Waste Conversion Methods

Abstract

introducing a waste feed material into a reaction vessel, at least a portion of the waste feed material comprising organic material; treating the waste feed material in a reactor vessel at elevated temperature in the presence of a catalyst to convert the organic material into one or more hydrocarbon compounds; removing one or more hydrocarbon compounds from the reaction vessel for use or further processing; 10. A method for the conversion of waste materials, comprising:

Description

[Technical Field]

[0001] The present invention relates to a waste conversion process, in particular to a waste conversion process for converting organic waste materials into energy.

[0002] Background technology For many years, alternative sources of hydrocarbon fuels to those produced from crude oil have been sought. The use of catalytic depolymerization to convert hydrocarbon waste materials into hydrocarbon fuels has been proposed as one such alternative.

[0003] Catalytic depolymerization (CDP) processes use heat and catalysts to convert biomass and mineral-based products (such as plastics) into hydrocarbon fuels, such as diesel. However, existing CDP technologies require extensive pretreatment of waste materials to minimize particle size through mechanical force. The required equipment, such as shredders and disintegrators, is energy-intensive and expensive to maintain and replace. Furthermore, existing CDP technologies typically experience frequent blockages and slow input rates, resulting in frequent interruptions in hydrocarbon fuel production. Furthermore, other competing technologies typically require the use of significantly higher temperatures (on the order of over 450°C) and pressures (typically above atmospheric pressure), which are expensive to maintain and require the use of specialized equipment.

[0004] Some attempts have been made to overcome these problems. For example, PCT Application No. PCT / AU2017 / 000137 describes a CDP process for generating diesel from waste materials. However, in this process, based on the nature of the feed material, the feed material is separated into distinct waste streams that must be processed separately and then recombined before being used in the CDP process.

[0005] Separating and processing the separate feed streams (including size reduction) is a labor-, time-, and energy-intensive process. Furthermore, when waste materials containing two materials (such as polymer-coated electrical wiring) are present, the separation of the feed materials is imprecise. While products produced by the process of PCT / AU2017 / 000137 may be of higher quality than more traditional CDP processes, the process itself is complex, time-consuming, imprecise, and expensive.

[0006] It would therefore be advantageous to be able to provide a method for converting waste materials into energy that is efficient, indiscriminate with respect to the composition of the waste material, cost-effective, and relatively rapid.

[0007] Where a prior art publication is referred to herein, it will be expressly understood that this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or any other country.

[0008] Summary of the Invention The present invention is directed to a waste conversion method that may at least partially overcome at least one of the above-mentioned drawbacks or provide a useful or commercial choice for consumers.

[0009] In view of the above, the present invention provides introducing a waste feed material into a reaction vessel, at least a portion of the waste feed material comprising organic material, the organic material comprising a biomass portion and / or a polymer portion; treating the waste feed material in a reaction vessel at elevated temperature in the presence of a medium comprising one or more ionic liquids, and / or one or more catalysts, and / or one or more solvents, wherein the medium is configured to convert organic material into one or more hydrocarbon compounds; removing one or more hydrocarbon compounds from the reaction vessel for use or further processing; It broadly belongs to methods for the transformation of waste, including

[0010] The waste feed material may be in any suitable form. The waste materials forming the waste feed material may originate from a single source or from multiple sources. In embodiments of the present invention in which the waste materials originate from multiple sources, the waste materials may be combined at the location where the method of the present invention is performed or at a location remote from the location where the method is performed. In this embodiment, the waste materials may be provided to the location where the method is performed in the form of a waste feed material.

[0011] At least a portion of the waste feed material may be contained in a storage vessel at the location where the method of the present invention is performed. Any suitable storage vessel, such as a bag, sack, box, container, drum, or the like, may be used. In some embodiments, for example, when the waste material is contained in bags, sacks, and boxes, the storage vessel may also be processed by the method of the present invention, and thus the waste material may be introduced into the method without opening the storage vessel. However, in some embodiments, it may be beneficial to open the storage vessel to prevent the introduction of hazardous or dangerous materials (e.g., batteries, asbestos, etc.) into the method. The storage vessel may be opened manually or may be opened using one or more machines. Similarly, any hazardous or dangerous materials may be removed from the exposed waste material manually or with one or more machines (e.g., a robotic arm, etc.).

[0012] The waste may be from any suitable source, for example, the waste may be from agricultural, residential, commercial, construction, or industrial sources, or a combination thereof.

[0013] As noted above, at least a portion of the waste feed material comprises organic material. The organic material may comprise any suitable proportion of the waste feed material. Preferably, however, the organic material comprises at least 1% w / w of the waste feed material. More preferably, the organic material comprises at least 10% w / w of the waste feed material. More preferably, the organic material comprises at least 25% w / w of the waste feed material. More preferably, the organic material comprises at least 50% w / w of the waste feed material.

[0014] The organic material may be in any suitable form. Preferably, however, at least a portion of the organic material comprises biomass. Biomass may be in any suitable form, such as, but not limited to, plant matter (including fruits, vegetables, legumes, grains, grasses, leaves, etc.) or animal matter. Biomass may also include wood, paper, cardboard, waste products (such as bagasse), food waste, etc.

[0015] In some embodiments, at least a portion of the organic material may comprise polymeric materials such as plastics (e.g., but not limited to, HDPE, PP, PET, PVC, or polystyrene), agricultural waste plastics, rubber (synthetic and / or natural), or oils (including crude oil) and other materials derived from oils.

[0016] In the most preferred embodiment of the present invention, the organic material comprises a mixture of biomass and / or polymeric material. The organic material may be liquid, solid, or a combination of both.

[0017] It is contemplated that at least a portion of the waste feed material may include inorganic materials. The inorganic materials may include materials such as metal, glass, rock, and the like. In some embodiments of the present invention, the waste feed material may undergo a pre-sorting process. It is contemplated that this pre-sorting process occurs prior to pre-treatment or processing to remove large or hazardous materials and / or items, or materials and / or items that are incompatible with the methods of the present invention. These items may include, but are not limited to, easily removable inorganic materials such as asbestos, batteries, explosives, pressurized containers, radioactive materials, corrosive materials, toxic materials, and / or electrical appliances.

[0018] The waste feed material may undergo one or more processing steps prior to processing in the reaction vessel. The one or more processing steps may be of any suitable form, although in one embodiment of the present invention the waste feed material may undergo a dewatering process. It will be understood that in this context the term "dewatering" is intended to refer to at least partial removal of water and any other liquids that may be present from the waste feed material.

[0019] The dehydration process may be of any suitable type and may include heating, drying, evaporation, or filtration. In preferred embodiments, the waste feed material may be heated to remove at least a portion of the water contained therein. The waste feed material may be heated to any suitable temperature and for any suitable period of time in any suitable vessel (e.g., oven, furnace, etc.). However, it will be understood that the waste feed material should be heated for a period of time sufficient to remove the desired amount of water therefrom. In preferred embodiments of the present invention, the waste feed material may be heated to a temperature of about 90°C to about 110°C. More preferably, the waste feed material may be heated to a temperature of about 100°C. In some embodiments, the waste feed material may be combined with a solvent, particularly an organic solvent, to enhance the dehydration process.

[0020] Preferably, the waste feed material does not undergo a specific dehydration process. The waste feed material may be incidentally dehydrated during high temperature processing in the reactor vessel to reduce energy consumption and system costs.

