Styrene production from used tires and its use in tire rubber

Abstract

A process comprising: (a) providing a feedstock containing a carbonaceous material; (b) thermally converting the feedstock to produce a gas stream containing carbon monoxide, hydrogen, and carbon dioxide; (c) converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide into ethanol; (d) converting at least a portion of the ethanol into ethylene; (e) reacting at least a portion of the ethylene with benzene to produce ethylbenzene; and (f) dehydrogenating the ethylbenzene to form styrene.

Description

[Technical Field]

[0001] Embodiments of the present invention relate to a process for converting used tires into styrene. The styrene can then be copolymerized with a conjugated diene monomer to produce an elastomer that can be used to manufacture tires. In certain embodiments, the styrene is copolymerized with butadiene, which is also produced from used tires. [Background technology]

[0002] Used tires contain a significant amount of carbonaceous material. Recycling carbon into other carbon-based materials presents many challenges, at least in part, due to the fact that a large portion of the carbon is bound to the vulcanization network. As a result, technically efficient methods for recycling used tires are quite limited, including, for example, mechanically crushing vulcanized rubber products and using the crushed rubber for various applications such as fillers in composite materials. Other modes of carbon recycling are desirable, considering carbon efficiency. [Overview of the Initiative]

[0003] One or more embodiments of the present invention provide a process comprising: (a) providing a feedstock containing a carbonaceous material; (b) thermally converting the feedstock to produce a gas stream containing carbon monoxide, hydrogen, and carbon dioxide; (c) converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide into ethanol; (d) converting at least a portion of the ethanol into ethylene; (e) reacting at least a portion of the ethylene with benzene to produce ethylbenzene; and (f) dehydrogenating the ethylbenzene to form styrene.

[0004] Another embodiment of the present invention provides a method for producing an elastomeric polymer, the method comprising (a) providing a styrene monomer synthesized from components of a gaseous stream obtained from the gasification of a feedstock containing a carbonaceous material, and (b) polymerizing the styrene with a diene monomer to form an elastomeric polymer.

[0005] A further embodiment of the present invention provides a tire component comprising a cured rubber matrix containing a filler dispersed therein, wherein the cured rubber matrix comprises more than 40% by weight, or more than 50% by weight, or more than 60% by weight, or more than 70% by weight, or more than 80% by weight, or more than 90% by weight, or more than 99% by weight of crosslinked cyclic synthetic rubber obtained by polymerizing monomers synthesized from components of a gaseous flow obtained from the gasification of a feedstock containing a carbonaceous material.

[0006] A further embodiment of the present invention provides a tire comprising tire components as provided above, the tire comprising more than 40% by weight, or more than 50% by weight, or more than 60% by weight, or more than 70% by weight, or more than 80% by weight, or more than 90% by weight, or more than 99% by weight of sustainable material. [Modes for carrying out the invention]

[0007] Embodiments of the present invention are at least in part based on the discovery of a process for consuming used tires in the production of styrene. Styrene has the advantage of being copolymerizable with conjugated diene monomers to produce elastomeric polymers that can be used to manufacture tire components. Thus, embodiments of the present invention provide a method for returning used tires to useful tires or tire components. In certain embodiments, the styrene produced by the present invention is copolymerized with conjugated diene monomers also produced from used tires. According to one or more embodiments, styrene is produced by thermally decomposing used tires to form a gas stream. One or more components of this gas stream are then converted to styrene. In one or more embodiments, one or more components of the gas stream are converted to ethanol, which is then converted to ethylene. The ethylene is then reacted with benzene to finally form styrene.

[0008] Process Overview - Styrene Synthesis The present invention provides a feedstock which may include used tire feedstock, which is converted via pyrolysis into a gaseous stream containing hydrogen, carbon monoxide, and optionally carbon dioxide. This gaseous stream, which may be called synthesis gas or syngas, is then converted to ethanol, for example, by using a biological fermentation process. The ethanol is then converted to ethylene by using a known process. The ethylene is then reacted with benzene to produce ethylenebenzene. The ethylbenzene is then dehydrogenated to form styrene. Conveniently, the dehydrogenation step produces by-product hydrogen that can be returned to the fermentation process, thereby improving the overall efficiency of the process.

[0009] Characteristics of supplied raw materials In one or more embodiments, the feedstock, which is pyrolyzed to form a gaseous flow, may include tire feedstock from used tires, which may also be referred to as used tire feedstock or simply tire feedstock. As those skilled in the art will understand, the tire feedstock may include vulcanized polymers, carbon black fillers, silica, resins, oils, fibers, and metals. The vulcanized polymer may include sulfur crosslinking residues of one or more synthetic elastomers, including natural rubber and / or diene polymers and copolymers. In one or more embodiments, the used tire feedstock may include tires from which one or more components of used tires have been removed, shredded, or otherwise pulverized. For example, the tire feedstock may be treated to remove metals by methods known in the art (e.g., magnetic separation). Alternatively, or in combination therewith, the used tire feedstock may optionally be treated to remove fiber reinforcing materials such as fibers or cords, which those skilled in the art will understand are often found together with vulcanized rubber in many tire components. Alternatively, or in combination therewith, the used tire feed material may be optionally treated to remove inorganic materials such as silica fillers, which are commonly found in used tire components, as will be understood by those skilled in the art. In any case, the tire feed material may be processed into tire fragments, tire chips, or crushed or crumbed rubber and fed into a pyrolysis unit.

[0010] In one or more embodiments, the tire feedstock is characterized by a relatively small amount of metal, which may be due to pretreatment of the tire feedstock to remove at least some of the metal normally present in used tires. In one or more embodiments, after pretreatment of used tires to remove metal, the tire feedstock may contain less than 25% by weight, less than 15% by weight in other embodiments, and less than 1% by weight in other embodiments, based on the total weight of the feedstock supplied to the pyrolysis according to the present invention.

[0011] In one or more embodiments, the tire feedstock is characterized by a relatively small amount of fiber or cord, which may be due to pretreatment of the tire feedstock to remove at least a portion of the fiber or cord that is normally present in used tires. In one or more embodiments, after pretreatment, the tire feedstock contains less than 5% by weight, less than 4% by weight in other embodiments, less than 3% by weight in other embodiments, less than 2% by weight in other embodiments, and less than 1% by weight in other embodiments, based on the total weight of the feedstock supplied to the pyrolysis according to the present invention.

