System and method for converting waste plastic materials into useful products and solids compression unit

Abstract

A system for converting waste plastic materials into useful products may be provided. The system may include a continuous thermal processing arrangement including a melting stage for subjecting a molten mixture to a thermal pyrolysis process and then a catalytic pyrolysis process, and a thermal-catalytic pyrolysis stage downstream of the melting stage. The thermal-catalytic pyrolysis stage may include at least two catalyst feed points distributed along the thermal-catalytic pyrolysis stage. The thermal-catalytic pyrolysis stage may be operable to selectively feed catalyst through any one or more of the at least two catalyst feed points to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal-catalytic pyrolysis stage in a manner that varies the proportion of thermal pyrolysis and catalytic pyrolysis within the thermal-catalytic pyrolysis stage.

Description

Detailed Description of the Invention

[0001] [Technical field] Various embodiments relate generally to systems and methods for converting waste plastic materials into useful products, and solids compression units for such systems. In particular, various embodiments relate generally to pyrolysis systems and methods for converting waste plastic materials into useful products, and solids compression units for such pyrolysis systems.

[0002] [background] Generally, waste plastics can be converted into useful gas, liquid and / or solid products through pyrolysis processes. However, many challenges lie in the adoption of pyrolysis processes for waste plastics. For example, the challenges include inconsistent quality and mixture of waste plastic raw materials / feedstocks, or contaminated waste plastic raw materials / feedstocks that require costly sorting and / or pre-treatment to ensure the quality of the raw materials / feedstocks for the pyrolysis process. Another challenge is the difficulty in controlling and achieving the desired pyrolysis products, resulting in dedicated pyrolysis systems / equipment for specific waste plastic product raw materials / feedstocks, which is costly.

[0003] Therefore, there is a need to provide a more efficient and versatile system and method for the pyrolysis of waste plastic materials that addresses the above-mentioned problems.

[0004] [Summary of the Invention] According to various embodiments, a system for converting waste plastic materials into useful products can be provided. The system can include a continuous thermal processing arrangement. According to various embodiments, the continuous thermal processing arrangement can include a melting stage for melting a compressed waste plastic feed produced from the waste plastic material to form a molten mixture. According to various embodiments, the continuous thermal processing arrangement can further include a thermal-catalytic pyrolysis stage downstream of the melting stage, which subjects the molten mixture to a thermal pyrolysis process, followed by a catalytic pyrolysis process for producing pyrolysis gas products and a pyrolysis solid residue. According to various embodiments, the thermal-catalytic pyrolysis stage can include at least two catalyst feed points distributed along the thermal-catalytic pyrolysis stage. According to various embodiments, the thermal-catalytic pyrolysis stage can be operable to selectively feed catalyst through any one or more of the at least two catalyst feed points to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal-catalytic pyrolysis stage in a manner that provides a variation in the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage. According to various embodiments, the continuous heat treatment arrangement may further include a termination stage downstream of the thermal-catalytic pyrolysis stage, where the pyrolysis solid residue is heated for conversion to a solid product.

[0005] According to various embodiments, a method for converting waste plastic material into useful products may be provided. According to various embodiments, the method may include introducing a compressed waste plastic feed produced from the waste plastic material into a melting stage of a continuous thermal processing arrangement of a system for converting waste plastic material into useful products. According to various embodiments, the melting stage may melt the compressed waste plastic feed to form a molten mixture. The method may further include selectively feeding catalyst through any one or more of at least two catalyst feed points of a thermal-catalytic pyrolysis stage of the continuous thermal processing arrangement of the system to vary the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage based on the desired end product output from the system or the characteristics of the waste plastic material or feed introduced into the system. According to various embodiments, the thermal-catalytic pyrolysis stage may be downstream of the melting stage and may subject the molten mixture to a pyrolysis process and then a catalytic pyrolysis process to produce pyrolysis gas products and pyrolysis solid residue. The method may further include removing solid products from a termination stage of the continuous thermal processing arrangement of the system. According to various embodiments, the termination stage may be downstream of the thermal-catalytic pyrolysis stage, where the pyrolysis solid residue is heated for conversion to a solid product.

[0006] According to various embodiments, a solid compression unit is provided that includes at least two rotating screws arranged in series from an inlet of the solid compression unit to an outlet of the solid compression unit, wherein the at least two rotating screws are cooperatively operable to compress the solid material as the solid material moves from the inlet of the solid compression unit to the outlet of the solid compression unit.

[0007] In the drawings, like reference features generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments are described with reference to the following drawings: [Brief description of the drawings]

[0008] [Figure 1A] FIG. 1 is a schematic diagram of a system for converting waste plastic materials into useful products, according to various embodiments. [Figure 1B] FIG. 1B is a schematic diagram of a compression unit of the system of FIG. 1A in accordance with various embodiments. [Figure 1C] FIG. 1B is a schematic diagram of a secondary compression unit of the system of FIG. 1A, according to various embodiments.

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS It will be appreciated that embodiments described below in the context of an apparatus are equally valid for the individual methods and vice versa. Furthermore, it will be understood that the embodiments described below may be combined, e.g., parts of one embodiment may be combined with parts of another embodiment.

[0010] It should be understood that terms such as "on," "over," "top," "bottom," "down," "side," "back," "left," "right," "front," "lateral," "side," "up," "down," and the like, when used in the following description, are used for convenience and to aid in the understanding of relative positions or directions, and are not intended to limit the orientation of any device or structure, or any part of any device or structure. Additionally, the singular words "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Similarly, the word "or" is intended to include "and" unless the context clearly dictates otherwise.

[0011] Various embodiments relate generally to systems and methods for converting waste plastic materials into useful products. According to various embodiments, the waste plastic materials can include municipal waste, which may include, but is not limited to, various types of polymers, such as polypropylene, polyethylene, and the like. According to various embodiments, the useful products can include, but are not limited to, hydrocarbons having carbon atoms in the range of C2-C34, preferably hydrocarbons suitable for petrochemical processes or fuels (e.g., naphtha, diesel, or other hydrocarbon products) and solid products. According to various embodiments, the solid products can include, but are not limited to, solid carbon (e.g., carbon black), or other solids contained in the waste plastic materials, and the like. Various embodiments relate generally to pyrolysis systems and methods for converting waste plastic materials into useful products. Thus, various embodiments may seek to realize systems and methods for pyrolysis or degradation of waste plastic materials into useful products. According to various embodiments, the system can include an apparatus or arrangement or equipment for performing a thermal process for pyrolysis of the waste plastic materials.

[0012] According to various embodiments, the system may include a thermal treatment arrangement or device or equipment for performing the pyrolysis of the waste plastic material. According to various embodiments, the thermal treatment arrangement may be configured to perform a thermal treatment sequence including a thermal pyrolysis process followed by a catalytic pyrolysis process. According to various embodiments, the thermal treatment arrangement may be configured to vary or adjust or change the ratio of thermal pyrolysis process and catalytic pyrolysis process performed on the waste plastic material in the thermal treatment arrangement to change or vary the end product produced by the system from the waste plastic material. Thus, depending on the desired end product, the ratio of thermal pyrolysis process and catalytic pyrolysis process in the thermal treatment arrangement may be varied or adjusted or changed to subject the waste plastic material to a thermal treatment sequence having the ratio of thermal pyrolysis process and catalytic pyrolysis process required to produce the desired end product. According to various embodiments, the ratio of thermal pyrolysis process and catalytic pyrolysis process may be the ratio of the duration (or holding period) of the thermal pyrolysis process to the duration (or holding period) of the catalytic pyrolysis process.

[0013] According to various embodiments, the thermal treatment arrangement can include at least two (e.g., two or more) catalyst feed points along the thermal treatment arrangement for feeding catalyst to the thermal treatment arrangement to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal treatment arrangement to change the point along the thermal treatment arrangement, thereby switching the thermal pyrolysis process to a catalytic pyrolysis process. According to various embodiments, the system and method can include selectively changing a point along the thermal treatment arrangement, where a catalyst is added to convert, modify, switch, or convert the thermal pyrolysis process to a catalytic pyrolysis process based on the desired end product output from the system or the characteristics of the waste plastic material or feed introduced into the system. For example, according to various embodiments, a catalyst may be selectively added to any one or more of at least two catalyst feed ports of the thermal treatment arrangement to achieve or obtain or realize the required ratio of thermal pyrolysis process to catalytic pyrolysis process, and the thermal pyrolysis process is converted or modified or switched or converted to a catalytic pyrolysis process by feeding or adding the catalyst at the required point along the thermal treatment arrangement. Thus, the catalyst may be added or fed or injected at the point where the catalytic pyrolysis process will take place. For example, according to various embodiments, the catalyst may be selectively added to the zone, or stage, or chamber, or reactor where the catalytic pyrolysis process will take place. Various embodiments are distinguished and different from conventional catalytic pyrolysis systems and methods, whereby the catalyst is usually mixed with the waste plastic material in the feed stage (e.g., the feedstock feed zone).

[0014] According to various embodiments, the ratio of the thermal pyrolysis process and the catalytic pyrolysis process along the thermal treatment arrangement can be changed or adjusted to produce a desired end product output from the system, so that various embodiments provide a versatile and efficient system and method. Various embodiments may be capable of accepting a wide variety of waste plastic materials, including, but not limited to, waste plastic materials of inconsistent quality and mixtures, or contaminated waste plastic materials, and by varying the ratio of the thermal pyrolysis process and the catalytic pyrolysis process along the thermal treatment arrangement, to produce a desired end product output. Furthermore, various embodiments may also enable or provide simple and easy feedback control for the end product by monitoring the end product output from the system and varying the ratio of the thermal pyrolysis process and the catalytic pyrolysis process along the thermal treatment arrangement to adjust or fine-tune the end product output from the system.

[0015] According to various embodiments, by selectively varying the point or points along the system where the catalyst is added and selectively adding the catalyst to the same zone, or stage, or chamber, or reactor where catalytic pyrolysis actually takes place, the ideal amount of catalyst can be determined, measured, and added to the system without wasting catalyst. Furthermore, the catalyst may be added to the system of various embodiments at a point where the waste plastic material contained therein has already been broken down to a size small enough to fit into the pore sites of the catalyst used. Thus, all catalyst added to the systems and methods of various embodiments can perform the function of the catalyst with minimal or no waste. According to various embodiments, the catalyst is not mixed with the waste plastic feed at the start of the system or process (e.g., in the raw feed section). Thus, various embodiments can avoid or minimize catalyst waste or deactivation due to molecules of the waste plastic feed that are too large to enter the pore sites of the catalyst, or these large molecules of the waste plastic feed blocking the pore sites of the catalyst before the catalyst can be activated, etc. Thus, systems and methods according to various embodiments may provide cost savings due to no catalyst waste or minimal catalyst waste.

[0016] Various embodiments also relate to a solids compression unit for the system described herein. According to various embodiments, the system may include at least one solids compression unit for compressing the waste plastic material before feeding it to the thermal treatment arrangement. Thus, the at least one solids compression unit may compress the waste plastic material to remove moisture and air to prevent moisture and air from entering the thermal treatment arrangement. According to various embodiments, the system may also include at least one other solids compression unit for removing the solid product from the thermal treatment arrangement. According to various embodiments, the solid product may be removed from the system without shutting down the process by the at least one other solids compression unit. According to various embodiments, the solids compression unit may include at least two rotating screws arranged in series operative to reduce the volumetric flow rate of solids from one rotating screw to the subsequent rotating screw. Due to the reduced volumetric flow rate caused by each of the at least two rotating screws, the solids (e.g., the waste plastic material or the solid product) may be compressed into compressed solids as the solids move along the at least two rotating screws. Thus, by reducing the volumetric flow rate of at least two rotating screws arranged in series, the solids can move at different volumetric flow rates along different segments of the solids compression unit, whereby the volumetric flow rate between the different segments is reduced from the inlet to the outlet of the solids compression unit. According to various embodiments, the solids (e.g., waste plastic material or solid product) can be compressed or compacted by the solids compression unit to prevent air from entering the system and / or prevent gas products generated from the system from escaping to the atmosphere during operation of the system or feeding of the waste plastic material and / or removal of the solid product.

[0017] The following examples relate to various embodiments: Example 1 is a system for converting waste plastic materials into useful products, including a continuous thermal processing arrangement. The continuous thermal processing arrangement can include a melting stage for melting a compressed waste plastic feed produced from the waste plastic materials to form a molten mixture. The continuous thermal processing arrangement can further include a thermal-catalytic pyrolysis stage downstream of the melting stage for subjecting the molten mixture to a thermal pyrolysis process, followed by a catalytic pyrolysis process for producing a pyrolysis gas product and a pyrolysis solid residue. The thermal-catalytic pyrolysis stage can include at least two catalyst feed points distributed along the thermal-catalytic pyrolysis stage. The thermal-catalytic pyrolysis stage can be operable to selectively feed catalyst through any one or more of the at least two catalyst feed points to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal-catalytic pyrolysis stage in a manner that changes the ratio of the thermal pyrolysis process to the catalytic pyrolysis process within the thermal-catalytic pyrolysis stage. The continuous heat treatment arrangement may further include a termination stage downstream of the thermal-catalytic pyrolysis stage, in which the pyrolysis solid residue is heated for conversion to a solid product.

[0018] In Example 2, the subject matter of Example 1 may optionally include a waste material compaction unit upstream of the continuous heat treatment arrangement. The waste material compaction unit may be operable to compact the waste plastic material and remove air and moisture to generate a compressed waste plastic feed for feeding to the continuous heat treatment arrangement.

[0019] In Example 3, the subject matter of Example 1 or Example 2 may optionally include a temperature range for the termination step that is higher than a temperature range for the thermal-catalytic pyrolysis step that is higher than a temperature range for the melting step.