[0021] Preferably, the waste feed material may undergo one or more processing steps prior to processing in the reactor vessel. The one or more processing steps may be of any suitable form, although in preferred embodiments of the present invention, the waste feed material may be compressed or compacted prior to processing in the reactor vessel. Compression or compaction of the waste feed material may be carried out using any suitable technique, such as using a press, compactor, or the like.

[0022] The waste feed material may be compressed or compacted to any suitable degree. However, it is envisioned that the waste feed material will not be compacted to the point that the ionic liquid in the reaction vessel cannot contact substantially all of the surfaces of the waste material in the waste feed material. It will be understood that the purpose of compressing or compacting the waste feed material may instead be to increase the amount of waste that can be processed in a single batch in the reaction vessel and to facilitate transportation.

[0023] In some embodiments, the waste feed material may be compressed to facilitate and streamline transportation to the location where the method is performed, and the compressed waste feed material may then be decompressed before being introduced into the reaction vessel.

[0024] It will be understood that the one or more processing steps that the waste feed material may undergo prior to processing do not include separating the waste feed material into separate streams based on the characteristics of the waste. Typically, the one or more processing steps do not include subjecting the waste feed material to a particle size reduction process, although it will be understood that some disruption may be required to reduce the size of large pieces of waste so that they can be introduced into the reaction vessel. Similarly, if the waste material is too compacted, it may be necessary to disrupt the waste to increase the available surface area. It will be understood, however, that an exhaustive grinding process is not performed.

[0025] In some embodiments, the particle size of the waste feed material is reduced in a grinding process. Any suitable grinding process may be used, and the grinding process may be an autogenous grinding process or grinding media may be provided. In a preferred embodiment, the particle size of the waste feed material is reduced in an agitated mill. In some embodiments of the present invention, agitation of the mill may be achieved using an impeller. In other embodiments, agitation of the mill may be achieved by introducing one or more jets of fluid into the mill, thereby causing rotation of the contents of the mill. Preferably, the one or more jets of fluid may be introduced through an inlet in the wall of the mill reactor vessel. The inlet fluid provides circulation, causing rotation of the waste feed material to aid in the decomposition of organic matter and increasing the surface area for further interaction with one or more fluids.

[0026] In some embodiments, the waste feed material may be subjected to a classification process before continuing to a consolidation process or a reaction vessel. While any suitable classification process may be used, in preferred embodiments of the present invention, the classification process may include separating the waste feed material based on particle size. In this embodiment of the present invention, the classification process may include a screening process. In certain embodiments, the waste feed material may be introduced into a trommel screen (or similar rotary screen) to separate materials such as soil, dirt, glass, metal, etc. from the waste feed material before continuing to a consolidation process or a reaction vessel.

[0027] The waste feed material may be introduced into the reactor vessel using any suitable technique. For example, the waste feed material may be introduced into the reactor vessel manually (e.g., by using handheld equipment including shovels, etc., or vehicles such as bobcats, loaders, backhoes, etc., or any suitable combination thereof). Alternatively, the waste feed material may be introduced into the reactor vessel using conveyors, augers, feeders (vibratory feeders, apron feeders, etc.), or similar equipment.

[0028] In a preferred embodiment, the method of the present invention is a batch process, such that once a predetermined amount of waste feed material has been introduced into the reactor vessel, processing of the waste feed material within the reactor vessel can begin.

[0029] In a preferred embodiment, the method of the present invention is a continuous process. It is envisioned that a continuous process may reduce or eliminate adverse effects on processing equipment that may result from periodic shutdown and startup of equipment in a batch process, as well as reduce environmental and / or financial costs. In some embodiments, a reactor vessel can receive a predetermined amount of waste feed material and begin the liquefaction process. While the liquefaction process is occurring, the liquefied waste material can be transferred to one or more secondary reactor vessels to liquefy more waste feed material.

[0030] In some embodiments of the present invention, the secondary reaction vessel may comprise multiple reaction vessels, in which one or more reaction vessels may be pressurized to sequentially charge and transfer waste feed material and liquefied waste feed material.

[0031] The predetermined amount of waste feed material may be in the form of a predetermined volume of waste feed material or a predetermined mass of waste feed material. Accordingly, one or more measuring devices (such as a scale) may be provided to determine the predetermined amount of waste feed material to be introduced into the reaction vessel.

[0032] The reaction vessel may be of any suitable form. For example, the reaction vessel may be of any suitable size, shape, or configuration and may include a tank, a reactor, etc. The reaction vessel may be a pressure vessel. Preferably, the reaction vessel is substantially circular in shape to facilitate fluid circulation.

[0033] In some embodiments, the reaction vessel can be agitated. Agitation of the reaction vessel can be achieved using any suitable technique, such as one or more impellers, a recirculation pump, or the like, or any suitable combination thereof. The reaction vessel can be a pressurized or non-pressurized reactor.

[0034] The reaction vessel may be an open vessel or a sealed vessel. However, in a preferred embodiment of the present invention, the reaction vessel may be a sealed vessel with a controlled venting procedure to alleviate pressure buildup. Any suitable atmosphere may be present in the reaction vessel. However, in a preferred embodiment of the present invention, the atmosphere in the reaction vessel is relatively inert. The relatively inert atmosphere may be provided by introducing an inert gas or a mixture of two or more inert gases into the reaction vessel. While any suitable inert gas may be used, in one specific example, the inert gas may comprise nitrogen. Beneficially, using an inert gas as the atmosphere in the reaction vessel may help remove oxygen from the reaction vessel, thereby reducing or eliminating the risk of fire or explosion due to the generation of volatile gases in the reaction vessel. Additionally, the use of an inert atmosphere in the reaction vessel may improve the removal of reaction gases from the vessel.

[0035] The reaction vessel may be of any suitable volume, and it will be understood that the exact volume of the reaction vessel will depend on the desired throughput of the process and the availability of waste materials. Thus, the volume of the reaction vessel may vary depending on these factors, or may be scaled up or down depending on the availability of waste materials, etc.

[0036] The reaction vessel may be a single reaction vessel or may comprise multiple reaction vessels. Preferably, the multiple reaction vessels may be in fluid communication with each other. The multiple reaction vessels may be in fluid communication with each other in any suitable manner. In some embodiments, the multiple reaction vessels are connected in a recirculation loop.

[0037] The recirculation loop may transfer fluids between the multiple reaction vessels using any suitable technique. In some embodiments, the recirculation loop transfers fluids using a pumping mechanism. While any suitable pumping device may be used for the pumping mechanism, in some embodiments, the multiple reaction vessels are connected using an in-line pump and / or mixing device.

[0038] Multiple reaction vessels may require one or more heating and / or heat recovery processes. In some embodiments, multiple reaction vessels may transfer heat between the reaction vessels to heat and / or cool the separate reaction vessels. This may be accomplished using any suitable technique. For example, heated liquids may be transferred between the reaction vessels and heat recovered from the heated liquid. In other embodiments, one or more heat exchange devices may be used to heat and / or cool fluids transferred between the reaction vessels.