[0012] In one or more embodiments, the tire feedstock is characterized by a relatively small amount of inorganic filler (e.g., silica), which may be due to pretreatment of the tire feedstock to remove at least a portion of the inorganic filler normally present in used tires. In one or more embodiments, after pretreatment, the tire feedstock contains less than 30% by weight of inorganic filler, less than 20% by weight in other embodiments, less than 10% by weight in other embodiments, and less than 5% by weight in other embodiments, based on the total weight of the feedstock supplied to the pyrolysis according to the present invention.

[0013] In one or more embodiments, the used tire supply material includes tire residue from passenger car tires. In other embodiments, the used tire supply material includes tire residue from non-passenger car tires, including but not limited to truck and bus tires, off-road vehicle tires, agricultural tires, and racing tires.

[0014] In one or more embodiments, used tires are mechanically processed (e.g., crushed or shredded) to form crushed or shredded material (i.e., the feed material is crushed or shredded). This crushed or shredded material (i.e., tire feed material) is also called crumb and may be characterized by a favorable compressive density. For example, the feed material may have a density of 640 kg / m³. 3 In other embodiments, the rate is 720 kg / m³. 3 In other embodiments, the rate is 770 kg / m³. 3It can have ultracompressible densities, which are determined by ASTM D698-07.

[0015] In one or more embodiments, the feedstock provided to the pyrolysis unit includes used tires and optionally complementary feedstocks. In one or more embodiments, the complementary feedstocks, which may also be referred to as co-feeds, include carbonaceous materials other than the tire feedstocks. Carbonaceous materials refer to any carbon material, whether in solid, liquid, gaseous, or plasma state. Non-limiting examples of carbonaceous materials include carbonaceous liquid products, industrial liquid recycling, solid waste from municipalities (MSW or msw) including solid waste from municipalities with high biomass content and / or reduced renewable material content, urban waste, agricultural materials, forestry materials, wood waste, building materials, plant materials, industrial waste, fermentation waste, petrochemical by-products, alcohol production by-products, coal, plastics, waste plastics, coke oven tar, lignin, black liquor, polymers, waste polymers, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, energy crops, forest treatment residues, wood treatment residues, livestock waste, poultry waste, food treatment residues, ethanol by-products, spent grains, spent microorganisms, waste from municipalities, construction waste, demolition waste, biomedical waste, hazardous waste, or combinations thereof. In one or more embodiments, the carbonaceous material includes biomass. In one or more embodiments, the biomass includes, but is not limited to, residues of sugarcane, sorghum, and guayure plants. In one or more embodiments, the feedstock comprises a blend of used tires and solid waste from a municipality, the solid waste from the municipality may include biomass. In other embodiments, the feedstock comprises used tires and solid waste from a municipality that is substantially free of biomass (i.e., substantially petroleum-based solid waste from a municipality). In yet another embodiment, the feedstock comprises used tires and biomass. In yet another embodiment, the feedstock comprises used tires and solid waste from a municipality from which most of the recyclable plastics have been removed (i.e., substantially free of recyclable plastics). In its sub-embodiments, recyclable glass and metals are also substantially removed from the solid waste components from the municipality.

[0016] In further embodiments, the guayule residue is produced as a result of a process for extracting rubber and resin from the guayule plant, as described in U.S. Publication No. 2022 / 0356273, which is incorporated herein by reference. A method for desolvating the guayule residue is described in U.S. Patent No. 10,132,563, which is also incorporated herein by reference. In one or more embodiments, the guayule residue contains 1% by weight or less of an organic solvent (based on the total weight of the dry residue). In certain embodiments, the dry residue contains 0.5% by weight or less of an organic solvent (based on the total weight of the dry residue). In one or more embodiments, the dry residue may contain some amount of water and higher boiling terpenes. In certain embodiments, the total amount of water and higher boiling terpenes in the dry residue may be higher than the amount of organic solvent.

[0017] In one or more embodiments, the co-supplied material (e.g., biomass or waste from a municipality) is 600 kg / m³. 3 Less than 580 kg / m³ in other embodiments. 3 Less than, and in other embodiments, 560 kg / m³ 3 It may also be characterized by a compressive density of less than a certain value, which is determined by ASTM D 698-07.

[0018] The supply material may be characterized by the amount of co-supply (e.g., biomass or waste from municipalities). In one or more embodiments, the supply material includes co-supply in about 0 to about 95% by weight, in other embodiments about 1 to about 75% by weight, in other embodiments about 2 to about 55% by weight, with the remainder being used tires. In one or more embodiments, the supply material includes co-supply in less than 95% by weight, in other embodiments less than 80% by weight, in other embodiments less than 70% by weight. In these embodiments or other embodiments, the supply material includes more than 10% by weight, in other embodiments more than 20% by weight, in other embodiments more than 30% by weight, in other embodiments more than 40% by weight, in other embodiments more than 50% by weight, in other embodiments more than 70% by weight, with the remainder being complementary supply material.

[0019] In alternative embodiments, the feedstock consists essentially, and in certain embodiments exclusively, of the identified carbonaceous materials other than tire feedstock. That is, the feedstock consists essentially or exclusively of the co-feedstock identified above. For example, in one or more embodiments, the feedstock comprises more than 80 wt%, in other embodiments more than 90 wt%, and in other embodiments more than 99 wt% of solid waste from municipalities. Alternatively, in other exemplary embodiments, the feedstock comprises more than 80 wt%, in other embodiments more than 90 wt%, and in other embodiments more than 99 wt% of biomass.

[0020] Pyrolysis of the feedstock As described above, the feedstock (which may include tire feedstock and optionally co-feed) is pyrolyzed into a gas stream containing hydrogen, carbon monoxide, and optionally carbon dioxide, by using techniques generally known in the art. As will be appreciated by those skilled in the art, these processes can include gasification processes, and it is also known that these processes can be adjusted to control the chemical nature of the resulting gas stream. For example, the degree of combustion can be controlled by controlling the amount of oxygen present during pyrolysis. In one or more embodiments, the pyrolysis step is conducted in a substantially inert environment.

[0021] Processes that can be used for the thermal decomposition step can include pyrolysis or gasification reactions, as disclosed in U.S. Patent Publications Nos. 2021 / 0207037, 2019 / 0295734, 2019 / 0249089, 2018 / 0273415, 2017 / 0009162, 2017 / 0002271, 2016 / 0107913, 2016 / 0068773, 2016 / 0024404, 2014 / 0182205, 2014 / 0157667, and 2014 / 0100294, which are incorporated herein by reference.