[0020] In Example 4, the subject matter of any one of Examples 1-3 may optionally include that the thermal-catalytic pyrolysis stage includes a first thermal pyrolysis zone for heating the molten mixture received from the melting stage at or above the pyrolysis temperature of the molten mixture, one or more intermediate variable zones, each of which has a catalyst feed port at the beginning of the intermediate variable zone, a catalyst feed port serving as one of at least two catalyst feed points along the thermal-catalytic pyrolysis stage, and a final catalytic pyrolysis zone having a catalyst feed port at the beginning of the final catalytic pyrolysis zone serving as the final catalyst feed point of the at least two catalyst feed points along the thermal-catalytic pyrolysis stage for receiving catalyst. Catalyst may be fed from the catalyst feed port of the one or more intermediate variable zones or the catalyst feed port of the final catalytic pyrolysis zone to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal-catalytic pyrolysis stage.

[0021] In Example 5, the subject matter of Example 4 may optionally include that the final catalytic pyrolysis zone of the thermal-to-catalytic pyrolysis stage includes at least one pyrolysis gas outlet for discharging pyrolysis gas products.

[0022] In Example 6, the subject matter of any one of Examples 1-5 may optionally include that the termination stage includes at least one pyrolysis gas outlet for releasing pyrolysis gas products.

[0023] In Example 7, the subject matter of any one of Examples 1-6 may optionally include that the termination stage includes at least one solid product outlet for removing the solid product.

[0024] In Example 8, the subject matter of any one of Examples 1-7 may optionally include that the continuous heat treatment arrangement includes a reactor including a thermal to catalytic pyrolysis stage.

[0025] In Example 9, the subject matter of any one of Examples 1-7 may optionally include that the continuous heat treatment arrangement includes a reactor including a melting stage and a thermal-catalytic pyrolysis stage.

[0026] In Example 10, the subject matter of any one of Examples 1-7 may optionally include that the continuous heat treatment arrangement includes a reactor including a thermal-catalytic pyrolysis stage and a termination stage.

[0027] In Example 11, the subject matter of any one of Examples 1 to 7 may optionally include that the continuous heat treatment arrangement includes a reactor including a melting stage, a thermal-catalytic pyrolysis stage, and a termination stage.

[0028] In Example 12, the subject matter of any one of Examples 8-11 may optionally include, wherein the reactor comprises a cylindrical reactor.

[0029] In Example 13, the subject matter of any one of Examples 8-12 may optionally include, wherein the reactor includes a conveyor mechanism configured to transport material along a length of the reactor.

[0030] In Example 14, the subject matter of Example 13 may optionally include that the conveyor mechanism includes at least one screw conveyor extending along the entire length of the reactor.

[0031] In Example 15, the subject matter of any one of Examples 8-14 may optionally include the reactor being inclined at a rise rate per horizontal distance of 1:250 to 1:20.

[0032] In Example 16, the subject matter of any one of Examples 8-15 may optionally include the reactor being inclined at a rise rate per horizontal distance of 1:200 to 1:50.

[0033] In Example 17, the subject matter of any one of Examples 8-16 may optionally include the reactor being inclined at a rise rate per horizontal distance of 1:150 to 1:80.

[0034] In Example 18, the subject matter of any one of Examples 1-17 may optionally include the waste material compaction unit including at least a first rotating screw and a second rotating screw arranged in series, and the waste plastic material being fed to the waste material compaction unit at a first end of the first rotating screw and being moved from the waste material compaction unit via the first rotating screw and then the second rotating screw.

[0035] In Example 19, the subject matter of Example 18 may optionally include a rotational speed of the first rotatable screw of the waste material compaction unit being faster than a rotational speed of the second rotatable screw of the compaction of the waste material.

[0036] In Example 20, the subject matter of Example 18 may optionally include a diameter of the screw shaft of the first rotatable screw being smaller than a diameter of the screw shaft of the second rotatable screw.

[0037] In Example 21, the subject matter of Example 18 may optionally include a pitch range of the first rotatable screw being greater than a pitch of the second rotatable screw.

[0038] In Example 22, the subject matter of Examples 1-21 may optionally include at least one solid product compression unit for compressing a solid product take-off from a termination stage of the continuous heat treatment arrangement, the solid product compression unit being downstream of the termination stage of the continuous heat treatment arrangement.

[0039] In Example 23, the subject matter of Example 22 may optionally include wherein the solid product compression unit includes a first rotatable screw and a second rotatable screw.

[0040] In Example 24, the subject matter of Example 23 may optionally include that the first rotating screw of the solid product compression unit and the second rotating screw of the solid product compression unit are arranged in series.

[0041] In Example 25, the subject matter of Example 23 or Example 24 may optionally include that the first rotating screw of the solid product compression unit and the second rotating screw of the solid product compression unit have the same pitch range, which is 70 mm to 220 mm or 80 mm to 200 mm.

[0042] In Example 26, the subject matter of Examples 23-25 ​​may optionally include the second rotatable screw of the solid product compression unit having a rotational speed of 40% to 100%, or 55% to 98%, or 70% to 97%, or 80% to 95% of the rotational speed of the first rotatable screw of the solid product compression unit.

[0043] In Example 27, the subject matter of any one of Examples 22-26 may optionally include wherein the solid product compression unit further includes a third rotating screw.

[0044] In Example 28, the subject matter of Example 27 may optionally include, wherein the first rotating screw of the solid product compression unit, the second rotating screw of the solid product compression unit, and the third rotating screw of the solid product compression unit are arranged in series.

[0045] In Example 29, the subject matter of Example 27 or Example 28 may optionally include that the first rotatable screw of the solid product compression unit, the second rotatable screw of the solid product compression unit, and the third rotatable screw of the solid product compression unit have the same pitch range.

[0046] In Example 30, the subject matter of any one of Examples 27-29 may optionally include the third rotatable screw of the solid product compression unit having a rotational speed of 35% to 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85% of the rotational speed of the first rotatable screw of the solid product compression unit.

[0047] In Example 31, the subject matter of Examples 23-30 may optionally include that the solid product compression unit further includes one or more additional rotating screws.

[0048] In Example 32, the subject matter of Example 23 may optionally include a pitch range of the first rotatable screw of the solid product compression unit that is greater than a pitch range of the second rotatable screw of the solid product compression unit, and the pitch range of the second rotatable screw of the solid product compression unit is between 70% and 100%, or between 75% and 99%, or between 78% and 98% of the pitch range of the first rotatable screw of the solid product compression unit.

[0049] In Example 33, the subject matter of Example 23 may optionally include a third rotating screw, wherein the pitch range of the first rotating screw of the solid product compression unit is greater than the pitch range of the second rotating screw of the solid product compression unit, the pitch range of the second rotating screw of the solid product compression unit is equal to or greater than the pitch range of the third rotating screw of the solid product compression unit, the pitch range of the second rotating screw of the solid product compression unit is 70% to 100%, or 75% to 99%, or 78% to 98% of the pitch range of the first rotating screw of the solid product compression unit, and the pitch range of the third rotating screw of the solid product compression unit is 65% to 98%, or 75% to 95%, or 80% to 93% of the pitch range of the first rotating screw of the solid product compression unit.

[0050] In Example 34, the subject matter of Examples 23-26 may optionally include, wherein a shaft diameter of the first rotatable screw of the solid product compression unit is smaller than a shaft diameter of the second rotatable screw of the solid product compression unit, and the shaft diameter of the second rotatable screw of the solid product compression unit is 100% to 135%, or 105% to 130%, of the shaft diameter of the first rotatable screw of the solid product compression unit.

[0051] In Example 35, the subject matter of Examples 23-26 is a third rotating screw, wherein the shaft diameter of the first rotating screw of the solid product compression unit is smaller than the shaft diameter of the second rotating screw of the solid product compression unit, the shaft diameter of the second rotating screw of the solid product compression unit is equal to or larger than the shaft diameter of the third rotating screw of the solid product compression unit, the shaft diameter of the second rotating screw of the solid product compression unit is 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw of the solid product compression unit, and the shaft diameter of the third rotating screw of the solid product compression unit is 105% to 155% or 108% to 145% of the shaft diameter of the first rotating screw of the solid product compression unit.

[0052] In Example 36, the subject matter of any one of Examples 23-35 may optionally include, in the solid product compression unit, a cooling jacket around at least one rotating screw of the solid product compression unit, and a cooling fluid circulating through the cooling jacket to cool the solid product being compressed.

[0053] In Example 37, the subject matter of any one of Examples 1-36 may optionally include, wherein the termination step includes a first heating zone that elevates the temperature of the solid product, and a second heating zone that maintains the solid product at an elevated temperature.

[0054] In Example 38, the subject matter of any one of Examples 5 to 37 may optionally include, in combination with Example 5 or Example 6, that at least one pyrolysis gas outlet includes a vacuum pump.

[0055] In Example 39, the subject matter of any one of Examples 5 to 38 may be combined with Example 5 or Example 6 and optionally include at least one heat exchanger unit connected to the at least one pyrolysis gas outlet for condensing long-chain carbon compounds in the pyrolysis gas product.

[0056] In Example 40, the subject matter of Example 39 may optionally include at least one heat exchanger unit configured to minimize pressure drop in the thermal to catalytic pyrolysis stage, and at least one heat exchanger including a dual pipe heat exchanger or a shell-and-tube heat exchanger, preferably at least one heat exchanger including a dual pipe heat exchanger.

[0057] In Example 41, the subject matter of Example 39 or Example 40 may optionally include at least one gas separator unit downstream of the at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product.

[0058] In Example 42, the subject matter of Example 41 may optionally include wherein the at least one gas separator unit includes a cyclone separator or a drum separator.

[0059] In Example 43, the subject matter of Example 41 or Example 42 may optionally include at least one product separation and purification unit downstream of the at least one gas separator unit for separating and purifying the pyrolysis gas products to obtain desired end products.

[0060] Example 44 is a method of converting waste plastic material into a useful product. The method can include introducing a compressed waste plastic feed produced from the waste plastic material according to any one of Examples 1-43 or Example 121 into a continuous thermal processing arrangement of the system. The method can include feeding the catalyst through one or more of at least two catalyst feed points of a thermal-catalytic pyrolysis stage of the continuous thermal processing arrangement to vary the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage. The method can include removing a solid product from a termination stage of the system.

[0061] In Example 45, the subject matter of Example 44 may optionally include a step of monitoring at least one characteristic of an end product output from the system to determine whether adjustment of the ratio of thermal pyrolysis processes to catalytic pyrolysis processes within the thermal-catalytic pyrolysis stage is necessary to produce a desired end product output from the system.

[0062] In Example 46, the subject matter of Example 45 may optionally include feeding catalyst through one or more of at least two catalyst feed points based on the proportion of thermal pyrolysis process and catalytic pyrolysis process determined to be required.

[0063] In Example 47, the subject matter of Example 45 or Example 46 may optionally include that at least one property of the end product monitored is specific gravity.

[0064] In Example 48, the subject matter of any one of Examples 44-47 may optionally include withdrawing pyrolysis gas products from the continuous thermal treatment arrangement.

[0065] In Example 49, the subject matter of any one of Examples 44-48 may optionally include a step of condensing long-chain carbon compounds from the pyrolysis gas product by at least one heat exchanger unit, when the system is according to any one of Examples 39-43.

[0066] In Example 50, the subject matter of Example 49 may optionally include a step of returning the long chain carbon compounds to the thermal to catalytic pyrolysis stage.

[0067] In Example 51, the subject matter of any one of Examples 44-50 may optionally include a step of removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product by at least one gas separator unit, when the system is according to any one of Examples 41-43.

[0068] In Example 52, the subject matter of Example 51 may optionally include a step of returning the residual particulates or heavy hydrocarbons, or a combination thereof, to the thermal-catalytic pyrolysis stage.

[0069] In Example 53, the subject matter of Examples 44-52 may optionally include the catalytic pyrolysis process being at a temperature in the range of 250°C to 440°C, or 250°C to 370°C, or 270°C to 320°C, or 300°C to 440°C, or 320°C to 420°C, or 350°C to 400°C.

[0070] In Example 54, the subject matter of any one of Examples 44-53 may optionally include a step of compressing the waste plastic material via a waste material compression unit with a compression ratio in the range of 2.0 to 5.0 when the system is according to any one of Examples 2-43 in combination with Example 2.

[0071] In Example 55, the subject matter of Example 54 may optionally include compressing the waste plastic material through a waste material compression unit to remove air, such that the compressed waste plastic feed output from the compression unit has an air (e.g., oxygen) content in the range of 2% to 16% by weight, preferably 5% to 10% by weight.

[0072] In Example 56, the subject matter of Examples 54 or 55 may optionally include compressing waste plastic material through a waste material compression unit to remove moisture, such that the compressed waste plastic feed output from the compression unit has a moisture content in the range of 2% to 16% by weight, preferably 5% to 10% by weight.

[0073] In Example 57, the subject matter of any one of Examples 54-56 may optionally include compression of the waste plastic material via the waste material compression unit at a temperature in the range of 80°C to 170°C, or 90°C to 140°C, or 90°C to 160°C, or 110°C to 120°C, or 130°C to 150°C, or 120°C to 155°C.

[0074] In Example 58, the subject matter of any one of Examples 54 to 57 may optionally include that the compression of the waste plastic material via the waste material compression unit is at a pressure in the range of 100 kPa to 150 kPa (or 0 bar gauge pressure to 0.5 bar gauge pressure or 1 bar to 1.5 bar), preferably 100 kPa to 110 kPa (or 0 bar gauge pressure to 0.1 bar gauge pressure or 1 bar to 1.1 bar).

[0075] In Example 59, the subject matter of any one of Examples 54-58 may optionally include that the compression of the waste plastic material via the waste material compression unit is for a hold time of 30 seconds to 120 seconds (or 0.5 minutes to 2 minutes).

[0076] In Example 60, the subject matter of any one of Examples 44-59 may optionally include a step of melting the compressed waste plastic feed via a melting stage by heating to a temperature equal to or higher than the melting point of the compressed waste plastic feed, preferably the temperature being in the range of 110°C to 350°C, or 110°C to 160°C, or 120°C to 140°C, or 200°C to 350°C, or 240°C to 320°C, or 250°C to 300°C.

[0077] In Example 61, the subject matter of any one of Examples 44-60 may optionally include the thermal pyrolysis process being at a temperature suitable to reduce the molecular size to be equal to or smaller than the pore size of the catalyst, preferably the temperature being in the range of 130°C to 380°C, or 130°C to 370°C, or 130°C to 280°C, or 150°C to 250°C, or 300°C to 380°C, or 310 to 360°C, or 320°C to 350°C.