[0039] The waste feed material may include a solid, a liquid, or a combination of the two. In some embodiments, the reaction vessel may contain a delivery mechanism for introducing the waste feed material into the reaction vessel. Any suitable delivery mechanism may be provided, such as a conveyor, a feed chute, a hopper, or the like. In some embodiments, the delivery mechanism may include a container configured to hold at least a portion of the waste feed material and introduce it into the reaction vessel. Thus, the delivery mechanism may include a basket, a bucket, a bag, a net, or the like, or a combination thereof.

[0040] In some embodiments of the present invention, the reaction vessel may comprise a plurality of one or more relatively small reaction vessels, and it is contemplated that providing a plurality of relatively small reaction vessels may reduce operating and capital costs compared to a relatively large reaction vessel.

[0041] The processing of the waste feed material in the reaction vessel may be in any suitable form. Preferably, however, the waste feed material (or at least the organic portion thereof) may be converted to one or more hydrocarbon compounds using any suitable technique. Preferably, the conversion of the waste feed material (or at least the organic portion thereof) may be achieved by solubilization, such that at least the organic portion of the waste feed material may be decomposed into liquids and / or gases. In one embodiment, the organic portion of the waste feed material may be subjected to chemical decomposition and / or depolymerization within the reaction vessel.

[0042] Preferably, solubilization of at least the organic portion of the waste feed material can be achieved by the presence of a catalyst in combination with elevated temperatures in the reaction vessel.

[0043] It will be appreciated that the decomposition, depolymerization, and / or solubilization of the organic portion of the waste feed material may result in the production of hydrocarbons. While any suitable hydrocarbons may be produced, it is contemplated that the hydrocarbons may include saturated hydrocarbons, unsaturated hydrocarbons, aromatic hydrocarbons, or mixtures thereof. In a preferred embodiment, the hydrocarbons may be saturated hydrocarbons, particularly alkanes.

[0044] In some embodiments of the present invention, a portion of the organic portion of the waste feed material may not be converted to hydrocarbons. In these embodiments, the remaining or unconverted organic portion of the waste feed material may be liquefied and transferred to a separation and / or purification vessel.

[0045] The separation and / or purification vessel may optionally be pressurized.

[0046] In some embodiments of the present invention, the first reaction vessel may be at atmospheric pressure, and the separation and / or purification vessel may be pressurized to any suitable pressure to complete the depolymerization process. In some embodiments, the pressure in the separation and / or purification vessel may be 60 to 80 bar, more preferably, the pressure in the separation and / or purification vessel may be 50 to 70 bar, and most preferably, the pressure in the separation and / or purification vessel may be 30 to 50 bar.

[0047] The separation and / or purification vessel is typically maintained at a relatively low temperature. In particular, it is contemplated that the separation and / or purification vessel may be maintained at a temperature of less than about 310°C.

[0048] In some embodiments, the separation and / or purification vessel may include or be associated with a distillation column.

[0049] It is contemplated that the separation and / or purification vessel may be provided with one or more catalysts. The one or more catalysts may be in any suitable form. In some embodiments of the present invention, the catalyst may be in a solid state, such as, but not limited to, a powdered material. It is contemplated that a solid state catalyst may facilitate recovery and reuse of the catalyst.

[0050] In some embodiments of the present invention, the catalyst may include a catalyst on a solid support, such as, but not limited to, an extrudate or a bead. It is envisioned that a solid-state supported catalyst may also provide a means for reusing the catalyst.

[0051] In some embodiments of the present invention, the conversion process may include one or more different catalyst forms in different reaction steps. In a preferred embodiment of the present invention, a first reaction vessel may contain a liquid catalyst to prevent equipment blockage and eliminate a separation step, and a second reaction vessel may contain an immobilized solid catalyst.

[0052] In certain embodiments of the present invention, the second reactor vessel may contain an immobilized solid catalyst in a packed bed configuration to allow for reuse of the catalyst without the need for a separation process.

[0053] In certain embodiments, the one or more catalysts may comprise Cu / TiO. Other examples of the one or more catalysts include zeolites (e.g., type A sodium aluminosilicate, 2NaO.2AlO.4SiO.9HO), homogeneous or heterogeneous organometallic catalysts for tandem dehydrogenation (e.g., but not limited to, SnPt / γ-AlO), olefin metathesis catalysts (e.g., but not limited to, WO x / SiO2), etc., or any suitable combination thereof.

[0054] The separation and / or purification vessel may also be provided with one or more solvents. The one or more solvents may be in any suitable form, although it is contemplated that one or more solvents may be added to the reaction vessel to assist in solubilizing the organic portion of the waste feed stream.

[0055] In some embodiments of the present invention, a medium may be provided in the reaction vessel. The medium may be in any suitable form, but in some embodiments, the medium may comprise one or more ionic liquids, a plurality of nanoparticles, or a combination of the two. In this embodiment, the one or more ionic liquids may also comprise a catalyst. While any suitable ionic liquid may be used, it is contemplated that the ionic liquid may comprise a liquid salt. In preferred embodiments, the ionic liquid comprises a liquid organic salt. In some embodiments, a single ionic liquid may be used to decompose and / or depolymerize substantially all of the organic material in the waste feed material. In certain embodiments of the present invention, the medium may comprise a nanocatalytic treatment fluid (NCTF).

[0056] Preferably, the medium may include two or more ionic liquids, a plurality of nanoparticles, and / or one or more additional catalysts. In these embodiments of the invention, it will be understood that different ionic liquids in the medium may support the decomposition and / or depolymerization of different components of the organic material in the waste feedstock. For example, one or more ionic liquids may be present to support the decomposition and / or depolymerization of the biomass portion of the organic material, while one or more different ionic liquids may be present to support the decomposition and / or depolymerization of the polymer portion of the organic material.

[0057] Preferably, the ionic liquid may contain methylimidazolium ions and / or pyridinium ions. One specific example of a suitable ionic liquid may be 1-butyl-3-methylimidazolium chloride-aluminum chloride. Other ionic liquids may contain any suitable counterion, such as, but not limited to, [H2PO4] - , [HSO4] - , [TsO] - and / or [TfO] - [Benz-SO3Him] + Examples include:

[0058] In some embodiments, the one or more ionic liquids include BuPyCl / AlCl3, [Bmim][Cl / AlCl3], (mSiO2 / Pt / SiO2), [C4Py]Cl-AlCl3, SnPt / γ-Al2O3, WOx / SiO2, [P14,6,6,6] + , CaMTC16, H-DBN Cl / ZnCl2, and / or NEt3AlCl4.

[0059] It is contemplated that ionic liquids may also act as solvents. Thus, in certain embodiments of the present invention, it is contemplated that an ionic liquid (or a mixture of ionic liquids) may constitute the entire medium within the reaction vessel and may function as both solvent and catalyst.

[0060] In alternative embodiments of the present invention, the medium may further comprise one or more solvents. The one or more solvents may be in any suitable form, although it is contemplated that one or more solvents may be added to the reaction vessel to assist in solubilizing the organic portion of the waste feed stream.

[0061] Any suitable solvent may be used, but in a preferred embodiment of the invention the solvent is a polar organic solvent.

[0062] Polar organic solvents can include, but are not limited to, dimethyl sulfoxide (DMSO), n-pentane, and / or glycerol.

[0063] In some embodiments, the polar organic solvent can include glycerol. In a preferred embodiment, the glycerol is crude glycerol.

[0064] In some embodiments, the organic solvent may include crude solvent products such as, but not limited to, crude diesel, petroleum, biodiesel, fractionated oil, or kerosene.