[0022] In one or more embodiments where the feedstock includes both the tire feedstock and the co-feed, the tire feedstock and the co-feed can be introduced simultaneously into the same pyrolysis unit. For example, the tire feedstock and the co-feed can be premixed in a desired ratio to form a feedstock that is supplied to the pyrolysis unit. Alternatively, separate streams of the tire feedstock and the co-feed can be supplied separately and individually to the pyrolysis unit at a desired rate. In yet other embodiments, the two feedstocks (i.e., the tire feedstock and the co-feed) can be processed continuously within the same pyrolysis unit. In still other embodiments, the two feedstocks (i.e., the tire feedstock and the co-feed) can be processed within separate pyrolysis units operating in parallel, and then the gas streams generated by each unit can be combined to achieve a desired ratio of gas components.

[0023] Characteristics of the gas product stream As described above, the gas product stream generated by the pyrolysis of the feedstock includes carbon monoxide, hydrogen, and optionally carbon dioxide. In one or more embodiments, the gas product stream includes from about 5 to about 50 weight percent, in other embodiments from about 7 to about 25 weight percent, and in other embodiments from about 8 to about 15 weight percent carbon dioxide. In one or more embodiments, the gas product stream includes from about 10 to about 85 weight percent, in other embodiments from about 20 to about 65 weight percent, and in other embodiments from about 25 to about 45 weight percent hydrogen. In one or more embodiments, the gas product stream includes from about 20 to about 85 weight percent, in other embodiments from about 30 to about 75 weight percent, and in other embodiments from about 40 to about 60 weight percent carbon monoxide. In one or more embodiments, the gas product stream generated by pyrolysis includes from about 40 to about 80 weight percent, in other embodiments from about 45 to about 75 weight percent, and in other embodiments from about 50 to about 70 weight percent carbon (i.e., carbon within carbon-based compounds) based on the total weight of the gas product stream.

[0024] Adjustment of the gas stream In one or more embodiments, the gas stream is adjusted (i.e., treated) before the gas stream is converted to ethanol. In one or more embodiments, the gas product stream from pyrolysis may be pressurized. In one or more embodiments, the pressurization of the gas stream achieves a pressure sufficient to overcome the opposing forces within the bioreactor. As those skilled in the art will understand, this allows the gas to flow through the bioreactor and allows the inert gas (e.g., nitrogen) in the gas stream to enter the reactor's headspace. In one or more embodiments, the gas stream is pressurized to a pressure of about 5 to about 20 bar.

[0025] Furthermore, the gas flow can be cooled. As those skilled in the art will understand, the gas flow can be cooled in a heat exchanger, for example, a water cooling unit. In one or more embodiments, the gas flow is cooled to a temperature lower than what would otherwise have a detrimental effect on the microbial culture in the bioreactor. In one or more embodiments, the gas flow is cooled to a temperature of about 25 to about 45°C before being delivered to the bioreactor.

[0026] Furthermore, the gas stream can be treated to remove any undesirable components that may be present in the gas stream. For example, the gas stream can be treated in a scrubber before being introduced into the bioreactor. In one or more embodiments, this may involve the use of a catalyst (e.g., iron oxide) to remove sulfur compounds such as hydrogen sulfide. The gas stream can be further treated to remove acids (e.g., treatment with calcium carbonate or sodium carbonate, of particular interest in removing hydrogen cyanide). An exemplary system for removing hydrogen sulfide from a gas stream is available from EcoVapor (Denver, Colorado). Another method is the use of corrosive agents, such as a system available from DMT under the trade name Sulfurex BF (Netherlands).

[0027] Synthesis gas to ethanol As described above, the components of the gas stream are converted into ethanol contained in the ethanol-containing stream, i.e., into an ethanol-containing product stream. In one or more embodiments, the gas stream is supplemented with hydrogen before the gas stream is converted into an ethanol-containing stream.

[0028] In one or more embodiments of the present invention, the gas stream is converted to ethanol via biosynthesis techniques. For example, it is known that synthesis gas can be converted to ethanol by fermentation using microorganisms such as bacteria. The microorganisms may be autotrophic microorganisms that produce acetic acid. Acetic acid-producing microorganisms (i.e., bacteria) generally convert CO, H2, and CO2 in the synthesis gas to acetyl-CoA. The acetyl-CoA is then converted to organic products such as acetic acid and ethanol. In one or more embodiments of the present invention, it may be desirable to preferentially produce ethanol over acetic acid.

[0029] As an alternative potential pathway, some microorganisms (e.g., acetogens) can reduce acetic acid (e.g., organic acids) to alcohol (e.g., ethanol). This acetic acid production mechanism, and the selected microorganisms, may be considered in relation to preferentially producing ethanol. Microorganisms other than acetogens may be suited to different pathways for reaching ethanol. One or more useful microorganisms can simultaneously take up both CO and H2 in synthesis gas. In these or other embodiments, certain microorganisms can reduce CO2 to CO in the presence of excess hydrogen. For example, useful microorganisms and techniques for their use are disclosed in "A Techno-Economic Assessment of Bioethanol Production from Switchgrass Through Biomass Gasification and Syngas Fermentation," Regis et al, Energy 274, 127318, (2023).

[0030] Those skilled in the art will further understand that various conditions for microbial-driven biosynthesis can be adjusted for the preferential production of ethanol. For example, the pH, temperature, and nutrient concentrations within the bioreactor where biosynthesis takes place can be adjusted. The desired pH, temperature, and nutrient concentrations may depend on the specific microorganism used.

[0031] In other embodiments, synthesis gas is converted to ethanol via thermochemical techniques. Those skilled in the art will understand that several thermochemical techniques exist for converting synthesis gas to ethanol. For example, there is a two-step process that can convert synthesis gas to methanol using a hydrogen-to-carbon monoxide ratio of 2:1. These reactions are typically carried out in the gas phase using a copper-based catalyst. The resulting product stream is typically saturated with water and can be purified by known distillation techniques. Methanol can then be catalytically converted to ethanol. One-step catalytic techniques are also known. An exemplary thermochemical process for converting synthesis gas to ethanol is described in U.S. Patent No. 9,115,046, which is incorporated herein by reference.

[0032] The resulting ethanol is included with the ethanol-containing stream. According to embodiments of the present invention, a crude ethanol-containing stream obtained directly from a reactor (e.g., a bioreactor) where ethanol is synthesized is delivered to a downstream step. In other embodiments, the ethanol-containing stream is purified to produce an ethanol-containing stream with a higher ethanol content. In one or more embodiments, the ethanol-containing stream (optionally purified) that leaves the step where synthesis gas is converted to ethanol (e.g., a bioreactor) and is delivered to a downstream step where ethanol is further converted contains more than 80% by weight, more than 90% by weight in other embodiments, and more than 95% by weight in other embodiments, based on the total weight of the ethanol-containing stream.