[0078] In Example 62, the subject matter of any one of Examples 44-61 may optionally include a step of heating the pyrolysis solid residue by a termination step to a temperature suitable for cleaving remaining carbon-hydrogen bonds, and a step of removing residual hydrogen and moisture from the pyrolysis solid residue, preferably at a temperature of at least 350°C.

[0079] In Example 63, the subject matter of Example 62 may be combined with Example 60, optionally including that the melting of the compressed waste plastic feed, the thermal pyrolysis process, the catalytic pyrolysis process, and the heating of the pyrolysis solid residue are at the same pressure, preferably in the range of 100 kPa to 110 kPa, or 120 kPa to 180 kPa, or 140 kPa to 160 kPa (or 0 bar gauge pressure to 0.1 bar gauge pressure, 0.2 bar gauge pressure to 0.8 bar gauge pressure, or 0.4 bar gauge pressure to 0.6 bar gauge pressure, or 1 bar to 1.1 bar, 1.2 bar to 1.8 bar, or 1.4 bar to 1.6 bar).

[0080] In Example 64, the subject matter of Example 60 may optionally include melting the compressed waste plastic feed by the melting stage for a retention time of 10 seconds to 120 seconds or 18 seconds to 90 seconds (i.e., 0.16 minutes to 2 minutes or 0.3 minutes to 1.5 minutes).

[0081] In Example 65, the subject matter of any one of Examples 44-64 may optionally include, wherein the ratio of the thermal pyrolysis process to the catalytic pyrolysis process includes a ratio of a retention time of the thermal pyrolysis process to a retention time of the catalytic pyrolysis process.

[0082] In Example 66, the subject matter of Example 62 may optionally include that the step of heating the pyrolysis solid residue through the termination stage is for a holding time of 10 seconds to 120 seconds or 18 seconds to 210 seconds (i.e., 0.16 minutes to 2 minutes or 0.3 minutes to 3.5 minutes).

[0083] In Example 67, the subject matter of Example 62 or Example 66 may optionally include removing moisture by heating the pyrolysis solid residue via a termination stage, such that the solid product has a moisture content in the range of 5% to 35% by weight, preferably 10% to 30% by weight, and a solids content in the range of 60% to 95% by weight, preferably 70% to 90% by weight, or more preferably at least 90% by weight.

[0084] In Example 68, the subject matter of any one of Examples 44-67 is according to any one of Examples 22-43 in combination with Example 22, and may optionally include, wherein the particle size of the solid product exiting the solid product compression unit is in the range of 30 nm to 500 nm.

[0085] In Example 69, the subject of Example 68 is a process for preparing a solid product having a melting point of 1.0 g / cm 3~ 3.0g / cm 3 , preferably 1.4 g / cm 3~ 2.2g / cm 3 The solid product may optionally include a solid product compression unit to reduce the bulk density to have a bulk density in the range of

[0086] Example 70 is a solids compression unit that includes a first screw conveyor and a second screw conveyor.

[0087] In Example 71, the subject matter of Example 70 may optionally include wherein the first screw conveyor and the second screw conveyor are arranged in series.

[0088] In Example 72, the subject matter of Example 70 or Example 71 may optionally include that the first screw conveyor and the second screw conveyor have the same pitch range, which may be from 70 mm to 220 mm or from 80 mm to 200 mm.

[0089] In Example 73, the subject matter of any one of Examples 70-72 may optionally include the second screw conveyor having a rotational speed that is between 40% and 100%, or between 55% and 98%, or between 70% and 97%, or between 80% and 95% of the rotational speed of the first screw conveyor.

[0090] In Example 74, the subject matter of any one of Examples 70-72 may optionally include a third screw conveyor.

[0091] In Example 75, the subject matter of Example 74 may optionally include wherein the first screw conveyor, the second screw conveyor, and the third screw conveyor are arranged in series.

[0092] In Example 76, the subject matter of Example 74 or Example 75 may optionally include, wherein the first screw conveyor, the second screw conveyor, and the third screw conveyor have the same pitch range.

[0093] In Example 77, the subject matter of any one of Examples 74-76 may optionally include the third screw conveyor having a rotational speed of 35% to 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85% of the rotational speed of the first screw conveyor.

[0094] In Example 78, the subject matter of any one of Examples 70-77 may optionally include one or more additional screw conveyors.

[0095] In Example 79, the subject matter of Example 70 may optionally include the pitch range of the first screw conveyor being greater than the pitch range of the second screw conveyor, and the pitch range of the second screw conveyor being 70% to 100%, or 75% to 99%, or 78% to 98% of the pitch range of the first screw conveyor.

[0096] In Example 80, the subject matter of Example 79 may optionally include a third screw conveyor, wherein the pitch range of the first screw conveyor is greater than the pitch range of the second screw conveyor, the pitch range of the second screw conveyor is the same as or greater than the pitch range of the third screw conveyor, the pitch range of the second screw conveyor is 70%-100%, or 75%-99%, or 78%-98% of the pitch range of the first screw conveyor, and the pitch range of the third screw conveyor is 65%-98%, or 75%-95%, or 80%-93% of the pitch range of the first screw conveyor.

[0097] In Example 81, the subject matter of Example 70 may optionally include the shaft diameter of the first screw conveyor being smaller than the shaft diameter of the second screw conveyor, and the shaft diameter of the second screw conveyor being 100% to 135% or 105% to 130% of the shaft diameter of the first screw conveyor.

[0098] In Example 82, the subject of Example 81 may optionally include a third screw conveyor as described above, wherein the shaft diameter of the first screw conveyor is smaller than the shaft diameter of the second screw conveyor, and the shaft diameter of the second screw conveyor is the same as or smaller than the shaft diameter of the third screw conveyor, preferably the shaft diameter of the second screw conveyor is 100% to 135% or 105% to 130% of the shaft diameter of the first screw conveyor, and preferably the shaft diameter of the third screw conveyor is the same as the shaft diameter of the second screw conveyor, or the shaft diameter of the third screw conveyor is 105% to 155% or 108% to 145% of the shaft diameter of the first screw conveyor.

[0099] In Example 83, the subject matter of any one of Examples 70-81 may optionally include a cooling jacket around at least one screw conveyor.

[0100] In Example 84, the subject matter of Example 4 may optionally include, wherein the continuous heat treatment arrangement includes at least one pyrolysis gas outlet for discharging pyrolysis gas products, the at least one pyrolysis gas outlet being in a final catalytic pyrolysis section of the thermal-to-catalytic pyrolysis stage or the termination stage, or both, and the at least one pyrolysis gas outlet including a vacuum pump.

[0101] In Example 85, the subject matter of Example 84 may optionally include at least one heat exchanger unit connected to at least one pyrolysis gas outlet for condensing long-chain carbon compounds in the pyrolysis gas product, the at least one heat exchanger unit being configured to minimize pressure drop in the thermal-catalytic pyrolysis stage, the at least one heat exchanger including a dual pipe heat exchanger or a shell-and-tube heat exchanger.

[0102] In Example 86, the subject matter of Example 85 may optionally include at least one gas separator unit downstream of the at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product.

[0103] In Example 87, the subject matter of any one of Examples 1-4 and Examples 84-86 may optionally include that the termination stage includes at least one solid product outlet for removing solid product.

[0104] In Example 88, the subject matter of any one of Examples 1-4 and Examples 84-87 may optionally include that the continuous heat treatment arrangement includes a reactor including any one of a melting stage, a thermal-catalytic pyrolysis stage, or a termination stage, or a combination thereof.

[0105] In Example 89, the subject matter of Example 88 may optionally include that the reactor is inclined at a rise rate per horizontal distance of 1:250 to 1:20.

[0106] In Example 90, the subject matter of any one of Examples 2-4 and Examples 84-89 may be combined with Example 2, optionally including that the waste material compaction unit includes at least two rotating screws arranged in series from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit, and the direction of solids transport is from the inlet of the waste material compaction unit to the outlet of the waste material compaction unit.

[0107] In Example 91, the subject matter of Example 90 may optionally include a volumetric flow rate produced by each of the at least two rotating screws of the waste material compaction unit being successively decreased from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit to compress the waste plastic material into a compressed waste plastic feed.

[0108] In Example 92, the subject matter of Example 91 may optionally include the diameter of the screw shaft of each of the at least two rotating screws of the waste material compaction unit increasing successively from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit.

[0109] In Example 93, the subject matter of Example 91 may optionally include the pitch range of each of the at least two rotatable screws of the waste material compaction unit decreasing sequentially from one rotatable screw to another rotatable screw from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit.

[0110] In Example 94, the subject matter of any one of Examples 1-4 and Examples 84-93 may optionally include at least one solid product compression unit for compressing a solid product discharge from a termination stage of the continuous heat treatment arrangement, the at least one solid product compression unit being downstream of the termination stage of the continuous heat treatment arrangement.

[0111] In Example 95, the subject matter of Example 94 may optionally include, wherein the solid product compression unit includes at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, and the direction of solids transport is from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

[0112] In Example 96, the subject matter of Example 95 may optionally include compressing the solid product by sequentially decreasing the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

[0113] In Example 97, the subject matter of Example 95 may optionally include the pitch range of each of the at least two rotating screws of the solid product compression unit decreasing sequentially from one rotating screw to another rotating screw from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

[0114] In Example 98, the subject matter of Example 95 may optionally include, wherein the diameter of the screw shaft of each of the at least two rotating screws of the solid product compression unit increases successively from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

[0115] In Example 99, the subject matter of Example 95 may optionally include the rotational speed of each of the at least two rotating screws of the solid product compression unit being sequentially decreased from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

[0116] In Example 100, the subject matter of any one of Examples 95-99 may optionally include the solid product compression unit further comprising at least three rotating screws.

[0117] Example 101 is a method for converting waste plastic materials into useful products, comprising introducing a compressed waste plastic feed produced from the waste plastic materials into a melting stage of a continuous thermal processing arrangement of a system for converting waste plastic materials into useful products, the melting stage melting the compressed waste plastic feed to form a molten mixture. The method may further include selectively feeding a catalyst through any one or more of at least two catalyst feed points of a thermal-catalytic pyrolysis stage of the continuous thermal processing arrangement of the system to vary the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage (e.g., based on the desired end product output from the system or the characteristics of the waste plastic material or feed introduced into the system), the thermal-catalytic pyrolysis stage being downstream of the melting stage, and subjecting the molten mixture to a thermal pyrolysis process and then a catalytic pyrolysis process to produce pyrolysis gas products and pyrolysis solid residues. The method may further include removing the solid product from a termination stage of the continuous heat treatment arrangement of the system, the termination stage being downstream of the thermal to catalytic pyrolysis stage, and heating the pyrolysis solid residue for conversion to a solid product.

[0118] In Example 102, the subject matter of Example 101 may optionally include monitoring at least one characteristic of an end product output from the system to determine whether adjustment of the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage is necessary to produce a desired end product output from the system, and selectively feeding catalyst through any one or more of the at least two catalyst feed points based on the ratio of thermal pyrolysis process to catalytic pyrolysis process determined to be necessary.

[0119] In Example 103, the subject matter of Examples 101 or 102 may optionally include withdrawing pyrolysis gas products from the continuous heat treatment arrangement via at least one pyrolysis gas outlet of the continuous heat treatment arrangement.

[0120] In Example 104, the subject matter of Example 103 may optionally include a step of condensing long-chain carbon compounds from the pyrolysis gas product by at least one heat exchanger unit coupled to the at least one pyrolysis gas outlet, and returning the long-chain carbon compounds to the thermal-catalytic pyrolysis stage.

[0121] In Example 105, the subject matter of Example 104 may optionally include removing residual particulates or heavy hydrocarbons, or combinations thereof, from the pyrolysis gas product by at least one gas separator unit downstream of the at least one heat exchanger unit, and returning the residual particulates or heavy hydrocarbons, or combinations thereof, to the thermal-catalytic pyrolysis stage.

[0122] In Example 106, the subject matter of Examples 104 or 105 may optionally include compressing waste plastic material via a waste material compression unit, the waste material compression unit being upstream of a continuous thermal processing arrangement of a system for converting waste plastic material into useful products.

[0123] In Example 107, the subject matter of any one of Examples 104-106 may optionally include the thermal pyrolysis process being at a temperature suitable to reduce the molecular size to be equal to or smaller than the pore size of the catalyst, the temperature being in the range of 130°C to 380°C, or 130°C to 280°C, or 150°C to 250°C, or 150°C to 320°C, or 300°C to 380°C, or 310°C to 360°C, or 320°C to 350°C.

[0124] In Example 108, the subject matter of any one of Examples 104-107 may optionally include the catalytic pyrolysis process being at a temperature in the range of 250°C to 440°C, or 250°C to 370°C, or 270°C to 320°C, or 300°C to 440°C, or 320°C to 420°C, or 350°C to 400°C.

[0125] In Example 109, the subject matter of any one of Examples 104-108 may optionally further include a step of heating the pyrolyzed solid residue by a termination step to a temperature suitable for cleaving remaining carbon-hydrogen bonds, and a step of removing residual hydrogen and moisture from the pyrolyzed solid residue, preferably both of the above steps, wherein the temperature is at least 350°C, or at least 400°C, or at least 410°C.

[0126] In Example 110, the subject matter of any one of Examples 104-109 may optionally include, wherein the ratio of the thermal pyrolysis process to the catalytic pyrolysis process includes a ratio of a retention time of the thermal pyrolysis process to a retention time of the catalytic pyrolysis process.

[0127] In Example 111, the subject matter of any one of Examples 101-110 may optionally include a step of removing solid product from a termination stage of the continuous heat treatment arrangement of the system by a solid product compression unit, the solid product compression unit including at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, and the direction of solid transport is from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

[0128] In Example 112, the subject matter of Example 111 may optionally include compressing the solid product by sequentially decreasing the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

[0129] In Example 113, the subject matter of Example 111 may optionally include the rotational speed of each of the at least two rotating screws of the solid product compression unit being sequentially decreased one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

[0130] Example 114 is a solids compression unit including at least two rotating screws arranged in series from an inlet of the solids compression unit to an outlet of the solids compression unit. The at least two rotating screws can be cooperatively operable to compress the solids material as the at least two rotating screws move the solids material from the inlet of the solids compression unit to the outlet of the solids compression unit.

