmetic ingredients refers to personal care and / or cosmetic compositions or formulations as defined in more detail in paragraph

[7007] of reference RF1. One or more conversion steps used to obtain cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, or other cosmetic ingredients are defined in more detail in paragraph

[7008] of reference RF1.

[0200] The terms “polymer B”, “polymer composition B”, “coating composition”, “other functional composition”, “foil”, “molded body”, “coating” and “coated substrate” are well known to those skilled in the art and are defined in more detail from paragraphs

[8000] to

[8005] of reference RF1.

[0201] The present invention will be further explained through the following non-limiting examples. Example

[0202] For the following example, a fixed-bed plasma gasifier PG is compared with a combination of fluidized-bed and entrained-flow gasifiers using conventional solid-feed gasifiers. As the main feed, automotive crushing residue with 50 wt.-% carbon, 6 wt.-% hydrogen, 10 wt.-% oxygen, 1 wt.-% nitrogen, 3 wt.-% sulfur, and 30 wt.-% ash (“inert matter”) is used as the first feedstock F1 for sorting.

[0203] Example 1 (This invention)

[0204] The plasma fixed-bed gasifier is fed with a mass ratio (kg:kg) of "first feedstock F1: first gas stream GS1" = 1.01. The first feedstock F1 is sorted automotive wreck residue as a sorting crushed residue SSR. The plasma is generated by steam, and for the desired amount of plasma, a mass ratio (kg:kg) of "steam: generated gas stream GS1" = 0.25 is used. The steam has a pressure of 5.4 bar and a temperature of 180°C. A ratio (kW / h:kg) of "electrical power applied to the plasma torch: mass of generated gas stream GS1" = 3.91 is used to achieve the desired gas phase temperature of 1350°C at the outlet of the fixed-bed plasma gasifier PG. The fixed-bed plasma gasifier PG operates under atmospheric pressure. In step (iv), all the CO2 generated in the gas stream GS1 is separated from the gas stream in the gas processing unit GTU and fed into the fixed-bed plasma gasifier PG. Therefore, no CO2 is emitted from this process. The molar ratio of H2:CO in gas streams GS1 and GS2 is 2.07.

[0205] Example 2 (contrast)

[0206] For comparison, a conventional solid-feed gasifier combination of 1. a fluidized bed gasifier and 2. an entrained gasifier was simulated (the fluidized bed gasifier generates a rough first gas stream GS1r from a first feedstock F1, which is then converted into a gas stream GS1 containing syngas in the entrained gasifier). The fluidized bed gasifier was fed with a mass ratio (kg:kg) "first feedstock F1 : generated first gas stream GS1r" = 0.98 kg. Additionally, oxygen was fed with a syngas ratio of 0.53 kg / kg, and steam was fed with rough syngas at a mass ratio (kg:kg) "steam : generated rough gas stream GS1" = 0.49 kg / kg for fluidization. The steam had a pressure of 5.4 bar and a temperature of 180°C. The rough first gas stream GS1r exiting the fluidized bed gasifier had a temperature of 850°C and a pressure of 4 bar. In the secondary reformer (gutter gas reactor), the crude gas stream GS1r is heated in the second gasifier (gutter gas reactor) by introducing additional oxygen at a mass ratio (kg:kg) "oxygen:produced first gas stream GS1" = 0.14 kg. A temperature of 1350°C is reached at the outlet of the gutter gasifier. In step (iv), CO2 from the synthesis gas contained in the produced gas stream GS2 at a CO2 ratio of 0.39 kg / kg is separated and subsequently discharged. The molar ratio of H2:CO in gas streams GS1 and GS2 is 0.94.

Claims

1. A method for producing syngas from raw materials, the method comprising the following steps: (i) A first raw material F1 is provided, wherein the first raw material F1 comprises sorted crushed residue SSR, the sorted crushed residue SSR being formed by sorting unsorted crushed residue NSR. The unsorted fragmented residue (NSR) comprises metal fragments and / or non-metallic inorganic fragments, as well as fragments of at least one polymer selected from the group consisting of polyamides, polyisocyanate addition polymers, rubbers, epoxy resins, and polyolefins. The unsorted crushed residue NSR is pre-sorted to form the sorted crushed residue SSR, preferably pre-sorted in the following order and manner: a) Optionally, further reduce the size of the metal fragments and / or non-metallic inorganic fragments and at least one polymer fragment, and b) Separate the metal fragments and / or the non-metallic inorganic fragments. Thus, through step b), the sorted crushed residue SSR consists of metal-poor fragments and / or non-metallic inorganic fragments. (ii) Provide at least one additional raw material F2, (iii) The first raw material F1 provided in step (i) is combined with at least one additional raw material F2 provided in step (ii) and converted into a gas stream GS1 in at least one plasma gasification furnace PG, the gas stream GS1 comprising syngas, wherein the syngas comprises H2, CO and CO2, and wherein the at least one plasma gasification furnace PG comprises at least one plasma torch, the at least one plasma torch being electrically operated, wherein the plasma in the at least one plasma gasification furnace PG is generated by at least one plasma source PS, and (iv) At least a portion of the CO2 is removed from the gas stream GS1 formed in step (iii) in the syngas upgrade unit SUP, thereby forming a gas stream GS2.