[0033] Ethanol vs. Ethylene As described above, ethanol in the ethanol-containing stream is converted to ethylene and then incorporated into the ethylene-containing stream. In one or more embodiments, ethanol is converted to ethylene using catalytic techniques well known in the art. Examples of useful catalysts include acid catalysts, alumina and transition metal oxides, silicoaluminophosphate (SAPO), HZSM-5 zeolite catalysts, and heteropoly acid catalysts. Variations of these catalysts, e.g., nanoscale versions, may also be used. As those skilled in the art will understand, some catalytic techniques proceed by dehydrating ethanol to form ethylene. For example, an acid catalyst first protonates the hydroxyl group of ethanol, forming a water molecule as a leaving group. Then, the conjugate base of the remaining catalyst deprotonates the methyl group, and the hydrocarbon rearranges to ethylene. In other embodiments, ethanol is converted to ethylene via catalytic dehydration on an aluminum oxide catalyst. In one or more embodiments, the conversion of ethanol to ethylene takes place at a temperature of about 180°C to about 500°C.

[0034] Those skilled in the art will understand that processes for the conversion of ethanol to ethylene are well known and commercially available. For example, a commercial process is available from Braskem SA, Technip Energies, Axens SA and Scientific Design Company, Inc.

[0035] The resulting ethylene is contained in the ethylene-containing stream. According to embodiments of the present invention, the crude ethylene-containing stream obtained directly from the reactor in which ethylene is synthesized is delivered to a downstream step. In other embodiments, the ethylene-containing stream is purified to produce an ethylene-containing stream with a higher ethylene content. In one or more embodiments, the ethylene-containing stream (optionally purified) that leaves the step in which ethanol is converted to ethylene and is delivered to a downstream step in which ethylene is further converted contains more than 80% by weight, more than 90% by weight in other embodiments, and more than 95% by weight in other embodiments, based on the total weight of the ethylene-containing stream.

[0036] Ethylene reacted with benzene As described above, ethylene in an ethylene-containing stream reacts with benzene to produce ethylbenzene. Those skilled in the art will understand that benzene can be alkylated with ethylene by known techniques. For example, a combination of benzene and ethylene streams can be reacted in the presence of a suitable catalyst. Useful catalysts include aluminosilicate zeolites such as Zeolite Socony Mobil-5 catalyst (i.e., ZSM-5). These reactions can be carried out in the gas phase using a fixed-bed catalyst. To maintain the desired polymerization medium, these reactions can typically be carried out under pressure (e.g., high pressure equivalent to 10 atmospheres) and at a temperature of about 200 to about 400°C. The synthesis of ethylbenzene by reacting ethylene with benzene is generally known, as described in U.S. Patents 4,547,605, 4,016,218, 4,891,458, and 5,334,795.

[0037] In one or more embodiments, the crude ethylbenzene-containing stream obtained directly from the reactor is delivered downstream for further conversion. In other embodiments, the ethylbenzene-containing stream is purified to produce an ethylbenzene-containing stream with a higher ethylbenzene content. In one or more embodiments, the ethylbenzene-containing stream that exits the step in which ethylene reacts with benzene and is delivered to the downstream step (after optional purification) contains more than 80% by weight, more than 90% by weight in other embodiments, and more than 95% by weight in other embodiments, based on the total weight of the ethylbenzene-containing stream.

[0038] From ethylbenzene to styrene In one or more embodiments, ethylbenzene in an ethylbenzene-containing stream is dehydrogenated to produce styrene and by-product hydrogen. Those skilled in the art will understand that the dehydrogenation of ethylbenzene can be catalyzed by known techniques. For example, iron(II) oxide can catalyze the dehydrogenation reaction at high temperatures (e.g., about 540 to about 675°C) in the presence of water. It is also known that mixed catalyst systems, such as those containing potassium oxide, can be used to prevent coking.

[0039] In one or more embodiments, the crude styrene-containing stream obtained directly from the reactor is delivered downstream for further use (e.g., polymerization). In other embodiments, the styrene-containing stream is purified to produce a styrene-containing stream with a higher styrene content. In one or more embodiments, the styrene-containing stream that leaves the step in which ethylbenzene is converted to styrene and is delivered to the downstream step (after purification, optionally) contains more than 80% by weight, more than 90% by weight in other embodiments, and more than 95% by weight in other embodiments, based on the total weight of the styrene-containing stream.

[0040] Recycling of by-product hydrogen As described above, the dehydrogenation of ethylbenzene is sent to the step of converting synthesis gas to ethanol, producing by-product hydrogen that can be used in that step. For example, as described above, the thermochemical process of converting synthesis gas to ethanol involves reacting hydrogen with carbon dioxide in a 2:1 ratio to form methanol, which is then converted to ethanol. This is particularly advantageous in the present invention because used tires are the primary feedstock, and used tires may contain a higher carbon-to-hydrogen molar ratio than other feedstocks such as biomass. Those skilled in the art will understand that hydrogen can be separated from other gases in the product stream by using various techniques, including pressure swing adsorption. [Industrial applicability]

[0041] In one or more embodiments, the styrene monomer produced by the method of the present invention can be used to produce elastomeric polymers. For the purposes of this specification, these polymers may be referred to as cyclic synthetic rubbers. In one or more embodiments, these cyclic synthetic rubbers can be used to manufacture tire components. As a result, the implementation of the present invention provides a method for returning waste materials, particularly waste materials from used tires, back into useful tires. In other words, a tire recycling method or tire circulation method is provided.

[0042] The elastomeric polymers that can be produced by the implementation of the present invention are also called styrene-containing elastomers and include, but are not limited to, poly(styrene-co-butadiene), poly(styrene-co-isoprene), and poly(styrene-co-isoprene-co-butadiene).

[0043] The synthesis of elastomeric polymers is well known and can be achieved by using several synthetic routes (i.e., polymerization mechanisms and techniques). For example, a blend of monomers (i.e., styrene monomer and diene monomer) can be polymerized by free radical emulsion polymerization, anionic polymerization, or coordination catalysts using, for example, neodymium-based catalyst systems.

[0044] In one or more embodiments, the diene monomer (e.g., butadiene monomer) copolymerized with styrene (obtained by the implementation of the present invention) can also be obtained from used tires, for example, as described in concurrently pending International Application No. PCT / US2022 / 081188 (incorporated herein by reference).