[0131] In Example 115, the subject matter of Example 114 may optionally include, as the solid material is being moved from the inlet of the solid product compression unit to the outlet of the solid product compression unit, the volumetric flow rates produced by each of the at least two rotating screws of the solid product compression unit are successively decreased one after the other so as to be cooperatively operated to compress the solid material from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

[0132] In Example 116, the subject matter of Example 115 may optionally include the rotational speed of each of the at least two rotating screws of the solid compression unit being sequentially decreased from an inlet of the solid compression unit to an outlet of the solid compression unit.

[0133] In Example 117, the subject matter of Example 115 may optionally include the diameter of the screw shaft of each of the at least two rotating screws of the solid compression unit increasing successively from an inlet of the solid compression unit to an outlet of the solid compression unit.

[0134] In Example 118, the subject matter of Example 115 may optionally include a pitch range for each of the at least two rotating screws of the solid product compression unit decreasing sequentially from one rotating screw to another rotating screw from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

[0135] In Example 119, the subject matter of any one of Examples 114-118 may optionally include at least three rotating screws.

[0136] In Example 120, the subject matter of any one of Examples 114-119 may optionally include further including a cooling jacket around the at least one rotating screw.

[0137] In Example 121, the subject matter of any one of Examples 1-43 may optionally include that the melting stage comprises at least one auxiliary catalyst feed point for feeding catalyst in the melting stage.

[0138] In Example 122, the subject matter of any one of Examples 44-69 may optionally include a step of feeding a catalyst via at least one auxiliary catalyst feed point in a melting stage of a continuous heat treatment configuration of the system.

[0139] According to various embodiments, the term "screw shaft diameter" as used herein may refer to the diameter of the shaft of a screw conveyor or rotating screw.

[0140] According to various embodiments, the term "pitch range" as used herein can refer to the distance between screw flights (e.g., adjacent screw flights) of a screw conveyor or rotating screw.

[0141] According to various embodiments, the term "end product" as used herein can refer to the hydrocarbon materials produced by and / or output from the system, or the hydrocarbon materials obtained from and / or exiting a separation and purification unit.

[0142] FIG. 1A shows a schematic diagram of a system 100 for converting waste plastic materials into useful products, according to various embodiments. According to various embodiments, the system 100 may be a pyrolysis system 100. According to various embodiments, the waste plastic materials may include municipal waste, which may include, but is not limited to, various types of polymers, e.g., polypropylene, polyethylene, and the like. According to various embodiments, the useful products may include, but is not limited to, hydrocarbons having carbon atoms in the range of C2-C34, such as hydrocarbons suitable for petrochemical processes or fuels (e.g., naphtha, diesel, or other hydrocarbon products), and solid products. According to various embodiments, the solid products may include, but is not limited to, solid carbon (e.g., carbon black), or other solids contained in the waste plastic materials, and the like.

[0143] According to various embodiments, the system 100 may include a waste material compaction unit 200 (or solids compaction unit). According to various embodiments, the waste material compaction unit 200 may receive waste plastic material (or waste plastic feed or feedstock). Thus, the waste plastic material may be fed to the waste material compaction unit 200. According to various embodiments, a feeder (not shown) may be connected to the waste material compaction unit 200. The feeder may be for feeding and transporting the waste plastic material to the waste material compaction unit 200. According to various embodiments, the feeder may include, but is not limited to, a fixed volume feeder, a gravity feeder, a bulk feeder, a linear feeder, a screw feeder, an auger feeder, or a hopper feeder. According to various embodiments, the feeder may be at an opening or inlet of the waste material compaction unit 200. According to various embodiments, the waste material compaction unit 200 may compress the waste plastic material and remove air (e.g., oxygen) and moisture from the waste plastic material to form or generate a compressed waste plastic feed. Thus, by compressing or compacting the waste plastic material, the air and moisture in the waste plastic material may be forced out or squeezed out. According to various embodiments, the waste material compaction unit 200 may compress the waste plastic material at a temperature or range of temperatures substantially within the range of 80° C. to 170° C., or 90° C. to 140° C., or 90° C. to 160° C., or 110° C. to 120° C., or 130° C. to 150° C., or 120° C. to 155° C. Thus, when the waste material compaction unit 200 is operated at an elevated temperature, moisture may be evaporated such that the compressed waste plastic feed may be moisture free.According to various embodiments, the waste material compaction unit 200 may include at least one moisture release port (e.g., an exhaust port or outlet port or conduit or opening or vent, e.g., to the atmosphere) that allows moisture within the waste material compaction unit 200 (e.g., moisture evaporated from heated waste plastic material) to escape or be discharged from the waste material compaction unit 200 or out of the system 100 (e.g., to the atmosphere). The at least one moisture release port may be located along the waste material compaction unit 200 (e.g., between the inlet and outlet of the waste material compaction unit 200 or from the inlet to the outlet of the waste material compaction unit 200). According to various embodiments, each moisture release port may include a one-way valve configured to allow moisture to be directed from the waste material compaction unit 200 or out of the system 100 and may prevent fluid (e.g., air from the atmosphere) from entering the waste material compaction unit 200 or the system 100. If moisture release is desired (e.g., moisture increases beyond a moisture volume threshold in the following zone(s)), and multiple moisture release ports are provided and distributed along the waste material compaction unit 200 of the system 100, any one or combination of the moisture release port(s) of the multiple moisture release ports can be selectively operated or opened to release moisture from the zone(s) of the waste material compaction unit 200 that is directly (e.g., fluidly) connected to the operated or opened moisture release port(s). According to various embodiments, each moisture release port can be a separate opening from the inlet of the waste material compaction unit 200 (or in other words, can be completely different), in which case the feeder can be located at and / or separate from the outlet of the waste material compaction unit 200 that produces the compacted waste plastic feed. According to various embodiments, the waste material compaction unit 200 can be heated to enhance the temperature within the waste material compaction unit 200, including a heating arrangement, including but not limited to an external fire source, electric heating, heating elements, heating coils, heating pads, and the like.According to various embodiments, the waste material compaction unit 200 can prepare the raw feed / raw material of the waste plastic material into a dry, compressed, air-free waste plastic feed for subsequent pyrolysis processing. More details of the waste material compaction unit 200 are described below.

[0144] Referring to FIG. 1A, according to various embodiments, the system 100 can include a thermal treatment arrangement. According to various embodiments, the thermal treatment arrangement can be configured to perform pyrolysis on the compacted waste plastic feed from the waste material compaction unit 200. According to various embodiments, the thermal treatment arrangement can be a continuous thermal treatment arrangement 300. Thus, the continuous thermal treatment arrangement 300 can perform pyrolysis in a continuous manner instead of by batch processing. In other words, the waste plastic material undergoing pyrolysis can be continuously moved, flowed, conveyed, or transported to the continuous thermal treatment arrangement 300 for pyrolysis processing, rather than processing the material in batches and moving the material for each batch.

[0145] As shown, the continuous heat treatment arrangement 300 may be coupled to the waste material compaction unit 200 at a location downstream of the waste material compaction unit 200. Thus, the waste material compaction unit 200 may be upstream of the continuous heat treatment arrangement 300. According to various embodiments, the compressed waste plastic feed may enter or be received in the continuous heat treatment arrangement 300 from the waste material compaction unit 200 for melting, pyrolyzing, and / or heating the waste plastic feed in the continuous heat treatment arrangement 300. According to various embodiments, the compressed waste plastic feed may be automatically fed or transported or conveyed to the continuous heat treatment arrangement 300. According to various embodiments, the compressed waste plastic feed may also be manually fed into the continuous heat treatment arrangement 300.

[0146] According to various embodiments, the continuous heat treatment arrangement 300 can include a melting stage 310, a thermal-catalytic pyrolysis stage 320, and a termination stage 330 for treating the compressed waste plastic feed by melting, pyrolysis, and / or heating. According to various embodiments, the thermal-catalytic pyrolysis stage 320 can be located or positioned downstream of the melting stage 310 between the melting stage 310 and the termination stage 330, and the termination stage 330 can be located downstream of the thermal-catalytic pyrolysis stage 320. Thus, the stages of the continuous heat treatment arrangement 300 can be in the order or sequence of the melting stage 310, then the thermal-catalytic pyrolysis stage 320, which is then followed by the termination stage 330. Thus, the flow or movement of material into the continuous heat treatment arrangement 300 can be continuous from the melting stage 310 to the thermal-catalytic pyrolysis stage 320, and then from the thermal-catalytic pyrolysis stage 320 to the termination stage 330.

[0147] According to various embodiments, the melting stage 310 of the continuous heat treatment arrangement 300 may be configured to melt the compressed waste plastic feed to form a molten mixture or molten plastic mixture. Thus, the compressed waste plastic feed passing through the melting stage 310 may be heated to or above a melting temperature. According to various embodiments, the melting stage 310 may heat the compressed waste plastic feed to a temperature or temperature range substantially within the range of 110°C to 350°C, or 110°C to 160°C, or 120°C to 140°C, or 200°C to 350°C, or 240°C to 320°C, or 250°C to 300°C to form a molten mixture in the melting stage 310. According to various embodiments, the melting stage 310 may include a heating arrangement, including but not limited to an external fire source, electrical heating, heating elements, heating coils, heating pads, etc., for heating the compressed waste plastic feed.

[0148] According to various embodiments, the molten mixture may be conveyed or transported from the melting stage 310 to the thermal-catalytic pyrolysis stage 320 of the continuous heat treatment arrangement 300 .

[0149] According to various embodiments, the thermal-catalytic pyrolysis stage 320 of the continuous thermal processing arrangement 300 can subject the molten mixture to a thermal pyrolysis process followed by a catalytic pyrolysis process to produce (or to produce) pyrolysis gas products and / or pyrolysis solid residues. Thus, the thermal-catalytic pyrolysis stage 320 can perform pyrolysis in the order of a thermal pyrolysis process followed by a catalytic pyrolysis process. According to various embodiments, the thermal-catalytic pyrolysis stage 320 can include at least two catalyst feed points (or a plurality of, or more than two catalyst feed ports) 32 distributed along the thermal-catalytic pyrolysis stage 320. Thus, the at least two catalyst feed points can be interspersed, distributed, or spread along the thermal-catalytic pyrolysis stage 320 in the direction of flow or movement of the material along the thermal-catalytic pyrolysis stage 320. According to various embodiments, the thermal to catalytic pyrolysis stage 320 may be operable to selectively feed or add or inject or receive catalyst via any one or more of at least two catalyst feed points to convert or switch or modify or convert from a thermal pyrolysis process to a catalytic pyrolysis process at various points or positions or locations or junctures along the thermal to catalytic pyrolysis stage 320 to vary or adjust or change the ratio of thermal pyrolysis process to catalytic pyrolysis process in the thermal to catalytic pyrolysis stage 320. According to various embodiments, the addition of catalyst to the thermal pyrolysis process may convert or modify or switch or convert the thermal pyrolysis process to a catalytic pyrolysis process. Thus, the catalyst may be added or fed or injected at the point where catalytic pyrolysis takes place. Thus, if catalyst is fed or added or injected at different catalyst feed points of at least two catalyst feed points, the thermal pyrolysis process may be converted or modified or switched or covered to a catalytic pyrolysis process at various points or locations or places or junctions along the thermal to catalytic pyrolysis stage 320.Thus, the ratio of thermal pyrolysis process to catalytic pyrolysis process in the thermal-catalytic pyrolysis stage 320 may be varied, adjusted or changed by feeding or adding or dosing catalyst at various catalyst feed points of at least two catalyst feed points. According to various embodiments, the ratio of thermal pyrolysis process to catalytic pyrolysis process in the thermal-catalytic pyrolysis stage 320 may be the ratio of the duration (or holding period) of the thermal pyrolysis process to the duration (or holding period) of the catalytic pyrolysis process. Thus, when the flow rate or speed of movement through the thermal-catalytic pyrolysis stage 320 is constant, the ratio of thermal pyrolysis process to catalytic pyrolysis process may be the ratio of the length of the thermal-catalytic pyrolysis stage 320 performing the thermal pyrolysis process to the length of the thermal-catalytic pyrolysis stage 320 performing the catalytic pyrolysis process.

[0150] According to various embodiments, by varying the ratio of thermal and catalytic pyrolysis processes along the thermal-catalytic pyrolysis stage 320, the end product 701 produced by the system 100 may be altered, modified or changed accordingly. Thus, depending on the desired end product 701, the ratio of thermal and catalytic pyrolysis processes along the thermal-catalytic pyrolysis stage 320 may be varied, adjusted or changed to produce a processing sequence having the ratio of thermal and catalytic pyrolysis processes required to produce the desired end product 701.

[0151] According to various embodiments, with at least two (e.g., two or more) catalyst feed points along the thermal-catalytic pyrolysis stage 320 for feeding catalyst to convert, modify, switch, or convert the thermal pyrolysis process to a catalytic pyrolysis process at various points or positions or locations or connections along the thermal-catalytic pyrolysis stage 320, the system 100 can be operated to selectively vary the points along the thermal-catalytic pyrolysis stage 320 where catalyst is added to convert, modify, switch, or convert the thermal pyrolysis process to a catalytic pyrolysis process based on the desired end product 701 output from the system 100 or the characteristics of the waste plastic material or feed introduced into the system 100. For example, according to various embodiments, catalyst may be selectively added at any one or more of the at least two catalyst feed points of the thermal-catalytic pyrolysis stage 320 to achieve, obtain, or realize the required ratio of thermal pyrolysis process to catalytic pyrolysis process.