[0065] In some embodiments of the present invention, it is contemplated that the solvent may also act as a catalyst.

[0066] In some embodiments of the present invention, the ionic liquid may function as the first solvent, and one or more additional solvents (e.g., but not limited to, DMSO, n-pentane, or glycerol) may be added to the reaction vessel.

[0067] Preferably, the one or more additional solvents may be configured to separate the ionic liquid from the decomposed and / or depolymerized organic material.

[0068] As previously mentioned, one or more ionic liquids may constitute a catalyst. In other embodiments, one or more catalysts may be added to the medium. The one or more catalysts may supplement the catalytic properties of one or more ionic liquids. Alternatively, if the one or more ionic liquids do not have catalytic functionality, the one or more catalysts may constitute the only catalyst in the medium.

[0069] The one or more catalysts may be in any suitable form. A specific example of the one or more catalysts is Cu / TiO. Other examples of the one or more catalysts include zeolites (e.g., type A sodium aluminosilicate, 2NaO.2AlO.4SiO.9H0), homogeneous or heterogeneous organometallic catalysts for tandem dehydrogenation (e.g., but not limited to, SnPt / γ-AlO), olefin metathesis catalysts (e.g., but not limited to, WO), and the like. x / SiO2), etc., or any suitable combination thereof.

[0070] In some embodiments, the one or more catalysts may comprise a naturally occurring material, such as a diatomaceous earth material or clay. While any suitable form of clay may be used, in preferred embodiments, the clay may comprise a modified clay. For example, the modified clay may include an ionic liquid-modified clay, such as, but not limited to, CaMTC16. It is contemplated that the modified clay may be modified to provide active surface moieties. Preferably, the active surface moieties may be configured to catalyze a reaction, to absorb one or more molecules, or a combination thereof.

[0071] The clay may be of any suitable form. For example, the clay may be a modified clay, such as, but not limited to, calcium-rich montmorillonite (CaMT) and alkyl chains. In a preferred embodiment, the modified clay may be an ionic liquid-modified clay, such as CaMTC16. It is contemplated that the modified clay may be modified to provide active surface moieties. Preferably, the active surface moieties may be configured to catalyze a reaction, to absorb one or more molecules, etc., or a combination thereof.

[0072] In some embodiments, the medium may include a plurality of nanoparticles. While any suitable nanoparticles may be used, it is contemplated that the nanoparticles may include tungsten, zinc disulfide oxide, silicon dioxide, diamond, clay, boron, boron nitride, silver, titanium dioxide, tungsten, gamma-aluminum oxide, carbon, or molybdenum disulfide nanoparticles.

[0073] The nanoparticles may be of any suitable size. Preferably, the nanoparticles have a size of less than 10 nm, and preferably, the nanoparticles have at least one dimension in the size range of 1 to 100 nm.

[0074] It is contemplated that the presence of nanoparticles in the medium can assist in reducing odors and suppressing dust and other aerosols when mixed with waste feed materials at relatively low temperatures. Additionally, the nanoparticles may also assist in reducing or eliminating deactivation of one or more ionic liquids and / or catalysts.

[0075] In some embodiments, nanoparticles can be condensed into colloidal suspensions in one or more ionic liquids to form nanofluids, which typically promote greater convective heat transfer and have increased viscosity, thermal diffusivity, and thermal conductivity compared to fluids such as water or oil.

[0076] It is contemplated that the medium may include a combination of two or more ionic liquids and / or two or more catalysts, which may be required to decompose and / or depolymerize different portions of the waste feed material. For example, a first catalyst and / or a first ionic liquid may be required to decompose and / or depolymerize the biomass portion of the waste feed material, while a second catalyst and / or a second ionic liquid may be required to decompose and / or depolymerize the polymer portion of the waste feed material.

[0077] The relative proportions of ionic liquid and / or catalyst in the medium may vary depending on the composition of the waste feed material.

[0078] It is envisioned that media in the form of NCTF will facilitate decomposition and depolymerization without the need for significant mechanical separation, high shear, or grinding machinery. This separation and size reduction in conventional processes is energy intensive, costly, and generally causes significant equipment wear and maintenance issues.

[0079] Additionally, traditional separation of inorganic components typically produces residues that cause problems for downstream equipment such as pumps. Therefore, NCTF not only supports more complete removal of inorganics and hazardous materials, but also results in more uniform reaction products resulting from the waste feed material.

[0080] Additionally, NCTF media can act as ion exchange materials, effectively retaining heteroatoms present in the waste feedstock, such as phosphorus, halogens, chlorine, and heavy metals. These heteroatoms can be converted to inorganic salts with specific catalysts and lime. Preferably, any residual sulfur can be further reduced using specific NCTF media. By comparison, the high temperatures of conventional pyrolysis and incineration processes require gas scrubbing to prevent the release of highly carcinogenic dioxins and furans. These conventional processes are expensive and do not always produce the desired results.

[0081] The medium may be of any suitable pH. It is contemplated that the pH of the medium may be acidic or basic. Alternatively, the pH of the medium may be modified depending on the nature of the waste being treated in the reaction vessel. While the pH may be modified in any suitable manner, in a preferred embodiment of the present invention, the pH may be modified by adding a pH-modifying substance to the medium. Any suitable pH-modifying substance may be used, such as, but not limited to, lime (if a basic pH is desired) or acid (if an acidic pH is desired).

[0082] The pH of the medium may be raised to any suitable pH. For example, the pH in the reaction vessel may be greater than 7. In other instances, the pH of the vessel may be less than 7. However, it should be noted that the exact pH in the reaction vessel is not critical, provided that the pH is maintained in a range suitable for the process.

[0083] In some embodiments of the present invention, the medium comprising one or more ionic liquids may contain nanoparticles. It is contemplated that the nanoparticles may be in the form of graphite, carbon nanotubes, mesoporous carbon, and / or boron nitride. In preferred embodiments, the solution comprises up to 20% by weight of nanoparticles. More preferably, the solution comprises up to 10% by weight of nanoparticles. Even more preferably, the solution comprises up to 5% by weight of nanoparticles. Even more preferably, the solution comprises up to 3% by weight of nanoparticles.

[0084] It is contemplated that the addition of nanoparticles to a medium containing one or more ionic liquids can aid in heat dispersion and / or heat transfer. It is also contemplated that nanoparticles can be used to modify the flash point of the solution.

[0085] As previously mentioned, the waste feed material is treated in the reaction vessel at an elevated temperature. It will be understood that any suitable elevated temperature may be used, and the elevated temperature used may depend on the nature of the waste feed material. In preferred embodiments of the present invention, the elevated temperature may be from about 25°C to about 400°C. More preferably, the elevated temperature may be from about 30°C to about 310°C. Even more preferably, the elevated temperature may be from about 60°C to about 220°C.

[0086] In a preferred embodiment, the reaction vessel may be heated to multiple elevated temperatures to process the waste feed material. It is contemplated that different components of the waste feed material may decompose and / or depolymerize at different temperatures. Thus, heating the reaction vessel to multiple different elevated temperatures may ensure that all organic components of the waste feed material are decomposed and / or depolymerized.

[0087] In some embodiments of the present invention, the temperature of the reaction vessel may be increased substantially continuously over any suitable period of time to a higher temperature. Alternatively, the temperature of the reaction vessel may be increased to a first higher temperature and held at the first higher temperature for a period of time. The reaction vessel may then be heated to a second higher temperature and held at the second higher temperature for a period of time. This process may be repeated until the higher temperature is reached.