[0045] In one or more embodiments, styrene from other sustainable sources is combined with the styrene of the present invention to produce the elastomeric polymer of the present invention. For example, styrene can be obtained from biosynthetic raw materials such as bioethanol, which is then converted to styrene. See, for example, U.S. Patent No. 9,663,445. Alternatively, styrene can be synthesized from bio-based materials such as cinnamic acid or hydrocinnamic acid. See, for example, U.S. Patent No. 9,868,853. Yet another example is styrene obtained from the depolymerization of polystyrene from spent waste. See, U.S. Publication No. 2022 / 0411351. Those skilled in the art will further understand that styrene can be obtained from mass-balanced processes that qualify as bio-based, bio-recycling, or recyclable, as specified by the International Sustainability and Carbon Certification (ISCC). In other embodiments, the styrene of the present invention is combined with fossil-derived styrene to produce the elastomeric polymer of the present invention.

[0046] It should be understood that the elastomeric polymers prepared by polymerizing styrene with a diene monomer of the present invention have a relatively high proportion of styrenemer units derived from the styrene produced by the present invention, and therefore the elastomeric polymers of the present invention have a relatively high sustainable content. This is especially true when the comonomers (i.e., diene monomers) are also supplied from a sustainable source. In one or more embodiments, more than 50 mol% of the styrenemer units, in other embodiments more than 60 mol%, in other embodiments more than 70 mol%, in other embodiments more than 80 mol%, in other embodiments more than 90 mol%, in other embodiments more than 95 mol%, and in other embodiments more than 99 mol% are derived from the polymerization of styrene produced by the present invention (i.e., styrene monomers synthesized from a gaseous stream obtained by gasification of carbonaceous materials). Similarly, when elastomeric polymers are synthesized by copolymerizing the styrene of the present invention with other sustainably derived comonomers, the resulting elastomeric polymers have a relatively high sustainable content. In one or more embodiments, the elastomeric polymer of the present invention comprises, together with sustainable comonomers, more than 50 mol%, more than 60 mol%, more than 70 mol%, more than 80 mol%, more than 90 mol%, more than 95 mol%, and more than 99 mol% of sustainable mer units (i.e., styrene mer units obtained from monomers synthesized from gaseous streams obtained by gasification of carbonaceous materials and other sustainable comonomers).

[0047] It will also be understood that the polymers produced by the present invention can be functionalized. For example, styrene-containing elastomers such as SBR are known to be modified to include substituents that interact with fillers. These substituents can be imparted to the polymer using a variety of techniques, including, but not limited to, reacting the reactive polymer with a terminal functionalizer before quenching polymerization. These terminal functionalizers may include, but are not limited to, compounds such as imines, cyclic amines, and alkoxysilanes. Exemplary functionalizers are disclosed, for example, in U.S. Patents 9,296,832, 9,127,109, 9,062,017, 8,962,745, and U.S. Patent Publication 2015 / 0274944, which are incorporated herein by reference. The polymers can further be polymerized using a functionalization initiator, for example, disclosed in U.S. Patent 9,884,923 (which is incorporated herein by reference).

[0048] The elastomeric polymers produced by the present invention exhibit excellent viscoelastic properties and are particularly useful in the manufacture of various tire components, including, but not limited to, tire treads, sidewalls, sub-treads, and bead fillers. These elastomeric polymers can be used as all or part of the elastomeric components of a tire stock. When the elastomeric polymers produced by the present invention are used together with other vulcanizing polymers to form the elastomeric components of a tire stock, these other vulcanizing polymers may be natural rubber, synthetic rubber, or mixtures thereof. Examples of synthetic rubbers include polyisoprene, poly(styrene-co-butadiene), and other polybutadienes, poly(styrene-co-butadiene-co-isoprene), and mixtures thereof. The polymers of the present invention can also be used in the manufacture of hoses, belts, shoe soles, window seals, other seals, vibration damping rubber, and other industrial products.

[0049] The embodiment of the present invention not only provides a method for recycling tires by using used tires as a feedstock for producing polymers that can be compounded back into tires, but also, conveniently, provides a method for producing tires with a relatively high content of sustainable components, including recycled materials, naturally derived materials and / or materials synthesized from biosynthetic or bio-based materials. Furthermore, these tires or tire components include a threshold amount of cyclic synthetic rubber, while being characterized by a high sustainable content. For example, the tires or tire components of the present invention may contain more than 40% by weight, more than 50% by weight in other embodiments, and more than 60% by weight in other embodiments, of sustainable materials. In one or more embodiments, the tires or tire components contain about 40 to about 90% by weight, about 45 to about 85% by weight in other embodiments, and about 50 to about 80% by weight in other embodiments, of styrene. In combination with this, the rubber component of the tire or tire component of the present invention comprises more than 10% by weight, more than 20% by weight in other embodiments, more than 30% by weight in other embodiments, more than 40% by weight in other embodiments, more than 45% by weight in other embodiments, and more than 50% by weight in other embodiments of cyclic synthetic rubber, which comprises synthetic rubber produced according to embodiments of the present invention.

[0050] As those skilled in the art will understand, tire components are manufactured by preparing and vulcanizing a rubber composition, often called a vulcanizable rubber composition or simply a rubber composition. Generally, a vulcanizable rubber composition contains rubber components, fillers, waxes, and curing agents. Other components that may be included in a vulcanizable rubber composition include extender oils, process oils, resins, and degradation inhibitors.

[0051] Elastomer The rubber component of a vulcanizable rubber composition includes a vulcanizable elastomer, which may also be called an elastomer, vulcanizable rubber, or simply rubber. Those skilled in the art will understand that a vulcanizable elastomer can be cured (sometimes referred to as vulcanized) to form an elastomer composition. In one or more embodiments of the present invention, the rubber component includes one or more synthetic polymers. These synthetic polymers may include, but are not limited to, synthetic polyisoprene, polybutadiene, polyisobutylene-co-isoprene, neoprene, poly(ethylene-co-propylene), poly(styrene-co-butadiene), poly(styrene-co-isoprene-co-butadiene), poly(isoprene-co-butadiene), poly(ethylene-co-propylene-co-diene), polysulfide rubber, acrylic rubber, urethane rubber, silicone rubber, epichlorohydrin rubber, and mixtures thereof. These elastomers can have countless macromolecular structures, including linear, branched, and star-shaped structures.

[0052] In these or other embodiments, the rubber component of the vulcanizable rubber composition of the present invention comprises one or more cyclic synthetic rubbers, which are vulcanizable rubbers produced from used tires. These cyclic synthetic rubbers may be used alone as the rubber component or in combination with synthetic polymers.