[0152] As shown in FIG. 1A, according to various embodiments, the thermal-catalytic pyrolysis stage 320 can include a first thermal pyrolysis zone 321, one or more intermediate variable zones 322, and a final catalytic pyrolysis zone 324. According to various embodiments, the first thermal pyrolysis zone 321, the one or more intermediate variable zones 322, and the final catalytic pyrolysis zone 324 can be arranged in series. Thus, the zones of the thermal-catalytic pyrolysis stage 320 can be in the order or sequence of the first thermal pyrolysis zone 321, then one or more intermediate variable zones 322, and then the final catalytic pyrolysis zone 324. According to various embodiments, the one or more intermediate variable zones 322 can be located downstream of the first thermal pyrolysis zone 321, between the first thermal pyrolysis zone 321 and the final catalytic pyrolysis zone 324, and the final catalytic pyrolysis zone 324 can be located downstream of the one or more intermediate variable zones 322. According to various embodiments, the molten mixture of compressed waste plastic feed may be conveyed or transported (e.g., by a conveyor mechanism) along the thermal-catalytic pyrolysis stage 320 from the first thermal pyrolysis zone 321 in the direction of the last catalytic pyrolysis zone 324, in particular from the first thermal pyrolysis zone 321 through one or more intermediate variable zones 322 to the last catalytic pyrolysis zone 324. According to various embodiments, the at least two catalyst feed points may be opened only when catalyst is fed or added to the system 100. For example, each of the at least two catalyst feed points (e.g., catalyst feed ports) may include a lid that can be opened to feed catalyst therein or that can be closed (e.g., to prevent air / gas from entering or escaping from the catalyst feed point). According to various embodiments, at least two catalyst feed points (e.g., catalyst feed ports) can include at least one safety valve to prevent air (e.g., from the atmosphere) from entering system 100 and / or to prevent any gases in system 100 from leaking or escaping to the atmosphere.According to various embodiments, catalyst may be fed or added to the system 100 by at least one catalyst feeder through at least two catalyst feed points. According to various embodiments, the catalyst feeder may include, but is not limited to, a screw feeder, an auger feeder, or a hopper feeder.

[0153] According to various embodiments, the initial thermal pyrolysis zone 321 of the thermal to catalytic pyrolysis stage 320 may heat the molten mixture at or above the pyrolysis temperature of the molten mixture to break down the molecules of the molten mixture. According to various embodiments, the initial thermal pyrolysis zone 321 may be configured to apply heat to the molten mixture under low oxygen conditions or inert atmosphere conditions to break down or break down the molten mixture. According to various embodiments, the thermal pyrolysis process may be configured to break down or break down the molten mixture into suitable molecular sizes for a subsequent catalytic pyrolysis process. According to various embodiments, the initial thermal pyrolysis zone 321 may heat the molten mixture at a temperature or temperature range substantially within the range of 130°C to 380°C, or 130°C to 280°C, or 150°C to 250°C, or 300°C to 380°C, or 310°C to 360°C, or 320°C to 350°C. According to various embodiments, the initial thermal pyrolysis zone 321 can include a heating arrangement, including but not limited to an external fire source, electrical heating, heating elements, heating coils, heating pads, etc., to provide heating.

[0154] According to various embodiments, the temperature and / or duration (i.e., retention time) at which the molten mixture is subjected to heating in the initial thermal pyrolysis zone 321 of the thermal to catalytic pyrolysis stage 320 can be based on the composition of the molten mixture of waste plastic material, and / or the type of catalyst used in the catalytic pyrolysis process and / or the desired end product 701 (e.g., a desired final useful hydrocarbon product or hydrocarbons having carbon atoms in the range of C2-C34, such as hydrocarbons suitable for petrochemical processes or fuels, e.g., naphtha, diesel, other hydrocarbon products, etc.) to be produced by the system 100. For example, according to various embodiments, the molten mixture in the initial thermal pyrolysis zone 321 can be heated at a temperature and / or duration that can result in the breaking down of the molecules of the molten mixture to a size (or average diameter of pores) suitable (or ideal, e.g., smaller) for entering the pore sites of the catalyst that can later be used (or added) to the catalytic pyrolysis process.

[0155] According to various embodiments, one or more intermediate variable zones 322 of the thermal-catalytic pyrolysis stage 320 can each include at least one catalyst feed port 32, 32a at the beginning of the intermediate variable zone 322 to receive a catalyst. According to various embodiments, at least one catalyst feed port 32a of each intermediate variable zone 322 can serve as one of at least two catalyst feed points along the thermal-catalytic pyrolysis stage 320. Thus, if there are more intermediate variable zones 322, the thermal-catalytic pyrolysis stage 320 can have more catalyst feed points to vary the points or positions or locations or connections along the thermal-catalytic pyrolysis stage 320 for adding or feeding or injecting catalyst. According to various embodiments, when catalyst is added to the intermediate variable zone 322 via at least one catalyst feed port 32a at the beginning of the intermediate variable zone 322, the thermal pyrolysis process can be converted or changed or switched or converted to a catalytic pyrolysis process in the intermediate variable zone. Thus, the remaining sections of the thermal-catalytic pyrolysis stage 320 after the intermediate variable section 322 can carry out a catalytic pyrolysis process. According to various embodiments, if no catalyst is added, fed or dosed to the intermediate variable section 322, the intermediate variable section 322 can continue to carry out a thermal pyrolysis process similar to the initial thermal pyrolysis section 321.

[0156] According to various embodiments, in the one or more intermediate variable zones 322, the molten mixture can undergo either a thermal pyrolysis process or a catalytic pyrolysis process, depending on whether a catalyst is added to the one or more intermediate variable zones 322 (e.g., via at least one catalyst feed port 32a of the one or more intermediate variable zones 322).

[0157] According to various embodiments, the one or more intermediate variable zones 322 may be operable to provide heating at a temperature or temperature range for a thermal pyrolysis process or at a temperature or temperature range for a catalytic pyrolysis process. Thus, according to various embodiments, depending on whether a catalyst is fed or added or injected via at least one catalyst feed port 32a of the one or more intermediate variable zones 322, the one or more intermediate variable zones 322 may be heated to a temperature or temperature range for a thermal pyrolysis process or a catalytic pyrolysis process. According to various embodiments, the one or more intermediate variable zones 322 of the thermal-catalytic pyrolysis stage 320 may be heated to a temperature or temperature range substantially within the range of 130°C to 480°C, or 130°C to 370°C, or 150°C to 320°C, or 280°C to 480°C, or 290°C to 440°C, or 300°C to 400°C, or 300°C to 420°C. For example, according to various embodiments, when no catalyst is fed, added or dosed via at least one catalyst feed port 32a of the one or more intermediate variable zones 322, the one or more intermediate variable zones 322 may be heated (or regulated or maintained) to a temperature substantially within the range of 130°C to 380°C, or 130°C to 280°C, or 150°C to 250°C, or 300°C to 380°C, or 310°C to 360°C, or 320°C to 350°C for the thermal pyrolysis process. On the other hand, according to various embodiments, when a catalyst is fed or added or injected via at least one catalyst feed port 32a of the one or more intermediate variable zones 322, the one or more intermediate variable zones 322 can be heated (or regulated or maintained) to a temperature or temperature range substantially within the range of the catalytic pyrolysis process, 250° C. to 440° C., or 250° C. to 370° C., or 270° C. to 320° C., or 300° C. to 440° C., or 320° C. to 420° C., or 350° C. to 400° C. According to various embodiments, each of the one or more intermediate variable zones 322 can include a heating arrangement, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, etc., to provide heating.

[0158] According to various embodiments, the last catalytic pyrolysis zone 324 of the thermal-catalytic pyrolysis stage 320 may include at least one catalyst feed port 32, 32b at the beginning of the last catalytic pyrolysis zone 324 for receiving catalyst. According to various embodiments, the at least one catalyst feed port 32b of the last catalytic pyrolysis zone 324 may serve as the last catalyst feed point of the at least two catalyst feed points along the thermal-catalytic pyrolysis stage 320 for receiving catalyst. According to various embodiments, if catalyst is not fed, added or dosed to any of the one or more intermediate variable zones 322 upstream of the last catalytic pyrolysis zone 324 (i.e., which is upstream of the last catalytic pyrolysis zone 324), the catalyst may be fed, added or dosed to the last catalytic pyrolysis zone 324 via the at least one catalyst feed port 32b. Thus, the last catalytic pyrolysis zone 324 may be the last zone of the thermal-catalytic pyrolysis stage 320 where the catalytic pyrolysis process can take place. Thus, the last catalytic pyrolysis zone 324 may be defined as the lowest percentage of the thermal to catalytic pyrolysis stage 320 in the case of a catalytic pyrolysis process. According to various embodiments, the last catalytic pyrolysis zone 324 may be configured to perform only a catalytic pyrolysis process. For example, according to various embodiments, the last catalytic pyrolysis zone 324 may be operable to provide heating at a temperature or temperature range for a catalytic pyrolysis process. As another example, according to various embodiments, the last catalytic pyrolysis zone 324 may be configured to feed, add, or inject catalyst via at least one catalyst feed port 32b such that a catalytic pyrolysis process is always performed in the last catalytic pyrolysis zone 324.According to various embodiments, if no catalyst is fed, added or injected into any of the one or more intermediate variable zones 322 (i.e., which are upstream of the final catalytic pyrolysis zone 324), then all of the initial thermal pyrolysis zone 321 and the one or more intermediate variable zones 322 can carry out a thermal pyrolysis process until (e.g., initially) catalyst is fed, added or injected through at least one catalyst feed port 32b of the final catalytic pyrolysis zone 324 to convert, change, switch or convert the thermal pyrolysis process to a catalytic pyrolysis process in the final catalytic pyrolysis zone 324.

[0159] According to various embodiments, catalyst may be fed from at least one catalyst feed port 32a of one or more intermediate variable zones 322 and / or at least one catalyst feed port 32b of the final catalytic pyrolysis zone 324 to convert, modify, switch or transform the thermal pyrolysis process into a catalytic pyrolysis process at various points along the thermal-catalytic pyrolysis stage 320. Thus, depending on the final product 701 output from the system 100, the thermal-catalytic pyrolysis stage 320 may be operated to selectively feed, add or inject catalyst from at least one catalyst feed port 32a of one or more intermediate variable zones 322 and / or at least one catalyst feed port 32b of the final catalytic pyrolysis zone 324 to vary the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage 320.

[0160] According to various embodiments, the system 100 may include at least three (or more) catalyst feed ports 32a, 32b. For example, according to various embodiments, the system 100 may include at least two (or more) intermediate variable zones 322, whereby the at least two (or more) intermediate variable zones 322 may correspondingly include at least two (or more) catalyst feed ports 32a. Furthermore, according to various embodiments, the system 100 may include a final catalytic pyrolysis zone 324 that includes at least one catalyst feed port 32b.

[0161] Thus, if there are two intermediate variable zones 322 and a final catalytic pyrolysis zone 324, there can be at least two catalyst feed ports 32a corresponding to the two intermediate variable zones 322 and one catalyst feed port 32b corresponding to the final catalytic pyrolysis zone 324. Thus, if catalyst can be added, fed, or injected into any one or combination of the feed ports 32a, 32b, there can be at least three catalyst feed ports in total. According to various embodiments, the decision of whether to feed, add, or inject catalyst into at least one catalyst feed port 32a of at least one intermediate variable zone 322 and / or at least one catalyst feed port 32b of the final catalytic pyrolysis zone 324, or where to do this, can be based on monitoring the characteristics of the final product 701 output from the system 100 or the characteristics of the waste plastic material or feed introduced into the system 100. According to various embodiments, the point at which the catalyst is added and the end product 701 output from the system 100 may depend on any one or combination of the composition of the waste plastic material, the type of catalyst used, or the desired end product 701 from the system 100.

[0162] For example, according to various embodiments, the duration of the thermal pyrolysis process required to break down or destroy the waste plastic material to perform the catalytic pyrolysis process and / or the duration of the catalytic pyrolysis process required to generate the desired pyrolysis gas products to obtain the desired end product 701 from the system 100 (or catalytic cracking time) can be determined based on the composition of the waste plastic material, and / or the average pore size of the catalyst pore sites, and / or the properties of the end product 701 (e.g., the determined specific gravity). In this way, the required ratio of thermal pyrolysis process to catalytic pyrolysis process in the thermal-catalytic pyrolysis stage 320 and / or the point at which the catalyst is added can be determined. As an example, if the catalyst is fed or added or injected in at least one catalyst feed port 32a of one or more intermediate variable zones 322, the catalytic pyrolysis process can be started in the corresponding intermediate variable zone 322, respectively, before reaching the last catalytic pyrolysis zone 324 located downstream of the corresponding intermediate variable zone 322. Thus, by adding catalyst to the corresponding intermediate variable zone 322 via its catalyst feed port 32a, a higher proportion of the catalytic pyrolysis process can take place within the thermal-to-catalytic pyrolysis stage 320 than if catalyst were only added to the final catalytic pyrolysis zone 324.

[0163] As another example, according to various embodiments, different desired end products 701 may require different corresponding retention times for the catalytic pyrolysis process. Thus, according to various embodiments, if it is determined that the desired end product 701 requires a longer retention time for the catalytic pyrolysis process, the catalyst may be fed, added, or dosed earlier into the system 100. For example, the catalyst may be fed, added, or dosed earlier in one or more intermediate variable zones 322 (e.g., closer to the melting stage 310) to allow (or enable) a longer catalytic pyrolysis process to obtain the desired end product 701.

[0164] As yet another example, according to various embodiments, different compositions of waste plastic materials may require different retention times of heating to decompose or break down into suitable molecular sizes for interaction with the catalyst used. Thus, if it is determined that a particular type of waste plastic material requires a longer retention time for the thermal pyrolysis process, the catalyst may be fed, added, or dosed later. For example, the catalyst may be fed, added, or dosed in a section after one or more intermediate variable sections 322, or the catalyst may only be fed, added, or dosed in the final catalytic pyrolysis section 324. According to various embodiments, by feeding, adding, or dosed the catalyst when the waste plastic material is sufficiently decomposed or broken down, all, or nearly all, or most of the added catalyst may be activated to perform its function with minimal catalyst waste, thereby optimizing the catalytic action for the catalytic pyrolysis process.