[0088] It is contemplated that the temperature of the reaction vessel may be reduced from one elevated temperature to another elevated temperature depending on the nature of the waste feed material.

[0089] In some embodiments of the invention, the temperature may be adjusted from a first temperature at which the biomass portion of the waste material is decomposed or disintegrated to a second temperature at which the polymer portion of the waste material is depolymerized. In these embodiments of the invention, it is contemplated that in a first stage, the temperature of the reactor may be adjusted to about 60°C to 300°C to decompose or disintegrate the biomass portion of the waste material, and thereafter the temperature of the reactor may be adjusted to about 100°C to about 310°C to depolymerize the polymer portion of the waste material.

[0090] The temperature of the reaction vessel can be raised to one or more elevated temperatures using any suitable technique. For example, the reaction vessel can be maintained at an elevated temperature using one or more heat sources (burners, heat probes, etc.). In further embodiments of the present invention, the reaction vessel can be provided with a heating and / or cooling system. While any suitable system can be used, it is contemplated that in certain embodiments of the present invention, the reaction vessel can be at least partially surrounded by a jacket through which a heating and / or cooling fluid can be circulated to control the temperature within the reaction vessel. Alternatively, the heating and / or cooling fluid can be circulated through one or more tubes or jackets located within the reaction vessel to control the temperature within the reaction vessel.

[0091] In some embodiments of the present invention, the temperature of the reaction vessel may be raised to one or more elevated temperatures using infrared radiation. While the infrared radiation may be indirect or direct, in preferred embodiments, direct infrared radiation is used to raise the temperature of the reaction vessel.

[0092] In some embodiments of the present invention, the infrared radiation may be of a broad spectrum of wavelengths, or alternatively, the infrared radiation may be of a targeted wavelength.

[0093] In some embodiments of the present invention, to increase the accuracy and / or stability of temperature control, the temperature of the reaction vessel may be raised to one or more elevated temperatures using both infrared radiation and an external heat source (such as a heat exchanger).

[0094] The temperature of the reaction vessel can be controlled by varying the wavelength and intensity of the infrared radiation.

[0095] In some embodiments of the present invention, the biomass portion of the waste feedstock is treated at a first elevated temperature using one or more ionic liquids. While the one or more ionic liquids may be of any suitable type, in preferred embodiments of the present invention, the one or more ionic liquids are selected from the group consisting of BuPyCl / AlCl3, [Bmim][Cl / AlCl3], (mSiO2 / Pt / SiO2), [C4Py]Cl-AlCl3, SnPt / γ-Al2O3, WOx / SiO2, [P14,6,6,6] + , CaMTC16, H-DBNCl / ZnCl2, and / or NEt3AlCl4.

[0096] It is envisioned that the first treatment step may remove substantially all of the biomass present in the waste feedstock. While the biomass may be removed using any suitable technique, in preferred embodiments the biomass may be digested, decomposed and / or disintegrated, it being understood that the purpose of the first treatment step is to generate hydrocarbons from the biomass.

[0097] Preferably, following removal of the biomass portion of the waste feed material, a subsequent processing step can be configured to process the plastic component of the waste feed material. It is contemplated that one or more ionic liquids are configured to treat the remaining waste feed material at a second elevated temperature. While any suitable process may be used, in preferred embodiments, the remaining waste feed material can be processed to recover polymeric portions therefrom. While the polymeric portions can be recovered using any suitable technique, in preferred embodiments, the polymeric portions may be digested, decomposed, and / or broken down, it will be understood that the purpose of the second processing step is to generate hydrocarbons from the polymeric portions.

[0098] In a preferred embodiment, one or more catalysts may be selected to process both the biomass and polymer portions of the waste feedstock without the need for subsequent processing steps.

[0099] In some embodiments of the present invention, a third process step can be performed to complete the separation of hydrocarbons from the waste feed material. Preferably, the third process step comprises removing hydrocarbons produced by processing the biomass and polymer portions of the waste feed material from the reaction vessel.

[0100] The total residence time for treatment of the waste feed material may vary depending on the composition and particle size of the waste feed material. It will be understood that any suitable residence time may be used, and such time may depend on the properties of the waste feed material. In preferred embodiments of the present invention, the residence time may be from about 3 hours to about 8 hours. More preferably, the residence time may be from about 2 hours to about 6 hours. Even more preferably, the elevated temperature may be from about 1 hour to about 4 hours.

[0101] In some embodiments of the present invention, solubilization of the organic portion of the waste feed material may result in the generation of sulfur and / or chlorine (or compounds thereof). In preferred embodiments of the present invention, the sulfur and chlorine generated in the reaction vessel may be removed separately from the hydrocarbons.

[0102] The sulfur and / or chlorine may be removed from the reaction vessel using any suitable technique. For example, sulfur and chlorine generated within the reaction vessel may be captured or sequestered using zeolites and lime, and / or one or more ionic liquids.

[0103] Alternatively, the sulfur and chlorine generated in the reaction vessel may be condensed and treated with one or more ionic liquids. In a preferred embodiment, the sulfur and chlorine may be treated with a trihexyl(tetradecyl)phosphonium cation.

[0104] In some embodiments of the present invention, solubilization of the organic portion of the waste feed material may result in the generation of heavy metals (or compounds containing heavy metals). In preferred embodiments of the present invention, the heavy metals generated in the reaction vessel can be removed separately from the hydrocarbons.

[0105] Heavy metals may be removed from the reaction vessel using any suitable technique. For example, heavy metals may be captured or sequestered using sorbents such as, but not limited to, zeolites and / or lime. In some embodiments of the present invention, residual heavy metals may be filtered and disposed of by algae ponds.

[0106] It is contemplated that some waste feed materials may contain fluorinated compounds and fluorinated contaminants (PFAS). In some embodiments of the present invention, the waste feed material and / or the product of the method of the present invention may be subjected to a PFAS removal process. The PFAS removal process may be carried out in a reaction vessel. Preferably, the PFAS removal process is carried out separately from the treatment process.

[0107] The PFAS removal process can be carried out using any suitable method. It is envisioned that PFAS can be removed using a substrate configured to absorb PFAS. Any suitable substrate can be used, such as, but not limited to, carbonaceous materials (including activated carbon, biochar, etc.), ion exchange resins, etc. Preferably, the substrate can include naturally occurring materials such as diatomaceous earth materials or clays.

[0108] The clay may be of any suitable form. For example, the clay may be a modified clay, such as, but not limited to, calcium-rich montmorillonite (CaMT) and alkyl chains. In a preferred embodiment, the modified clay may be an ionic liquid-modified clay, such as CaMTC16. It is contemplated that the modified clay may be modified to provide active surface moieties. Preferably, the active surface moieties may be configured to catalyze a reaction, to absorb one or more molecules, etc., or a combination thereof.

[0109] In another embodiment, PFASs can be removed using ion exchange resins, which can be of any suitable composition, including, but not limited to, anion exchange resins containing polystyrene or quaternary amines, and non-ionic exchange resins.

[0110] In another embodiment, PFAS can be removed using granular activated carbon (GAC).

[0111] Preferably, the PFASs may be removed using a membrane filtration process. In some embodiments, the PFASs may be removed using a distillation process.