[0053] In these or other embodiments, the rubber component may comprise one or more natural rubbers. Natural rubber may be used alone as a rubber component, or in combination with synthetic polymers and / or cyclic synthetic rubbers. As those skilled in the art will understand, natural rubber is synthesized by and obtained from plants. For example, natural rubber can be obtained from Hevea rubber trees, guayule shrub, gopher plant, mariola, rabbitbrush, milkweeds, goldenrods, pale Indian plantain, rubber vine, Russian dandelions, mountain mint, American germander, and tall bellflower.

[0054] Generally, the rubber composition of the present invention contains, based on the total weight of the tire components, about 30 to about 65% by weight of elastomer in other embodiments, about 35 to about 60% by weight in other embodiments, and about 40 to about 55% by weight in other embodiments.

[0055] Filler As suggested above, the rubber composition includes fillers such as organic and inorganic fillers. Examples of organic fillers include carbon black and starch. Examples of inorganic fillers include silica, aluminum hydroxide, magnesium hydroxide, mica, talc (hydrated magnesium silicate), and clay (hydrated aluminum silicate). In certain embodiments, mixtures of different fillers may be advantageously used.

[0056] The total amount of filler used in the rubber composition may be up to about 150 parts by weight per 100 parts by weight (phr) of rubber, and is typically about 30 to about 125 phr, or about 40 to about 110 phr. In certain embodiments, the total filler content is greater than about 100 phr. In other embodiments, the total filler content is about 50 to about 100 phr, and in further embodiments, it is about 55 to about 95 phr.

[0057] Conventional carbon blacks generally known in the art can be used. In one or more embodiments, the carbon blacks include furnace black, channel black, and lamp black. More specific examples of carbon blacks include ultra-abrasive furnace black, intermediate ultra-abrasive furnace black, high abrasion furnace black, high-speed extruded furnace black, fine furnace black, semi-reinforced furnace black, medium-machined channel black, hard-machined channel black, conductive channel black, and acetylene black.

[0058] In certain embodiments, the carbon black has a surface area (EMSA) of at least 20 m². 2 / g, in other embodiments at least 35m 2 The value may be / g, and the surface area value can be determined using the cetyltrimethylammonium bromide (CTAB) technique according to ASTM standard D-1765. The carbon black may be in pelletized form or in unpelleted cotton form. The preferred form of carbon black may depend on the type of mixing equipment used to mix the rubber compound.

[0059] In one or more embodiments, recycled materials may be used for the carbon black. Such recycled materials may include recycled or recycled vulcanized rubber, which is typically recycled from manufactured articles such as pneumatic tires, industrial conveyor belts, power transmission belts, and rubber hoses. Recycled carbon black can be obtained by a pyrolysis process or by other known methods for obtaining recycled carbon black. In one embodiment, recycled carbon black may be formed from the incomplete combustion of recycled rubber feedstock or rubber articles. In another embodiment, recycled carbon black can be formed from the incomplete combustion of feedstock containing oil resulting from a tire pyrolysis process. The carbon black used in the preparation of the vulcanizable elastomer composition may be in pelletized form or in non-pelletized cottony mass.

[0060] The total amount of filler used in the rubber composition may be up to about 75 parts by weight per 100 parts by weight (phr) of rubber, and is typically about 5 to 60 phr, or about 10 to 55 phr.

[0061] The rubber composition may further include fillers in the form of one or more recycled rubbers in particulate form. Recycled particulate rubber is typically broken down and regenerated (or recycled) by one of several processes, which may include physical decomposition, grinding, chemical decomposition, desulfurization, cryogenic grinding, or a combination thereof. The term recycled particulate rubber may relate to both vulcanized rubber and desulfurized rubber, with desulfurized recycled rubber or recycled rubber (recycled rubber) relating to rubber that has been vulcanized, ground into particles, and may further undergo substantial or partial desulfurization. In one example, recycled particulate rubber used in a rubber composition does not essentially contain recycled rubber resulting from desulfurization. Where the vulcanized rubber contains wires or textile fiber reinforcements, such wires or fiber reinforcements may be removed by an optional preferred process such as magnetic separation, air suction and / or air flotation steps. In certain embodiments, “recycled particulate rubber” includes cured, i.e., vulcanizable (crosslinked) rubber that has been ground or powdered into particulate matter having an average particle size as discussed below.

[0062] Certain silicas can be considered sustainable materials. Some commercially available silicas that can be used as sustainable materials in the present invention include Hi-Sil® 215, Hi-Sil® 233, and Hi-Sil® 190 (PPG Industries, Inc.; Pittsburgh, Pa.). Other suppliers of commercially available silica include Grace Davison (Baltimore, Md.), Degussa Corp. (Parsippany, NJ), Rhodia Silica Systems (Cranbury, NJ), and JMHuber Corp. (Edison, NJ). Other sustainable silicas include those derived from rice husk ash.

[0063] In one or more embodiments, silica can be characterized by its surface area, which is a measure of its reinforcing properties. The Brunauer, Emmet, and Teller ("Brunauer, Emmet and Teller, BET") method (described in J. Am. Chem. Soc., 1939, vol. 60, 2 p. 309-319) is an accepted method for determining surface area. The BET surface area of silica is generally less than 450 m 2 / g. Useful ranges of surface area include from about 32 to about 400 m 2 / g, from about 100 to about 250 m 2 / g, and from about 130 to about 240 m 2 / g, and from about 170 to about 220 m 2 / g. In certain embodiments, silica can have a BET surface area of from 190 to about 280 m 2 / g. The pH of silica is generally from about 5 to about 7, or slightly higher than 7, or in other embodiments, from about 5.5 to about 6.8.

[0064] In one or more embodiments, when silica is used as a filler (alone or in combination with other fillers), a coupling agent and / or a shielding agent may be added to the rubber composition during mixing to enhance the interaction between the silica and the elastomer. Useful coupling agents and shielding agents are disclosed in: U.S. Patent Nos. 3,842,111, 3,873,489, 3,978,103, 3,997,581, 4,002,594, 5,580,919, 5,583,245, 5,663,396, 5,674,932, 5,684,171, 5,684,172, 5,696,197, 6,608,145, 6,667,362, 6,579,949, 6,590,017, 6,525,118, 6,342,552, and 6,683,135, which are incorporated herein by reference.