[0165] According to various other embodiments, the melting stage 310 may optionally further include at least one auxiliary catalyst feed point (e.g., auxiliary feed port) (not shown) (i.e., in addition to the catalyst feed port 32 located along the thermal-catalytic pyrolysis stage 320) for or configured to receive or feed catalyst (e.g., additional catalyst) into the melting stage 310.

[0166] Thus, according to various other embodiments, if additional catalyst is added to the system 100 via at least one auxiliary catalyst feed point, the system 100 can accommodate bulkier or larger sized waste plastic feeds or materials, as the additional catalyst added to the system 100 can assist or aid in the breaking down of the bulkier or larger sized molecules of the waste plastic feeds or materials. Furthermore, the additional catalyst added to the system 100 can partially drive or accelerate the pyrolysis of a particular type(s) of waste plastic feeds or materials in the system 100. Thus, the system 100 can be easier to control and achieve the desired end product, especially when a small or smaller sized molecular end product is desired compared to the initial waste plastic feed or material.

[0167] According to various other embodiments, the catalyst fed or added to the melting stage 310 via at least one auxiliary catalyst feed point may be of the same type or composition as the catalyst that may be fed or added to one or more of the catalyst feed ports 32 located along the thermal-catalytic pyrolysis stage 320 located downstream of the melting stage 310 in the system 100, or may be of a different type or composition.

[0168] According to various other embodiments, the amount of catalyst fed or added to the melting stage 310 via at least one auxiliary catalyst feed point may be the same as or different from the amount of catalyst fed or added to the catalyst feed port 32 along the thermal-catalytic pyrolysis stage 320 located downstream of the melting stage 310 in the system 100.

[0169] According to various embodiments, and generally preferred, the melting stage 310 of the system 100 or the system 100 may not include (in other words, does not have or does not include) at least one auxiliary catalyst feed point (i.e., for receiving or configured to receive or for feeding catalyst) in the melting stage 310 of the system 100. Thus, according to various embodiments, the only point(s) or port(s) available in or within the system 100 for adding or feeding catalyst to the system 100 may be the catalyst feed point (e.g., port) 32 located in the thermal-catalytic pyrolysis stage 320 (i.e., downstream of the melting stage 310). In other words, according to various embodiments, the system 100 may not include any auxiliary catalyst feed points, so that catalyst may only be added or fed to the system 100 via the catalyst feed point (e.g., port) 32.

[0170] According to various embodiments, the termination stage 330 of the continuous thermal processing arrangement 300 can be downstream of the thermal-catalytic pyrolysis stage 320 and can receive the pyrolysis solid residue from the thermal-catalytic pyrolysis stage 320. According to various embodiments, the termination stage 330 can heat the pyrolysis solid residue (i.e., resulting from the thermal-catalytic pyrolysis stage 320 of the continuous thermal processing arrangement 300) for conversion to a solid product (e.g., solid carbon or other solids contained in the waste plastic material). According to various embodiments, the termination stage 330 can be heated to and / or at a temperature of at least substantially 350° C., preferably at least substantially 400° C., and more preferably at least or about 410° C. (in other words, substantially 350° C. or more, preferably substantially 400° C. or more, and more preferably substantially 410° C. or more). According to various embodiments, the termination stage 330 may include a first heating zone 333 (e.g., from a lower temperature to 350° C. or higher, preferably to 400° C. or higher, more preferably to 410° C. or higher) that raises the temperature of the pyrolyzed solid residue to maintain the pyrolyzed solid residue at an elevated temperature (e.g., 350° C. or higher, preferably to 400° C. or higher, more preferably to 410° C. or higher), and a second heating zone 334. According to various embodiments, the termination stage 330 may, among other things, break any remaining carbon-hydrogen (CH) bonds in the pyrolyzed solid residue, remove any hydrogen from the pyrolyzed solid residue, and / or dry the pyrolyzed solid residue to produce a solid product. According to various embodiments, the termination stage 330 may include a heating arrangement, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, etc., that provides heating.

[0171] According to various embodiments, the temperature or temperature range of the termination stage 330 may be higher than the temperature or temperature range of the thermal-catalytic pyrolysis stage 320. According to various embodiments, the temperature or temperature range of the thermal-catalytic pyrolysis stage 320 may be higher than the temperature or temperature range of the melting stage 310.

[0172] According to various embodiments, the continuous thermal processing arrangement 300 may include a reactor 350. According to various embodiments, the continuous thermal processing arrangement 300 may be integrated with the reactor 350. Thus, the reactor 350 may give the continuous thermal processing arrangement 300 its physical form or shape. According to various embodiments, the reactor 350 may be a single stage or a multi-stage / zone reactor (e.g., a six-zone reactor). According to various embodiments, the reactor 350 may include any one or combination of the melting stage 310, the thermal-catalytic pyrolysis stage 320, and the termination stage 330. For example, according to various embodiments, the reactor 350 may include only the thermal-catalytic pyrolysis stage 320. As another example, according to various embodiments, the reactor 350 may include only the melting stage 310 and the thermal-catalytic pyrolysis stage 320. As yet another example, according to various embodiments, reactor 350 may include only thermal-catalytic pyrolysis stage 320 and termination stage 330. As a further example, according to various embodiments, reactor 350 may include all of melting stage 310, thermal-catalytic pyrolysis stage 320, and termination stage.

[0173] According to various embodiments, reactor 350 may include or be a cylindrically shaped reactor. As such, the cylindrically shaped reactor may be segmented or sectioned or divided longitudinally (or along its length) into various stages or zones.

[0174] According to various embodiments, the continuous thermal processing arrangement 300 may include a conveyor mechanism 360 for carrying or transporting the waste plastic material along the continuous thermal processing arrangement 300 from the melting stage 310, through the thermal-catalytic pyrolysis stage 320, and to the termination stage 330. Thus, according to various embodiments, when the continuous thermal processing arrangement 300 includes a reactor 350, the reactor 350 may include a conveyor mechanism 360 for carrying or transporting the waste plastic material along a longitudinal direction of the reactor 350. Thus, the conveyor mechanism 360 may extend longitudinally along the reactor 350. According to various embodiments, the conveyor mechanism 360 may extend along the entire length of the reactor 350. For example, the conveyor mechanism 360 may carry or transport the waste plastic material from a front end (or a first longitudinal end) of the reactor 350 to a rear end (or a second longitudinal end) of the reactor 350. According to various embodiments, the conveyor mechanism 360 of the reactor 350 can include at least one screw conveyor or linear conveyor or belt conveyor or auger conveyor.

[0175] According to various embodiments, the speed at which the waste plastic material may be transported by a conveyor mechanism along the continuous heat treatment arrangement 300 (or along the reactor 350) may depend on the desired retention time of the required waste plastic material.

[0176] According to various embodiments, the reactor 350 may be inclined with respect to the ground 9 or a horizontal plane. For example, according to various embodiments, the rise rate per horizontal distance of the reactor 350 may be in the range of 1:250 to 1:20; 1:200 to 1:50; 1:150 to 1:80, etc. According to various embodiments, the term "rise rate per horizontal distance" as used herein may refer to the inclination of the reactor, which may be the ratio of the vertical change (e.g., the difference along a perpendicular or vertical axis with respect to the ground on which the reactor is placed) to the horizontal change (e.g., the difference along a horizontal line or axis with respect to the ground) between two different points on or along the reactor.

[0177] According to various embodiments, the melting stage 310, the thermal-catalytic pyrolysis stage 320 and the termination stage 330 may be maintained at the same pressure. Thus, according to various embodiments, the melting of the compressed waste plastic feed in the melting stage 310, the thermal pyrolysis process and / or the catalytic pyrolysis process in the thermal-catalytic pyrolysis stage 320, and the heating of the pyrolysis solid residue in the termination stage 330 may be performed (or carried out) at the same pressure. According to various embodiments, the reactor 350 may be airtight or hermetically sealed to maintain the pressure in the reactor for the melting stage 310, the thermal-catalytic pyrolysis stage 320 and / or the termination stage 330. According to various embodiments, the pressure may be substantially within the range of 100 kPa to 110 kPa, or 120 kPa to 180 kPa, or 140 kPa to 160 kPa (or 0 bar gauge to 0.1 bar gauge, or 0.2 bar gauge to 0.8 bar gauge, or 0.4 bar gauge to 0.6 bar gauge, or 1 bar to 1.1 bar, or 1.2 bar to 1.8, or 1.4 bar to 1.6 bar).

[0178] According to various embodiments, the last catalytic pyrolysis zone 324 of the thermal-catalytic pyrolysis stage 320 may include at least one pyrolysis gas outlet 326 for discharging pyrolysis gas products generated in the thermal-catalytic pyrolysis stage 320. Thus, when the continuous heat treatment arrangement 300 includes a reactor 350 including at least a thermal-catalytic pyrolysis stage 320, the reactor 350 may include at least one pyrolysis gas outlet 326 in the last catalytic pyrolysis zone 324 in the reactor 350. According to various embodiments, the at least one pyrolysis gas outlet 326 may be an opening or vent in the reactor 350 in the last catalytic pyrolysis zone 324 of the reactor 350. According to various embodiments, the at least one pyrolysis gas outlet 326 in the last catalytic pyrolysis zone 324 may include a pump 328 operable to draw or remove pyrolysis gas products from the last catalytic pyrolysis zone 324. Thus, the pump 328 may be coupled (e.g., fluidly connected) to at least one pyrolysis gas outlet 326 of the final catalytic pyrolysis zone 324. According to various embodiments, the pump may include a vacuum pump or a suction pump.

[0179] According to various embodiments, the termination stage 330 of the continuous thermal processing arrangement 300 may include at least one pyrolysis gas outlet 326 for discharging pyrolysis gas products produced in the thermal-catalytic pyrolysis stage 320. Thus, when the continuous thermal processing arrangement 300 includes a reactor 350 including at least the thermal-catalytic pyrolysis stage 320 and the termination stage 330, the reactor 350 may include at least one pyrolysis gas outlet 326 at the termination stage 330 within the reactor 350. According to various embodiments, the at least one pyrolysis gas outlet 326 may be an opening or vent in the reactor 350 at the termination stage 330 of the reactor 350. According to various embodiments, the at least one pyrolysis gas outlet 326 of the termination stage 330 may include a pump 328 operable to bleed or remove pyrolysis gas products from the termination stage 330. Thus, the pump 328 may be coupled to at least one pyrolysis gas outlet of the termination stage 330. According to various embodiments, the pump 328 may include a vacuum pump or a suction pump.

[0180] According to various embodiments, the termination stage 330 may include at least one pyrolysis solids outlet 332 for removing solid products produced in the termination stage 330 of the thermal-catalytic pyrolysis stage 320. Thus, when the continuous thermal processing arrangement 300 includes a reactor 350 including at least the thermal-catalytic pyrolysis stage 320 and the termination stage 330, the reactor 350 may include at least one pyrolysis solids outlet 332 in the termination stage 330 within the reactor. According to various embodiments, the at least one pyrolysis solids outlet 332 may be an opening or passage in the reactor in the termination stage 330 of the reactor 350.

[0181] 1A and 1C, according to various embodiments, the system 100 can include at least one solid product compression unit 400 (or solids compression unit). The solid product compression unit 400 can be coupled (e.g., fluidly coupled) to the pyrolysis solids outlet 332 of the termination stage 330 for receiving solid products removed from the termination stage 330. The solid product compression unit 400 can thus be located downstream of the termination stage 330 of the continuous thermal treatment arrangement 300 for removing solid products from the continuous thermal treatment arrangement 300. The solid product compression unit 400 can thus act as a solid product removal unit for the continuous thermal treatment arrangement 300. According to various embodiments, the solid product is compressed in the at least one solid product compression unit 400 to block and prevent air from entering the continuous heat treatment arrangement 300 from the at least one solid product compression unit 400, so that the solid product can be removed from the system 100 by the at least one solid product compression unit 400 without shutting down the continuous heat treatment arrangement 300. According to various embodiments, the solid product compression unit 400 can compress the solid product take-out from the termination stage 330 of the continuous heat treatment arrangement 300. According to various embodiments, the solid product compression unit 400 may be similar to the waste material compression unit 200 in terms of the compression mechanism. However, the solid product compression unit 400 may differ from the waste material compression unit 200 in that the solid product compression unit 400 may include a cooling arrangement rather than a heating arrangement.

[0182] According to various other embodiments, the solid product (e.g., as the final product) can be removed or obtained directly from the system 100 from the termination stage 330 of the system 100 (e.g., directly from the pyrolysis solids outlet 332 of the termination stage 330) without compression, for example, via a solid product compression unit 400. According to various embodiments, the solid product can be removed from the system 100 (e.g., from the termination stage 330 of the system 100) via or with the aid of a conveyor means, such as a screw conveyor.

[0183] According to various other embodiments, the system 100 may not include (i.e., may not have) a solid product compression unit 400 coupled to the pyrolysis solids outlet 332 of the termination stage 330.

[0184] FIG. 1B illustrates a schematic diagram of a waste material compaction unit 200 of the system 100 of FIG. 1A, according to various embodiments.

[0185] According to various embodiments, the waste material compaction unit 200 may include at least two (or more than two) rotating screws. For example, the waste material compaction unit 200 may include at least a first rotating screw 203a and at least a second rotating screw 203b. As another example, the waste material compaction unit 200 may further include a third rotating screw 203c. According to various embodiments, the inclusion of the third screw 203c in the waste material compaction unit 200 may enable the waste material compaction unit 200 to compress the waste plastic material to a higher extent or compression ratio, which provides better prevention of air (e.g., from the atmosphere) from entering the system 100 and / or better prevention of any gas in the system 100 from leaking or escaping to the atmosphere. As a further example, the waste material compaction unit 200 may include one or more other additional rotating screws.