2. The method according to claim 1, wherein, The unsorted crushed residue NSR and the sorted crushed residue SSR include parts of the scrapped vehicle.

3. The method according to claim 1 or 2, wherein, These fragments of at least one polymer are selected from fragments of at least one component, which is selected from the group consisting of: bumpers, interior trim panels, dashboards, cable insulation, electrical insulation materials, flexible foam seats, foam insulation panels, automotive suspension bushings, electrical potting compounds, body parts, pillar covers, polymer spoiler parts coated with automotive paint, wheel covers, gears, bushings, cams, bearings, weather-resistant coatings, interior and exterior trim, fuel systems, gear housings, headlight retainers, engine hoods, connector housings, door handles, carburetor components, exterior rearview mirror components, windshield wiper components, windshield wiper protection housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna covers, headlights and taillights, radiator grilles and exterior body parts, engine hoods, cylinder head covers, intake manifolds, cylinder head covers, engine hoods, turbocharger housings, and turbocharger valves.

4. The method according to any one of claims 1 to 3, wherein, Step a) is selected from the group consisting of or including the following: crushing, grinding, milling, screening, grading, and combinations thereof.

5. The method according to any one of claims 1 to 4, wherein, Step b) is selected from the group consisting of: magnetic separation, eddy current separation, density separation, manual sorting and combinations thereof.

6. The method according to any one of claims 1 to 5, wherein, In step (ii), at least one feedstock F2 is provided, wherein the at least one additional feedstock F2 is selected from the group consisting of or comprising: biomass, waste-derived fuel (RDF), pyrolysis oil derived from plastic waste, pyrolysis oil derived from scrap tires, pyrolysis oil derived from biomass, heating oil, vacuum residue, preferably vacuum distillation residue, crude oil residue, heavy crude oil, extra-heavy crude oil, tar sands asphalt, viscosity-reducing cracking bottom residue, deasphalting bottom residue, C5 asphaltene fraction, high-viscosity residue, fuel oil, pyrolytic gasoline, tire pyrolysis oil (TPO), waste oil, used oil, municipal solid waste (MSW), coal, tar, natural gas, CO2, contaminated vehicle parts and mixtures thereof.

7. The method according to any one of claims 1 to 6, wherein, The at least one plasma gasification furnace PG includes at least three plasma torches.

8. The method according to any one of claims 1 to 7, wherein, The power used to operate the at least one plasma torch of the at least one plasma gasifier PG is generated from a renewable source.

9. The method according to any one of claims 1 to 8, wherein, The plasma in the at least one plasma gasification furnace PG is generated by at least one plasma source PS, which is selected from the group consisting of steam, oxygen, CO2, air, and combinations thereof.

10. The method according to any one of claims 1 to 9, wherein, The ratio "electrical power applied to the one or more plasma torches: mass of the generated gas stream GS1" is preferably in the range of 0.1 to 15 kW / h: kg, more preferably 0.5 to 10 kW / h: kg, and most preferably 1 to 8 kW / h: kg.

11. The method according to any one of claims 1 to 10, wherein, In step (iii), steam is co-fed into the at least one plasma gasifier PG, and the weight ratio of "(combined first feedstock F1 and additional feedstock F2): steam" is preferably in the range of 1:1 to 10:1, more preferably 2:1 to 10:1 and most preferably 5:1 to 10:1 or higher.

12. The method according to any one of claims 1 to 11, wherein, In step (iv), at least a portion of the CO2 is removed by a method selected from the group consisting of: absorption, adsorption, membrane separation, cryogenic separation, and combinations thereof.

13. The method according to any one of claims 1 to 12, wherein, In step (v), the weight ratio of "CO2 : combined raw materials F1 and F2" fed into the at least one plasma gasifier ranges from 0 to 2, preferably from 0 to 1.5, and more preferably from 0 to 1.

14. The method according to any one of claims 1 to 13, comprising the following steps: - The synthesis gas or CO or H2 that can be obtained or acquired by the method according to any one of claims 1 to 12, or the chemical material that can be obtained or acquired by the method according to claim 13, is converted to obtain the product.

15. The method according to claim 14, wherein, This product is selected from: a) Building blocks or single units; or b) A polymer, preferably polymer A, a polymer composition, preferably polymer composition A, or a polymer product, preferably polymer product A; or c) Cleaning polymers, cleaning surfactants, descaling compounds, cleaning biocides, or combinations thereof; or d) Agricultural chemical compositions, agricultural chemical formulations, adjuvants, or agricultural chemical active ingredients; or e) Active pharmaceutical ingredients or intermediates thereof, pharmaceutical excipients, animal feed additives, human food additives, dietary supplements, aromatic chemicals or aromatic compositions; or f) The aqueous polymer dispersion is preferably a polyurethane or polyurethane-poly(meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings, polyisocyanate, hyperbranched polyester polyol, polymer dispersant for inorganic binder compositions, unsaturated polyester polyol, or 100% curable composition; or g) Cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, other cosmetic ingredients or combinations thereof; or h) Polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.