[0112] In some embodiments, PFAS may be hydrotreated to defluorinate them and reduce the toxicity of the waste product.

[0113] In some embodiments, the PFAS removal process requires dehydrochlorination.

[0114] It is contemplated that at the first elevated temperature, a first portion of the organic material in the waste feed material may decompose and / or depolymerize to form hydrocarbons. In some embodiments of the invention, the hydrocarbons generated at the first elevated temperature may be removed from the reaction vessel before the temperature is changed to a second elevated temperature. The hydrocarbons generated at the second elevated temperature may then be removed from the reaction vessel before the temperature is changed to a third elevated temperature, and so on.

[0115] The hydrocarbons removed from the reaction vessel at one of the plurality of elevated temperatures may be used upon removal. Alternatively, the hydrocarbons removed from the reaction vessel may be transferred to one or more storage vessels. In this embodiment of the invention, it is contemplated that the hydrocarbons generated at each of the plurality of elevated temperatures may be collected in one or more storage vessels prior to use. Thus, it is contemplated that all hydrocarbons generated from the processing of a batch of waste feed material may be collected in one or more storage vessels. In some embodiments, hydrocarbons generated in the processing of two or more batches of waste feed material may be collected in one or more storage vessels.

[0116] It is contemplated that the hydrocarbons removed from the reaction vessel may be in gaseous, liquid, or a combination of the two. In embodiments of the invention in which at least a portion of the hydrocarbons are in gaseous form, one or more condensers may be located between the reaction vessel and one or more storage vessels to convert the gaseous hydrocarbons to liquid form.

[0117] In embodiments of the present invention where at least a portion of the hydrocarbons are in liquid form, the hydrocarbons may be extracted using an organic solvent in a liquid-liquid extraction process.

[0118] In an alternative embodiment of the present invention, hydrocarbons can be distilled to obtain different fractions, which can be collected to provide various types of fuels. It will be appreciated that different fractions provide different compositions, and such compositions may be used without purification for applications such as, but not limited to, bunker fuel, diesel, gasoline, aviation fuel, etc.

[0119] In some embodiments, inorganic by-products may remain in the reactor after removing the hydrocarbons from the reactor. The oil product separated from the reactor is expected to contain a portion of one or more ionic liquids, solvents, and / or catalysts. In some embodiments, the oil product may be washed using a suitable solvent, such as, but not limited to, water, hexane, chloroform, or diethyl ether. Washing may then be used to recover one or more ionic liquids, solvents, and / or catalysts, which may be reintroduced and reused in the treatment process.

[0120] In some embodiments, the reactor residue is processed to recover catalyst fluids. The catalyst fluids may be processed using any suitable method. In some embodiments, the catalyst fluids may be collected using liquid-liquid extraction.

[0121] In some embodiments, separation of the remaining one or more ionic liquids and / or solvent from the oil product may occur in a secondary treatment vessel.

[0122] The oil product may be used for any suitable purpose. In some embodiments of the present invention, the oil product may be used in the manufacture of other materials (such as plastics).

[0123] It is contemplated that at least a portion of the waste feed material may not be decomposed and / or depolymerized by the process. It is contemplated that this portion may be the inorganic portion of the waste feed material. Preferably, upon completion of the process of the present invention, the inorganic portion of the waste feed material may be removed from the reaction vessel. The inorganic portion may be recycled or otherwise disposed of.

[0124] It is contemplated that some of the organic portion of the waste feed material may not be decomposed or depolymerized in the process of the present invention. For example, materials such as inert ash, wax, or bitumen may be produced. These materials may be removed from the reaction vessel and recycled, reused (such as in road construction), or otherwise disposed of.

[0125] As previously mentioned, the hydrocarbons generated in the methods of the present invention may be collected in one or more storage vessels. In some embodiments of the present invention, the hydrocarbons (in gaseous or liquid form) may be combusted, and the energy generated by the combustion of the hydrocarbons may be used to heat one or more boilers. The steam produced by the one or more boilers may then be used to drive one or more turbines to generate electrical energy. The electrical energy thus used may be stored, used to power the methods of the present invention, or exported to the power grid.

[0126] In an alternative embodiment, hydrocarbons (in gaseous or liquid form) and carbon residues can be combusted directly to produce fuel for combined cycle power plants and the like.

[0127] In this embodiment of the invention, the exhaust gases produced by the combustion of hydrocarbons may be transferred to a pond, such as an algae pond. The algae in the algae pond may consume the carbon monoxide and carbon dioxide in the exhaust gases to produce oxygen. The oxygen thus produced may be captured or released into the atmosphere.

[0128] It is envisioned that algae may be periodically removed from the algae ponds. The algae removed from the algae ponds may be added to a waste feedstock as part of the biomass fraction or may be exported for external use. In some embodiments, the collected algae may be used as fertilizer.

[0129] Although described as a "pond," it will be understood that an algae pond may include a pool, lake, dam, tank, or any suitable container capable of holding water and algae.

[0130] In another embodiment of the present invention, the hydrocarbons generated in the reactor may be transferred to a fractionation column. It is contemplated that the hydrocarbons may be separated into two or more hydrocarbon fractions in the fractionation column. The two or more hydrocarbon fractions may be used for any suitable purpose, such as vehicle fuel, heating fuel, etc.

[0131] Preferably, the ionic liquid, nanoparticles, and / or catalyst can be recovered from the reaction vessel. It is contemplated that the ionic liquid, nanoparticles, and / or catalyst can be separated from the residual inorganic material in the reaction vessel using any suitable technique. For example, the ionic liquid, nanoparticles, and / or catalyst can be separated by evaporation (and subsequent condensation), filtration, etc., or any suitable combination thereof. Alternatively, one or more solvents can be added to the medium to separate the desired residue from the inorganic material. The solvent (and the ionic liquid, nanoparticles, and / or catalyst) can then be removed from the reaction vessel and separated.

[0132] Separation of the ionic liquid, nanoparticles, and / or catalyst from the solvent can be achieved using any suitable technique. In a preferred embodiment of the present invention, the combined solvent and ionic liquid, nanoparticles, and / or catalyst can be heated to any suitable temperature. However, it is contemplated that the temperature can be between about 30°C and 300°C. More preferably, the temperature can be between about 45°C and 250°C. Most preferably, the temperature can be between about 60°C and 200°C.

[0133] In some embodiments of the present invention, the ionic liquid, nanoparticles, and / or catalyst can be separated from the solvent by spinning. Spinning can be performed in conjunction with or instead of heating the medium. Depending on the properties of the ionic liquid, nanoparticles, and / or catalyst, spinning can be performed in a magnetic or non-magnetic centrifuge.

[0134] Preferably, at least a portion of the separated ionic liquid, nanoparticles, and / or catalyst may be recycled to the reaction vessel for reuse. In some embodiments of the present invention, at least a portion of the catalyst may undergo a reactivation process before being recycled to the reaction vessel. Catalyst reactivation may be performed at any suitable location and using any suitable technique, although it is envisioned that catalyst reactivation may be performed using thermal or chemical reactivation. However, in preferred embodiments of the present invention, a process vessel in fluid communication with the reaction vessel may be used as a location for catalyst reactivation. Thus, after reactivation, the reactivated catalyst may be returned from the process vessel to the reaction vessel.