[0186] According to various embodiments, the at least two rotating screws 203 of the waste material compaction unit 200 may be arranged in series. For example, the first rotating screw 203a of the waste material compaction unit 200, the second rotating screw 203b of the waste material compaction unit 200, and the third rotating screw 203c of the waste material compaction unit 200 may be arranged in series. Thus, the at least two rotating screws 203 of the waste material compaction unit 200 may be arranged one after the other in sequence from the inlet 201 (or the front end) of the waste material compaction unit 200 to the outlet 202 (or the rear end) of the waste material compaction unit 200. According to various embodiments, the at least two rotating screws 203 of the waste material compaction unit 200 may be aligned in sequence with the end of one rotating screw in the direction of or toward the end of the adjacent subsequent rotating screw. According to various embodiments, the at least two rotating screws 203 may be in an end-to-end arrangement, where the end of one rotating screw is adjacent to, in contact with, or touching the end of the adjacent subsequent rotating screw. According to various embodiments, the at least two rotating screws 203 may be in a spaced end arrangement, where the end of one rotating screw is spaced from the end of the adjacent subsequent rotating screw with a gap or intervening space therebetween. According to various embodiments, the at least two rotating screws 203 of the waste material compaction unit 200 may be arranged in sequence between the inlet 201 and the outlet 202 of the waste material compaction unit 200. According to various embodiments, the direction of solids transport of the waste material compaction unit 200 may be from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. Therefore, the direction of solids transport may be along at least two rotating screws 203 of the waste material compaction unit 200, in succession from the rotating screw immediately adjacent to the inlet 201 of the waste material compaction unit 200 to the rotating screw immediately adjacent to the outlet 202 of the waste material compaction unit 200.

[0187] According to various embodiments, the waste material compaction unit 200 may be configured such that the volumetric flow rate generated by each of the at least two rotating screws 203 of the waste material compaction unit 200 is successively decreased from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. Thus, the volumetric flow rate of each successive rotating screw of the at least two rotating screws 203 of the waste material compaction unit 200 may be lower than the volumetric flow rate of the corresponding previous rotating screw. Thus, due to the decreased volumetric flow rate generated by each of the at least two rotating screws 203 of the waste material compaction unit 200 compared to the volumetric flow rate of the previous rotating screw, the waste plastic material may be compressed into a compressed waste plastic feed as the waste plastic material moves from the inlet 201 to the outlet 202 of the waste material compaction unit 200. Thus, by reducing the volumetric flow rate of at least two screws 203 arranged in series from the inlet 201 to the outlet 202 of the waste material compaction unit 200, the waste plastic material fed to the waste material compaction unit 200 can move at different volumetric flow rates along different segments of the waste material compaction unit 200, whereby the volumetric flow rate between different segments is reduced from the inlet 201 to the outlet 202 of the waste material compaction unit 200. Thus, the waste plastic material with a higher volumetric flow rate from the previous segment can collide with the subsequent segment with a lower volumetric flow rate and compress the waste plastic material due to the change in volumetric flow rate. According to various embodiments, the waste plastic material in the waste material compaction unit 200 can be compressed or compacted to remove air and / or moisture, to prevent air (e.g., from the atmosphere) from entering the system 100, and / or to prevent any gas in the system 100 from leaking or escaping to the atmosphere.

[0188] According to various embodiments, the waste material compaction unit 200 may be directly coupled to the melting stage 310 of the continuous heat treatment arrangement 300. According to various embodiments, the outlet 202 of the waste material compaction unit 200 may be connected to the melting stage 310. Thus, the waste plastic material fed to the waste material compaction unit 200 may be conveyed along the waste material compaction unit 200 by at least two rotating screws 203 arranged in series. For example, the waste plastic material may be fed to the waste material compaction unit 200 at a first end of the first rotating screw 203a, move through (or along) the waste material compaction unit 200 via the first rotating screw 203a, then the successive rotating screws (e.g., then the second rotating screw 203b, etc.), and then fed to the melting stage 310 of the continuous heat treatment arrangement 300.

[0189] According to various embodiments, the waste material compaction unit 200 may be operable such that the rotational speed of each of the at least two rotatable screws 203 of the waste material compaction unit 200 decreases successively from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. Thus, the rotational speed of each successive rotatable screw of the at least two rotatable screws 203 of the waste material compaction unit 200 may be lower than the rotational speed of the corresponding previous rotatable screw. For example, the second rotating screw 203b of the waste material compaction unit 200 may have a rotational speed of 40% to 100%, or 55% to 98%, or 70% to 97%, or 80% to 95% of the rotational speed of the first rotating screw 203a of the waste material compaction unit 200, and the third rotating screw 203c of the waste material compaction unit 200 may have a rotational speed of 35% to 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85% of the rotational speed of the first rotating screw 203a of the waste material compaction unit 200. Thus, as the rotational speed of each of the at least two rotatable screws 203 of the waste material compaction unit 200 decreases compared to the rotational speed of the previous rotatable screw, the volumetric flow rate generated by each of the at least two rotatable screws 203 of the waste material compaction unit 200 may decrease successively from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. According to various embodiments, the at least two rotatable screws 203 of the waste material compaction unit 200 may be of the same size and / or dimensions. For example, the screw shaft diameter, screw blade diameter, and pitch of the at least two rotatable screws 203 of the waste material compaction unit 200 may be the same.

[0190] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a, a second rotatable screw 203b, and a third rotatable screw 203c, two of the three rotatable screws 203a, 203b, 203c may have the same rotation speed. For example, according to various embodiments, both the first rotatable screw 203a and the second rotatable screw 203b may have the same rotation speed, while the third rotatable screw 203c may have a smaller rotation speed than both the first rotatable screw 203a and the second rotatable screw 203b. In yet another example, according to various embodiments, both the second rotatable screw 203b and the third rotatable screw 203c may have the same rotation speed, while the first rotatable screw 203a may have a faster rotation speed than both the second rotatable screw 203b and the third rotatable screw 203c.

[0191] According to various embodiments, the diameter of the screw shaft of each of the at least two rotating screws 203 of the waste material compaction unit 200 can be increased successively from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. Thus, the diameter of the screw shaft of each successive rotating screw of the at least two rotating screws 203 of the waste material compaction unit 200 can be larger than the diameter of the screw shaft of the corresponding previous rotating screw. For example, the diameter of the screw shaft of the first rotating screw 203a can be smaller than the diameter of the screw shaft of the second rotating screw 203b, which can be smaller than the diameter of the screw shaft of the third rotating screw 203c. Thus, due to the larger diameter of the screw shaft of each of the at least two rotating screws 203 of the waste material compaction unit 200 compared to the diameter of the screw shaft of the previous rotating screw, the volume of the solids transfer interval can be reduced from one rotating screw to the next. Thus, the volumetric flow rate produced by each of the at least two rotating screws 203 of the waste material compaction unit 200 may decrease successively from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200 . According to various embodiments, the at least two rotating screws 203 of the waste material compaction unit 200 may rotate at the same or different rotational speeds, preferably at the same rotational speed.

[0192] According to various embodiments, the pitch (or pitch range) of each of the at least two rotating screws 203 of the waste material compaction unit 200 may decrease from one rotating screw to another in succession from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. For example, the pitch range of the first rotating screw 203a may be greater than the pitch range of the second rotating screw 203b, which may be greater than the pitch range of the third rotating screw 203c. Thus, the pitch of each successive rotating screw of the at least two rotating screws 203 of the waste material compaction unit 200 may be narrower than the pitch of the corresponding previous rotating screw. Thus, the pitch of each of the at least two rotating screws 203 of the waste material compaction unit 200 is reduced compared to the pitch of the previous rotating screw, so that the volumetric flow rate generated by each of the at least two rotating screws 203 of the waste material compaction unit 200 can be successively reduced one after the other from the inlet 201 of the waste material compaction unit 200 to the outlet 202 of the waste material compaction unit 200. According to various embodiments, the at least two rotating screws 203 of the waste material compaction unit 200 can rotate at the same or different rotational speeds, preferably at the same rotational speed, and can have the same screw shaft diameter and the same screw blade diameter.

[0193] According to various embodiments, at least one of the at least two rotating screws 203 of the waste material compaction unit 200 may be inclined or oriented with an upward inclination with respect to the ground 9 or a horizontal plane so that any liquid or moisture may be drained downward by gravity. Thus, the inclination of at least one of the at least two rotating screws 203 may facilitate the removal of moisture from the waste plastic material. For example, as shown in FIG. 1B, the first rotating screw 203a may be positioned vertically, the second rotating screw 203b may be inclined, while the third rotating screw 203c may be positioned horizontally (e.g., to facilitate feeding the waste plastic material to the continuous heat treatment arrangement 300).

[0194] FIG. 1C shows a schematic diagram of a solid product compression unit 400 of the system 100 of FIG. 1A, according to various embodiments.

[0195] According to various embodiments, the solid product compression unit 400 may include at least two (or more than two) rotating screws, similar to the waste material compression unit 200. For example, the solid product compression unit 400 may include at least a first rotating screw 403a and at least a second rotating screw 403b. As another example, the solid product compression unit 400 may further include a third rotating screw 403c. According to various embodiments, the inclusion of the third screw 403c in the solid product compression unit 400 may enable the solid product compression unit 400 to compress the solid product or material to a higher degree or compression ratio, thereby providing better prevention of air (e.g., from the atmosphere) from entering the system 100 and / or better prevention of any gas in the system 100 from leaking or escaping to the atmosphere. As a further example, the solid product compression unit 400 may include one or more other additional rotating screws.

[0196] According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may be arranged in series, similar to the at least two rotating screws of the waste material compression unit 200. For example, the first rotating screw 403a of the solid product compression unit 400, the second rotating screw 403b of the solid product compression unit 400, and the third rotating screw 403c of the solid product compression unit 400 may be arranged in series. Thus, the at least two rotating screws 403 of the solid product compression unit 400 may be arranged one after the other in sequence from the inlet 401 (or the front end) of the solid product compression unit 400 to the outlet 402 (or the rear end) of the solid product compression unit 400. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may be aligned in sequence with the end of one rotating screw in the direction of or towards the end of the adjacent subsequent rotating screw. According to various embodiments, the at least two rotating screws 403 may be in an end-to-end arrangement, where the end of one rotating screw is adjacent to, in contact with, or touching the end of the adjacent subsequent rotating screw. According to various embodiments, the at least two rotating screws 403 may be in a spaced-apart end arrangement, where the end of one rotating screw is spaced from the end of the adjacent subsequent rotating screw with a gap or intervening space therebetween. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may be arranged in sequence between the inlet 401 and the outlet 402 of the solid product compression unit 400. According to various embodiments, the direction of solids transport of the solid product compression unit 400 may be from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. Thus, the direction of solid transport may be along at least two rotating screws 403 of the solid product compression unit 400, in succession from the rotating screw immediately adjacent to the inlet 401 of the solid product compression unit 400 to the rotating screw immediately adjacent to the outlet 402 of the solid product compression unit 400.

[0197] According to various embodiments, the solid product compression unit 400 may be configured, similar to the waste material compression unit 200, such that the volumetric flow rate generated by each of the at least two rotating screws 403 of the solid product compression unit 400 decreases successively from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. Thus, the volumetric flow rate of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 may be lower than the volumetric flow rate of the corresponding previous rotating screw. Thus, the solid product may be compressed as it moves from the inlet 401 to the outlet 402 of the solid product compression unit 400 due to the decrease in the volumetric flow rate generated by each of the at least two rotating screws 403 of the solid product compression unit 400 compared to the volumetric flow rate of the previous rotating screw. Thus, by reducing the volumetric flow rate of at least two screws arranged in series from the inlet 401 to the outlet 402 of the solid product compression unit 400, the solid product fed to the solid product compression unit 400 can move at different volumetric flow rates along different segments of the waste material compression unit 200, whereby the volumetric flow rates between different segments are reduced from the inlet 401 to the outlet 402 of the solid product compression unit 400. Thus, the solid product with a higher volumetric flow rate from the previous segment may collide with the subsequent segment with a lower volumetric flow rate and compress the solid product due to the change in the volumetric flow rate. According to various embodiments, the solid product in the solid product compression unit 400 may be compressed or compacted during operation to prevent air (e.g., from the atmosphere) from entering the system 100 and / or to prevent any gas in the system 100 from leaking or escaping to the atmosphere.

[0198] According to various embodiments, the solid product compression unit 400 may be directly coupled to the termination stage 330 of the continuous heat treatment arrangement 300. According to various embodiments, the inlet 401 of the solid product compression unit 400 may be connected to the pyrolysis solids outlet 332 of the termination stage 330. Thus, the solid product from the termination stage 330 may be fed to the solid product compression unit 400 and may be conveyed along the solid product compression unit 400 by at least two rotating screws 403 arranged in series. For example, the solid product may be fed to the solid product compression unit 400 at a first end of the first rotating screw 403a and moved (or along) the solid product compression unit 400 via the first rotating screw 403a, then the successive rotating screws (e.g., then the second rotating screw 403b, etc.).

[0199] According to various embodiments, the solid product compression unit 400, similar to the waste material compression unit 200, may be operable such that the rotational speed of each of the at least two rotatable screws 403 of the solid product compression unit 400 decreases successively from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. Thus, the rotational speed of each successive rotatable screw of the at least two rotatable screws 403 of the solid product compression unit 400 may be lower than the rotational speed of the corresponding previous rotatable screw. For example, the second rotating screw 403b of the solid product compression unit 400 may have a rotation speed of 40% to 100%, or 55% to 98%, or 70% to 97%, or 80% to 95% of the rotation speed of the first rotating screw 403a of the solid product compression unit 400, and the third rotating screw 403c of the solid product compression unit 400 may have a rotation speed of 35% to 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85% of the rotation speed of the first rotating screw 403a of the solid product compression unit 400. Thus, the volumetric flow rate generated by each of the at least two rotating screws 403 of the solid product compression unit 400 may be successively reduced from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400, due to the reduced rotational speed of each of the at least two rotating screws 403 of the solid product compression unit 400 compared to the rotational speed of the previous rotating screw. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may be of the same or different sizes and / or dimensions. For example, the screw shaft diameter, screw blade diameter and pitch of the at least two rotating screws 403 of the solid product compression unit 400 may be the same.