[0065] The amount of silica used in the rubber composition may be about 1 to about 150 phr, or in other embodiments, about 5 to about 130 phr. The useful upper limit is limited by the high viscosity provided by the silica. In certain embodiments, the silica used in the rubber composition is derived solely from rice husk ash, and in other embodiments, the rubber composition does not contain silica from non-rice husk ash-derived processes. When silica is used with carbon black, the amount of silica or carbon black each can be reduced to about 1 phr. Generally, the amounts of binders and shielding agents range from about 4% to about 20% by weight, based on the weight of silica used. In one or more embodiments in which carbon black and silica are used in combination as fillers, the weight ratio of silica to total fillers may be about 5% to about 99% by weight of total fillers, in other embodiments, about 10% to about 90% by weight of total fillers, or in yet another embodiment, about 50% to about 85% by weight of total fillers. In certain embodiments, the silica and carbon black fillers used in the rubber composition are selected from the group consisting of sustainably pyrolytic carbon black and / or silica derived from rice husk ash.

[0066] hardening agent Numerous rubber curing agents (also called vulcanizing agents) containing sulfur or peroxide-based curing systems may be used. (See Kirk-Othmer, Encyclopedia of Chemical Technology, Vol.20, pgs.365-468, (3) rd Ed.1982), especially Vulcanization Agents and Auxiliary Materials, pgs.390-402, and AYCoran, Vulcanization, Encyclopedia of Polymer Science and Engineering, (2 nd These are described in Ed. 1989, and are incorporated herein by reference. The vulcanizing agents may be used alone or in combination.

[0067] wax In one or more embodiments, the rubber composition may contain one or more natural waxes. Examples of natural waxes, or those that do not contain petroleum as a raw material, include carnauba wax, candelilla wax (e.g., extracted from candelilla flowers), rice wax (e.g., isolated from rice bran oil), and wood wax (e.g., extracted from sumac). In these embodiments or other embodiments, the natural wax may be used in combination with petroleum-based waxes.

[0068] In one or more embodiments, the rubber composition of the present invention contains a threshold amount of sustainable wax, including cyclic synthetic wax and natural wax for the purposes of the present invention. The amount of sustainable wax may be about 1% to about 99% by weight of the total wax, or in other embodiments, about 20% to about 80% by weight, relative to the total weight of the waxes included. In certain embodiments, the rubber composition contains only sustainable wax.

[0069] oil With regard to oils, sustainable oils, including vegetable oils and bio-based oils, may be used. Vegetable oils may contain vegetable triglycerides. Exemplary oils, but not limited to, include palm oil, soybean oil (also known herein as soybean oil), rapeseed oil, sunflower seed oil, peanut oil, cottonseed oil, oil derived from palm kernels, coconut oil, olive oil, corn oil, grape seed oil, hemp oil, linseed oil, rice oil, safflower oil, sesame oil, mustard oil, and flaxseed oil. Other examples include nut-derived oils such as those obtained from beech, cashew, mongono, macadamia, pine, hazelnut, chestnut, acorn, almond, pecan, pistachio, walnut, or Brazil nut. As those skilled in the art will understand, these oils can be produced by any suitable process, such as mechanical extraction (e.g., using an oil mill), chemical extraction (e.g., using a solvent such as hexane or carbon dioxide), pressure extraction, distillation, leaching, dissociation, refining, purification, hydrogenation, and sparging.

[0070] Bio-oils, also known as bio-oils, can include oils produced by recombinant cells. For example, recombinant cell-produced bio-oils are created using selected strains of algal cells that have been given sugars (e.g., sucrose), which are then fermented to produce a bio-oil with a selected profile. Once sufficiently grown or fermented, the bio-oil is separated from the cells and recovered.

[0071] Generally, the rubber composition of the present invention may contain about 1 to about 70 parts by weight of total oil per 100 parts by weight of rubber, or in other embodiments, about 5 to about 50 parts by weight of total oil. The amount of sustainable oil may be about 1% to about 99% by weight of the total weight of the oil contained, or in other embodiments, about 20% to about 80% by weight.

[0072] Other ingredients Other components typically used in rubber compounding can also be added to the rubber composition. These include accelerators, surfactants, oils, plasticizers, waxes, anticorrosion agents, processing aids, zinc oxide, tackifying resins, reinforcing resins, fatty acids such as stearic acid, reconstituters, and antioxidants and ozone degradation inhibitors.

[0073] Processing of rubber compositions All components of a rubber composition can be mixed using standard mixing equipment, such as a Banbury or Bravender mixer, extruder, kneader, and two-roll mill. In one or more embodiments, the components are mixed in two or more stages. In the first stage (often also called the masterbatch mixing stage), a so-called masterbatch (typically containing rubber components and fillers) is prepared. To prevent premature vulcanization (also known as scorching), the vulcanizing agent may be removed from the masterbatch. The masterbatch may be mixed at a starting temperature of about 25°C to about 125°C and an extrusion temperature of about 135°C to about 180°C. Once the masterbatch is prepared, in the final mixing stage, the vulcanizing agent may be introduced into the masterbatch and mixed. This final mixing stage is typically carried out at a relatively low temperature to reduce the possibility of premature vulcanization. Optionally, an additional mixing stage, often called a re-mill, can be used between the masterbatch mixing stage and the final mixing stage. If silica is included as a filler in the rubber composition, one or more re-mill stages are often used. Various components, including the polymer of the present invention, can be added during these remilling processes.

[0074] Mixing procedures and conditions particularly applicable to silica-filled tire formulations are described in U.S. Patents No. 5,227,425, 5,719,207, and 5,717,022, and European Patent No. 890,606, all of which are incorporated herein by reference. In one embodiment, the preparation of the initial masterbatch is carried out by incorporating the polymer and silica substantially in the absence of coupling agents and shielding agents.

[0075] Tire manufacturing To manufacture tire components using the polymer produced by the present invention, those skilled in the art will understand that the polymer can be mixed with various other components (e.g., fillers and curing agents) to produce a rubber composition (also called a vulcanizable composition), which can then be processed into tire components according to conventional tire manufacturing techniques, including standard rubber forming and molding techniques. Tire components may include, but are not limited to, tire treads, sidewalls, sub-treads, body price skims, and bead fillers. The various tire components are then assembled into a green tire (i.e., an uncured tire), placed in a mold, and then vulcanized. Typically, vulcanization is carried out by heating the vulcanizable composition in a mold, which may be heated to, for example, about 140°C to about 180°C. The cured or crosslinked rubber composition may also be called a vulcanized product, which generally contains a thermosetting three-dimensional polymer network structure. Other components, such as fillers and processing aids, may be uniformly dispersed throughout the crosslinked network structure. Pneumatic tires may be manufactured as described in U.S. Patents 5,866,171, 5,876,527, 5,931,211, and 5,971,046, which are incorporated herein by reference.