[0135] The present invention offers many advantages over the prior art. First, the ability to process waste feed materials without or with minimal pretreatment, such as separation of the biomass, polymer, and inorganic portions of the waste, or initial extensive size reduction, represents a significant savings in time, energy, and cost. Furthermore, processing the waste feed material primarily within a single reactor vessel not only reduces equipment and operating costs, but also reduces the process footprint (both physical and carbon).

[0136] Additionally, the reuse of NCTF and solvent reduces ongoing costs, while the use of algae ponds helps reduce carbon emissions and provides an additional source of biomass for the process.

[0137] Furthermore, the mild conditions (low temperature and atmospheric or relatively low pressure) and minimal pre-processing requirements reduce manufacturing costs and assembly time, facilitating modular construction. It will be appreciated that conventional methods of hydrocarbon production are carried out on a large scale to make the process economical. Thus, the modular assembly of the present invention provides a financially viable processing option for small-scale operations.

[0138] Any of the features described herein may be combined in any combination with any one or more of the other features described herein within the scope of the present invention.

[0139] The reference to any prior art herein is not, and should not be construed as, an acknowledgment or any form of suggestion that the prior art forms part of the common general knowledge.

[0140] Preferred features, embodiments, and variations of the present invention can be identified from the following detailed description, which provides sufficient information for one skilled in the art to practice the invention. The detailed description should not be deemed to limit the scope of the foregoing Summary of the Invention in any way. The detailed description makes reference to several drawings, including: [Brief explanation of the drawings]

[0141] [Figure 1] 1 is a schematic diagram of a method for the conversion of waste materials according to an embodiment of the present invention.

[0142] MODE FOR CARRYING OUT THE INVENTION 1 shows a schematic diagram of a process 10 for waste conversion according to an embodiment of the present invention. A waste feed material 11 is introduced into a reaction vessel 12 with minimal pre-sorting, classification, or size reduction. NCTF is also added to the reaction vessel 12 from a holding tank 13. Finally, a solvent is added to the reaction vessel 12 from a solvent holding tank 14.

[0143] In this embodiment of the invention, waste feed material 11 includes a biomass portion, such as food scraps and paper and cardboard products. Waste feed material 11 also includes a polymer portion, including waste plastics and composite materials, such as insulated electrical wire (which is metal wiring with a polymer coating). Waste feed material 11 also includes an inorganic portion, including metals (such as electrical wiring), ceramics, and the like.

[0144] The NCTF used in Method 10 comprises a combination of materials. Specifically, the NCTF is 1-butyl-3-methylimidazolium chloride-aluminum chloride and [Benz-SO3Him] + [HSO4] - Contains a mixture of SnPt / γ-Al2O3, WO x An additional catalyst in the form of SiO2, and / or zeolite is added to the ionic liquid.

[0145] 1-Butyl-3-methylimidazolium chloride-aluminum chloride and [Benz-SO3Him] + [HSO4] - It is envisioned that SnPt / γ-AlO, WO may act as catalysts to decompose or destructure the biomass portion of the waste feed material 11. Additionally, these catalysts may depolymerize at least a portion of the polymer portion of the waste feed material 11, while SnPt / γ-AlO, WO x / SiO2, and / or zeolite are prepared by the addition of 1-butyl-3-methylimidazolium chloride-aluminum chloride and [Benz-SO3Him] + [HSO4] - It is used to depolymerize a portion of the polymer portion that is not depolymerized by

[0146] The solvent added from holding tank 14 is dimethyl sulfoxide (DMSO), although n-pentane and / or crude glycerol, etc. may also form part of the solvent held in storage tank 14 .

[0147] Reactor vessel 12 is heated to multiple elevated temperatures to decompose or depolymerize the organic components of waste feed material 11. Because the biomass portion of waste feed material 11 typically decomposes at a lower temperature than the polymeric portion of waste feed material 11 depolymerizes, it is contemplated that the temperature of reactor vessel 12 may be increased from a first elevated temperature (to decompose the biomass portion) to a second elevated temperature (to depolymerize the polymeric portion). The temperature may be increased continuously, or may be increased to the first elevated temperature, held at that temperature to decompose the biomass portion, and then increased to the second elevated temperature.

[0148] In a first stage, the temperature of the reaction vessel 12 may be increased to a first elevated temperature of about 120°C to 300°C to decompose or disintegrate the biomass portion of the waste feed material 11. Preferably, the first elevated temperature is about 200°C to 280°C. The reaction vessel 12 may be maintained at the first elevated temperature for a period of about 1 hour to 2 hours to ensure that the biomass portion of the waste feed material 11 is substantially completely decomposed or disintegrated. It will be appreciated that this time and / or the first elevated temperature may vary depending on the nature and proportion of the biomass portion of the waste feed material 11.

[0149] The decomposition or structural breakdown of the biomass portions generates hydrocarbon gases 22. These hydrocarbon gases 22 may remain in the reaction vessel 12 until the completion of the method 10, or may be continuously removed or removed upon completion of the decomposition or structural breakdown of the biomass portions. Because the hydrocarbon gases 22 are combustible, they are transferred from the reaction vessel 12 to a boiler 15 where the hydrocarbon gases 22 are combusted. The heat generated by the combustion of the hydrocarbon gases 22 in the boiler 15 is used to convert water from a water tank 16 into steam, which then drives the operation of a turbine 17 to generate electricity. The electricity generated in FIG. 1 is exported to a power grid 18.

[0150] The steam used to drive the turbine 17 is condensed in the condenser 19 and the condensate is returned to the water tank 16 and reheated in the boiler 15 .

[0151] Exhaust gas 21 from the boiler, at least a portion of which contains carbon dioxide, is transferred to an algae pond 20. Preferably, exhaust gas 21 is bubbled through the algae pond 20 so that the algae in the pond consume or absorb the carbon dioxide (and carbon monoxide, if present) and filter out residual heavy metals. The product of this process is oxygen, which is released to the atmosphere.

[0152] At least a portion of the algae in the algae pond 20 may be removed periodically (especially as the algae grow or proliferate), and the removed portion of the algae may be added to the waste feed material 11 as part of the biomass fraction.

[0153] Once the biomass portion of the waste feed material 11 has decomposed or destructured, the temperature of the reaction vessel 12 is increased to a second elevated temperature to depolymerize the polymeric portion of the waste feed material 11. The second elevated temperature may be between about 250° C. and 310° C., and the reaction vessel 12 may be maintained at the second elevated temperature for between 1 hour and 4 hours. It will be appreciated that the time and / or the second elevated temperature may vary depending on the nature and proportion of the polymeric portion of the waste feed material 11.

[0154] Similar to the biomass portion, depolymerization of the polymer portion of the waste feed material 11 produces hydrocarbon gases 22 which are removed from the reaction vessel 12 and treated in the same manner as the hydrocarbon gases 22 produced by the decomposition or structural breakdown of the biomass portion.

[0155] Water vapor generated in reaction vessel 12 is removed and condensed in condenser 23 and stored in water tank 24. The water in water tank 24 may be used in method 10, filtered in algae pond 20, or used for other purposes.

[0156] In the embodiment of the invention shown in Figure 1, upon completion of depolymerization of the polymeric portion of waste feed material 11 and removal of hydrocarbon gases 22, reaction vessel 12 contains NCTF, inorganic materials 26 from waste feed material 11, and residual material 25. Residual material 25 may include a mixture of long-chain (high molecular weight) hydrocarbons such as bitumen or carbon residue. Residual material 25 may also contain inert ash, wax, etc. Residual material 25 is removed from reaction vessel 12 and can be used for road construction or any other suitable purpose.

[0157] The inorganic materials 26 (metals and other inorganics) are removed from the reaction vessel 12 and transported to a recycling center 27 to recycle suitable reusable portions of the inorganic materials 26. The non-reusable portions of the inorganic materials 25 may be reused or disposed of in any suitable manner.

[0158] The spent NCTF and solvent in reaction vessel 12 may be returned to NCTF holding tank 13 and solvent holding tank 14, respectively. If desired, the solvent and NCTF may be separated by heating the NCTF / solvent mixture in the reaction vessel and / or by subjecting the NCTF / solvent mixture to separation in a rotary centrifuge (not shown).

[0159] Once separated, the solvent is returned to the solvent holding tank 14. The NCTF may be returned directly to the NCTF holding tank 13 or may be reactivated using thermal and / or chemical reactivation before the NCTF is returned to the NCTF holding tank 13.

[0160] At the end of the described method 10, it is assumed that the reaction vessel 12 is substantially empty. A new batch of waste feed material 11 is then added to the reaction vessel 12 and the method 10 is repeated.

[0161] In this specification and claims (if any), the word "comprising," and derivatives thereof, including "comprises" and "comprise," includes each of the listed elements but does not exclude the inclusion of one or more additional elements.

[0162] Throughout this specification, references to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner, in one or more combinations.

[0163] In accordance with the statute, the invention has been described in language that is somewhat specific to structural or methodical features. It is to be understood that the present invention is not limited to the specific features shown or described, as the means described herein include preferred modes of carrying out the invention. The present invention is therefore claimed either in the form of the appended claims (if any), or modifications thereto within their proper scope, as appropriately interpreted by those skilled in the art.

Claims

1. introducing a waste feed material into a reaction vessel, at least a portion of the waste feed material comprising organic material, the organic material comprising a biomass portion and / or a polymer portion; treating the waste feed material in the reaction vessel at an elevated temperature in the presence of a medium comprising one or more ionic liquids, one or more catalysts, and / or one or more solvents, wherein the medium is configured to convert the organic material into one or more hydrocarbon compounds; removing the one or more hydrocarbon compounds from the reaction vessel for use or further processing; 10. A method for the conversion of waste materials, comprising:

2. 10. The method of claim 1, wherein said waste feed material comprises at least 10% w / w of said organic material.

3. 3. The method of claim 1 or 2, wherein the waste feed material is compressed or compacted prior to processing in the reaction vessel.

4. 4. The method of claim 1, wherein a relatively inert atmosphere is provided in the reaction vessel.

5. 5. The method of claim 1, wherein the medium is a nano-catalyzed processing fluid comprising the one or more ionic liquids, a plurality of nanoparticles, and / or one or more catalysts.

6. The method of claim 5 , wherein two or more ionic liquids are present in the nanocatalyst treatment fluid.

7. The two or more ionic liquids are butyl-3-methylimidazolium chloride-aluminum chloride and [Benz-SO ３ Him] ＋ [HSO ４ ] － The method of claim 6, comprising:

8. The method of claim 1 , wherein the medium comprises a solvent.

9. 9. The method of claim 1, wherein the one or more ionic liquids catalyze the conversion of the organic material to the one or more hydrocarbon compounds.

10. 10. The method of claim 1, wherein the one or more ionic liquids function as a solvent.

11. The method of claim 5 , wherein the one or more catalysts comprise a supported catalyst.

12. The method of claim 5 , wherein the one or more catalysts comprise a tandem dehydrogenation catalyst and an olefin metathesis catalyst.

13. 13. The method of claim 1, wherein the medium comprises a polar organic solvent.

14. 13. The method of any of claims 5, 11 or 12, wherein the one or more catalysts comprise a zeolite, a homogeneous or heterogeneous organometallic catalyst for tandem dehydrogenation, and / or an olefin metathesis catalyst.

15. The one or more catalysts are Cu(5%) / TiO ２ or CaMTC16.

16. 6. The method of claim 5, wherein the plurality of nanoparticles comprises tungsten, zinc disulfide oxide, silicon dioxide, diamond, clay, boron, boron nitride, silver, titanium dioxide, tungsten, gamma-aluminum oxide, carbon, or molybdenum disulfide nanoparticles.

17. 17. The method of any one of claims 1 to 16, wherein the elevated temperature is from about 25°C to about 400°C.

18. 18. The method of any one of claims 1 to 17, wherein the elevated temperature is adjusted from a first temperature at which the biomass is degraded or destructurized to a second temperature at which the polymeric material is depolymerized.

19. 19. The method of claim 18, wherein the first temperature is between about 60°C and 300°C and the second temperature is between about 100°C and about 310°C.

20. 20. The method of any one of claims 1 to 19, wherein the elevated temperature is controlled using infrared radiation.

21. 21. The method of claim 20, wherein the infrared radiation is direct infrared radiation.

22. 22. The method of claim 20 or 21, wherein the wavelength of the infrared radiation is a targeted wavelength.

23. 22. The method of claim 20 or 21, wherein the wavelength of the infrared radiation is a broad spectrum of wavelengths.

24. 20. The method of claim 18 or 19, wherein the hydrocarbon compounds evolved at the first temperature are removed from the reaction vessel before the temperature is changed to the second temperature.

25. 25. The method of any one of claims 1 to 24, wherein the hydrocarbon compounds generated in the reaction vessel are used to generate electrical energy or fuel.

26. 26. The method of claim 25, wherein exhaust gas produced in the generation of electrical energy or fuel is transferred to an algae pond to consume carbon dioxide and carbon monoxide in the exhaust gas and generate oxygen.

27. 27. The method of claim 26, wherein at least a portion of the algae in the algae pond is periodically removed and added to the waste feed material.

28. 6. The method of claim 5, wherein the one or more ionic liquids, the plurality of nanoparticles, and / or the one or more catalysts are separated from the remaining inorganic portion of the waste feed material upon completion of the method.

29. 30. The method of claim 28, wherein the one or more ionic liquids, the plurality of nanoparticles, and / or the one or more catalysts are separated from the remaining inorganic portion of the waste feed material using one or more solvents.

30. 30. The method of claim 28 or 29, wherein the one or more ionic liquids, the plurality of nanoparticles, and / or the one or more catalysts are separated from the remaining inorganic portion of the waste feed material at a temperature of about 45°C to 250°C.

31. 31. The method of claim 30, wherein the one or more ionic liquids, the plurality of nanoparticles, and / or the one or more catalysts are separated from the solvent by rotational separation.

32. 32. The method of any one of claims 28 to 31, wherein the one or more ionic liquids, the nanoparticles, and / or the one or more catalysts are recycled to the reaction vessel for reuse.

33. 33. The method of claim 32, wherein the catalyst undergoes a reactivation process before being recycled to the reaction vessel.

34. 29. The method of claim 28, wherein the residual inorganic portion is recycled.

35. 35. The method of any one of claims 1 to 34, which is a batch process.

36. 36. The method of any one of claims 1 to 35, wherein the medium comprises an ionic liquid modified clay or GAC for treating fluorinated contaminants.

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