[0076] Tire reinforcement In one or more embodiments, the tire may include fiber reinforcements made by using non-petroleum materials instead of synthetic fibers. For example, mechanically recycled fibers, chemically recycled fibers, or bio-based fibers can be used. Similarly, the tire may include metal reinforcements made from recycled steel and / or other circular or sustainable metals. These non-petroleum fibers and recycled metals can be used exclusively within the tire or in combination with conventional fiber and / or metal reinforcements.

[0077] Various modifications and changes that do not depart from the scope and spirit of the present invention will be apparent to those skilled in the art. The present invention is not formally limited to the exemplary embodiments described herein.

Claims

1. It is a process, (a) To provide raw materials containing carbonaceous materials, (b) Converting the supplied raw materials into heat to generate a gas stream containing carbon monoxide, hydrogen, and carbon dioxide, (c) Converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide into ethanol, (d) Converting at least a portion of the ethanol to ethylene, (e) Reacting at least a portion of the ethylene with benzene to produce ethylbenzene, (f) A process comprising dehydrogenating the ethylbenzene to form styrene.

2. The process according to claim 1, wherein the step of dehydrogenating the ethylbenzene to form styrene further comprises generating hydrogen gas as a byproduct and guiding the hydrogen gas to the step of converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide into ethanol.

3. The process according to claim 1 or 2, wherein the step of thermally converting the supply material includes gasifying the supply material.

4. The process according to any one of claims 1 to 3, wherein the step of converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide to ethanol comprises biosynthetically converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide to ethanol, or the step of converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide to ethanol comprises thermochemically converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide to ethanol.

5. The process according to any one of claims 1 to 4, wherein the step of converting at least a portion of the ethanol to ethylene comprises catalytically dehydrating the ethanol.

6. The process according to any one of claims 1 to 5, further comprising the steps of providing a diene comonomer and polymerizing the styrene with the diene comonomer to produce an elastomeric polymer.

7. The process according to any one of claims 1 to 6, wherein the diene comonomer is a sustainable diene comonomer.

8. The process according to any one of claims 1 to 7, wherein the supply material includes used tire supply material.

9. The process according to any one of claims 1 to 8, wherein the supply material includes biomass.

10. The process according to any one of claims 1 to 9, wherein the supply material includes solid waste from a local government.

11. The process according to any one of claims 1 to 10, wherein the supply material comprises a mixture of tire supply material and complementary supply material.

12. The process according to any one of claims 1 to 11, further comprising the step of manufacturing a tire component using the elastomeric polymer.

13. A method for producing an elastomeric polymer, wherein the method is (a) To provide a styrene monomer synthesized from the components of a gaseous stream obtained from the gasification of a supply material containing carbonaceous material, (b) A method comprising polymerizing the styrene with a diene monomer to form an elastomeric polymer.

14. The method according to any one of claims 1 to 13, wherein the gas stream comprises carbon monoxide, hydrogen, and carbon dioxide, and the styrene monomer is formed by converting at least a portion of the carbon monoxide, hydrogen, and carbon dioxide to ethanol, converting at least a portion of the ethanol to ethylene, reacting at least a portion of the ethylene with benzene to form ethylbenzene, and converting at least a portion of the ethylbenzene to styrene.

15. The method according to any one of claims 1 to 14, wherein more than 50 mol%, or more than 60 mol%, or more than 70 mol%, or more than 80 mol%, or more than 90 mol%, or more than 99 mol% of the styrenemer units of the elastomerized polymer are obtained by polymerizing the styrene monomer.

16. The method according to any one of claims 1 to 15, wherein more than 50 mol%, or more than 60 mol%, or more than 70 mol%, or more than 80 mol%, or more than 90 mol%, or more than 99 mol% of the mer units of the elastomerous polymer are obtained from the styrene and the sustainable comonomer.

17. The method according to any one of claims 1 to 16, wherein the carbonaceous material includes used tire supply raw materials.

18. The method according to any one of claims 1 to 17, wherein the carbonaceous material includes biomass.

19. The method according to any one of claims 1 to 18, wherein the carbonaceous material includes solid waste from a local government.

20. The method according to any one of claims 1 to 19, wherein the carbonaceous material comprises a mixture of used tire supply material and complementary supply material.

21. A tire component, A tire component comprising a cured rubber matrix containing a filler dispersed therein, wherein the cured rubber matrix contains more than 40% by weight, or more than 50% by weight, or more than 60% by weight, or more than 70% by weight, or more than 80% by weight, or more than 90% by weight, or more than 99% by weight of crosslinked cyclic synthetic rubber obtained by polymerizing monomers synthesized from components of a gaseous flow obtained from the gasification of a supply raw material containing a carbonaceous material.

22. The tire component according to any one of claims 1 to 21, wherein the cyclic synthetic rubber is polybutadiene, and the monomer synthesized from the gaseous components is 1,3-butadiene.

23. The tire component according to any one of claims 1 to 22, wherein the cyclic synthetic rubber is a polybutadiene copolymer, and the polybutadiene copolymer is obtained by copolymerization of the 1,3-butadiene monomer and a sustainable comonomer.

24. The tire component according to any one of claims 1 to 23, wherein the carbonaceous material includes used tire supply raw materials.

25. The tire component according to any one of claims 1 to 24, wherein the carbonaceous material includes biomass.

26. The tire component according to any one of claims 1 to 25, wherein the carbonaceous material includes solid waste from a local government.

27. The tire component according to any one of claims 1 to 26, wherein the carbonaceous material comprises a mixture of used tire supply material and complementary supply material.

28. The tire component according to any one of claims 1 to 27, wherein the tire component comprises one or more additional components dispersed within the cured rubber matrix, one or more of these additional components being sustainable materials, and more than 40% by weight, or more than 50% by weight, or more than 60% by weight, or more than 70% by weight, or more than 80% by weight, or more than 90% by weight, or more than 99% by weight of the tire component comprises cyclic synthetic rubber and sustainable materials.

29. The tire component according to any one of claims 1 to 28, wherein the filler comprises recycled carbon black.

30. The tire component according to any one of claims 1 to 29, wherein the filler comprises silica and carbon black, the silica being silica derived from rice husk ash, and the carbon black being pyrolysis carbon black.

31. The tire component according to any one of claims 1 to 30, wherein the tire component comprises sustainable oil dispersed within the rubber matrix.

32. A tire comprising the tire components described in any one of claims 1 to 31, wherein the tire comprises more than 40% by weight, or more than 50% by weight, or more than 60% by weight, or more than 70% by weight, or more than 80% by weight, or more than 90% by weight, or more than 99% by weight of sustainable material.

33. The tire according to any one of claims 1 to 32, wherein the tire comprises recycled metal.

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