[0200] According to various embodiments, when the solid product compression unit 400 includes a first rotatable screw 403a, a second rotatable screw 403b, and a third rotatable screw 403c, similar to that of the waste material compression unit 200, two of the three rotatable screws 403 may have the same rotation speed. For example, according to various embodiments, both the first rotatable screw 403a and the second rotatable screw 403b may have the same rotation speed, while the third rotatable screw 403c may have a smaller rotation speed compared to both the first rotatable screw 403a and the second rotatable screw 403b. In yet another example, according to various embodiments, the second rotatable screw 403b and the third rotatable screw 403c may have the same rotation speed, while the first rotatable screw 403a may have a faster rotation speed than both the second rotatable screw 403b and the third rotatable screw 403c.

[0201] According to various embodiments, the diameter of the screw shaft of each of the at least two rotating screws 403 of the solid product compression unit 400 can increase successively from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400, similar to the diameter of the screw shaft of the waste material compression unit 200. Thus, the diameter of the screw shaft of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 can be larger than the diameter of the screw shaft of the corresponding previous rotating screw. For example, the diameter of the screw shaft of the first rotating screw 403a can be smaller than the diameter of the screw shaft of the second rotating screw 403b, which can be smaller than the diameter of the screw shaft of the third rotating screw 403c. Thus, due to the larger diameter of the screw shaft of each of the at least two rotating screws 403 of the solid product compression unit 400 compared to the diameter of the screw shaft of the previous rotating screw, the spatial volume and / or the volumetric flow rate for solids transport may decrease from one rotating screw to the next. Thus, the volumetric flow rate generated by each of the at least two rotating screws 403 of the solid product compression unit 400 may decrease successively from one to the other from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may rotate at the same or different rotational speeds, preferably at the same rotational speed.

[0202] According to various embodiments, the pitch (or pitch range) of each of the at least two rotating screws 403 of the solid product compression unit 400 can be successively decreased from one rotating screw to another, similar to the pitch (or pitch range) of the waste material compression unit 200, from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. Thus, the pitch of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 can be narrower than the pitch of the corresponding previous rotating screw. For example, the pitch range of the first rotating screw 403a can be larger than the pitch range of the second rotating screw 403b, which can be larger than the pitch range of the third rotating screw 403c. Thus, the volumetric flow rate produced by each of the at least two rotating screws 403 of the solid product compression unit 400 may be successively decreased from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400, as the pitch of each of the at least two rotating screws 403 of the solid product compression unit 400 is decreased compared to the pitch of the previous rotating screw. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may rotate at the same or different rotational speeds, preferably at the same rotational speed, and may have the same screw shaft diameter and the same screw blade diameter.

[0203] According to various embodiments, at least one of the at least two rotating screws 403 of the solid product compression unit 400 may be inclined or oriented with an upward inclination with respect to the ground 9 or a horizontal plane, such that any solid product and / or liquid in the continuous heat treatment arrangement 300 may not be able to unintentionally escape from the outlet 402 of the solid product compression unit 400, similar to the waste material compression unit 200. For example, as shown in FIG. 1C, according to various embodiments, the first rotating screw 403a may be located vertically below the termination stage 330, the second rotating screw 403b may be located horizontally, and the third rotating screw 403c may be inclined with respect to the ground 9 so that any solid product or liquid, or combination thereof, that falls from the first rotating screw 403a may be collected along the second rotating screw 403b while preventing unintentional removal via the third rotating screw 403c.

[0204] According to various embodiments, the solid product compression unit 400 may include a cooling jacket 470 around at least one of the at least two rotatable screws 403 of the solid product compression unit 400. According to various embodiments, the cooling jacket 470 can serve as a cooling arrangement for the solid product compression unit 400. According to various embodiments, a cooling fluid (e.g., a refrigerant) can be circulated through and / or around the cooling jacket 470 to cool the solid product in the solid product compression unit 400 (e.g., traveling along and / or being compressed by the solid product compression unit 400).

[0205] 1B and 1C, the waste material compaction unit 200 and the solid product compaction unit 400 are similar in that they both serve to compact solids, however, the solids to be compacted by each of the waste material compaction unit 200 and the solid product compaction unit 400 may be different. For example, the waste material compaction unit 200 serves to compact waste plastic material, while the solid product compaction unit 400 serves to compact solid products from the continuous thermal processing arrangement 300. Thus, the waste material compaction unit 200 and the solid product compaction unit 400 may be configured differently to compact different solids, even when performing similar functions.

[0206] According to various embodiments, in the waste material compaction unit 200, the second rotating screw 203b can have a rotational speed of 40% to 100%, or 55% to 98%, or 70% to 97%, or 80% to 95% of the rotational speed of the first rotating screw 203a.

[0207] According to various embodiments, in the solid product compression unit 400, the second rotating screw 403b can have a rotational speed of 40% to 100%, or 55% to 98%, or 70% to 97%, or 80% to 95% of the rotational speed of the first rotating screw 403a.

[0208] According to various embodiments, in the waste material compaction unit 200, the third rotating screw 203c can have a rotational speed of 35% to 97%, or 40 to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85% of the rotational speed of the first rotating screw 203a.

[0209] According to various embodiments, in the solid product compression unit 400, the third rotating screw 403c can have a rotational speed of 35% to 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85% of the rotational speed of the first rotating screw 403a.

[0210] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a and a second rotatable screw 203b, the shaft diameter of the first rotatable screw 203a may be smaller than the shaft diameter of the second rotatable screw 203b. For example, the shaft diameter of the second rotatable screw 203b may be 100%-135% or 105%-130% of the shaft diameter of the first rotatable screw 203a.

[0211] According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 203a, 403a and a second rotating screw 403b, the shaft diameter of the first rotating screw 403a may be smaller than the shaft diameter of the second rotating screw 403b. For example, the shaft diameter of the second rotating screw 403b may be 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw 403a.

[0212] According to various embodiments, when the waste material compaction unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the shaft diameter of the first rotating screw 203a may be the same as or smaller than, and preferably smaller than, the second rotating screw 203b, and the shaft diameter of the second rotating screw 203b may be the same as or smaller than the shaft diameter of the third rotating screw 203c. For example, according to various embodiments, the shaft diameter of the second rotating screw 203b, 403b may be 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw 203a, 403a, and the shaft diameter of the third rotating screw 203c, 403c may be 105% to 155% or 108% to 145% of the shaft diameter of the first rotating screw 203a, 403a.

[0213] According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the shaft diameter of the first rotating screw 403a may be the same as or smaller than the second rotating screw 403b, and may be preferably smaller, and the shaft diameter of the second rotating screw 403b may be the same as or smaller than the shaft diameter of the third rotating screw 403c. For example, according to various embodiments, the shaft diameter of the second rotating screw 403b may be 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw 403a, and the shaft diameter of the third rotating screw 403c may be 105% to 155% or 108% to 145% of the shaft diameter of the first rotating screw 403a.

[0214] According to various embodiments, when the waste material compression unit 200 includes a first rotatable screw 203a, a second rotatable screw 203b and a third rotatable screw 203c, the shaft diameter of the first rotatable screw 203a may be the same as the shaft diameter of the second rotatable screw 203b, and the shaft diameter of the second rotatable screw 203b may be smaller than the shaft diameter of the third rotatable screw 203c.

[0215] According to various embodiments, when the solid product compression unit 400 includes a first rotatable screw 403a, a second rotatable screw 403b and a third rotatable screw 403c, the shaft diameter of the first rotatable screw 403a may be the same as the shaft diameter of the second rotatable screw 403b, and the shaft diameter of the second rotatable screw 403b may be smaller than the shaft diameter of the third rotatable screw 403c.

[0216] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a and a second rotatable screw 203b, the first rotatable screw 203a and the second rotatable screw 203b may have the same pitch range. For example, according to various embodiments, the first rotatable screw 203a and the second rotatable screw 203b may have a pitch range substantially within a range of 70 mm to 220 mm or 80 mm to 200 mm.

[0217] According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a and a second rotating screw 403b, the first rotating screw 403a and the second rotating screw 403b may have the same pitch range. For example, according to various embodiments, the first rotating screw 403a and the second rotating screw 403b may have a pitch range substantially within a range of 70 mm to 220 mm or 80 mm to 200 mm.

[0218] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a, a second rotatable screw 203b, and a third rotatable screw 203c, the first rotatable screw 203a, the second rotatable screw 203b, and the third rotatable screw 203c may all have the same pitch range. For example, according to various embodiments, the first rotatable screw 203a, the second rotatable screw 203b, and the third rotatable screw 203c may have a pitch range substantially within a range of 70 mm to 220 mm or 80 mm to 200 mm.

[0219] According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the first rotating screw 403a, the second rotating screw 403b, and the third rotating screw 403c may all have the same pitch range. For example, according to various embodiments, the first rotating screw 403a, the second rotating screw 403b, and the third rotating screw 403c may have a pitch range substantially within the range of 70 mm to 220 mm or 80 mm to 200 mm.

[0220] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a and a second rotatable screw 203b, the pitch range of the first rotatable screw 203a may be greater than the pitch range of the second rotatable screw 203b. For example, according to various embodiments, the pitch range of the second rotatable screw 203b may be substantially within a range of 70% to 100%, or 75% to 99%, or 78% to 98% of the pitch range of the first rotatable screw 203a.

[0221] According to various embodiments, when the solid product compression unit 400 includes a first rotatable screw 403a and a second rotatable screw 403b, the pitch range of the first rotatable screw 403a may be greater than the pitch range of the second rotatable screw 403b. For example, according to various embodiments, the pitch range of the second rotatable screw 403b may be substantially within a range of 70% to 100%, or 75% to 99%, or 78% to 98% of the pitch range of the first rotatable screw 403a.

[0222] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a, a second rotatable screw 203b, and a third rotatable screw 203c, the pitch range of the first rotatable screw 203a may be the same as or larger than, and preferably larger than, the pitch range of the second rotatable screw 203b, and the pitch range of the second rotatable screw 203b may be the same as or larger than the pitch range of the third rotatable screw 203c. For example, according to various embodiments, the pitch range of the second rotatable screw 203b may be substantially within the range of 70%-100%, 75%-99%, or 78%-98% of the pitch range of the first rotatable screw 203a, and the pitch range of the third rotatable screw 203c may be substantially within the range of 65%-98%, 75%-95%, or 80%-93% of the pitch range of the first rotatable screw 203a.

[0223] According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b and a third rotating screw 403c, the pitch range of the first rotating screw 403a may be the same as or larger than, preferably larger than, the pitch range of the second rotating screw 403b, and the pitch range of the second rotating screw 403b may be the same as or larger than the pitch range of the third rotating screw 403c. For example, according to various embodiments, the pitch range of the second rotating screw 403b may be substantially within the range of 70%-100%, 75%-99%, or 78%-98% of the pitch range of the first rotating screw 403a, and the pitch range of the third rotating screw 203c, 403c may be substantially within the range of 65%-98%, 75%-95%, or 80%-93% of the pitch range of the first rotating screw 403a.

[0224] According to various embodiments, when the waste material compaction unit 200 includes a first rotatable screw 203a, a second rotatable screw 203b and a third rotatable screw 203c, the pitch range of the first rotatable screw 203a may be the same as the pitch range of the second rotatable screw 203b, and the pitch range of the second rotatable screw 203b may be greater than the pitch range of the third rotatable screw 203c.

[0225] According to various embodiments, when the solid product compression unit 400 includes a first rotatable screw 403a, a second rotatable screw 403b and a third rotatable screw 403c, the pitch range of the first rotatable screw 403a may be the same as the pitch range of the second rotatable screw 403b, and the pitch range of the second rotatable screw 403b may be greater than the pitch range of the third rotatable screw 403c.

[0226] According to various embodiments, the solid product compression unit 400 compresses the solid product to a density of substantially 1.0-3.0 g / cm 3 , preferably 1.4 to 2.2 g / cm 3 The bulk density of the solid product may be reduced (or configured to be reduced) (i.e., passed along and / or compressed in solid product compression unit 400) so that the solid product may have a bulk density in the range of 0.25 to 1.0. According to various embodiments, the solid product may have a compression ratio in the range of substantially 2.0 to 6.0.

[0227] According to various embodiments, the particle size (or average particle size) of the solid product exiting the solid product compression unit 400 may depend on the particle size of the sand and stones in the waste plastic material. According to various embodiments, the particle size (or average particle size) of the solid product exiting the solid product compression unit 400 may be substantially in the range of 30 nm to 500 nm.

[0228] Referring back to FIG. 1A, according to various embodiments, the system 100 may include at least one heat exchanger unit 500 coupled (e.g., fluidly connected) to at least one pyrolysis gas outlet 326 of the final catalytic pyrolysis zone 324 or the termination stage 330. According to various embodiments, the at least one heat exchanger unit 500 can provide a heat transfer treatment to the pyrolysis gas product as it passes through the at least one heat exchanger unit 500 from the continuous thermal treatment arrangement 300 (e.g., the thermal-to-catalytic pyrolysis stage 320 and / or the termination stage 330). For example, according to various embodiments, the at least one heat exchanger unit 500 can condense a portion of the long-chain carbon compounds of the pyrolysis gas product that are not desirable or necessary for subsequent processing to produce useful or final products 701. These condensed long chain carbon compounds may be directed or flowed back to the thermal-catalytic pyrolysis stage 320 as recycled wax, e.g., by gravity, for further cracking in the thermal-catalytic pyrolysis stage 320. According to various embodiments, long chain carbon compounds may include, but are not limited to, compounds having carbon chains longer than the carbon chains of the desired products (e.g., naphtha or diesel).

[0229] According to various embodiments, the at least one heat exchanger unit 500 may be configured to minimize pressure drop in the continuous thermal processing arrangement 300. According to various embodiments, the at least one heat exchanger unit 500 may include any suitable type of heat exchanger unit 500. For example, according to various embodiments, the at least one heat exchanger unit 500 may include a shell-and-tube heat exchanger or a dual-pipe heat exchanger (e.g., a gravity-type dual-pipe heat exchanger) whereby a cooling fluid, such as a refrigerant having a temperature lower than that of the final catalytic pyrolysis zone 324, can flow or pass through an outer pipe of the dual-pipe heat exchanger, while hotter pyrolysis gas products generated from the continuous thermal processing arrangement 300 (e.g., the melting stage and / or the thermal-to-catalytic pyrolysis stage 320 and / or the termination stage 330) can flow or pass through an inner pipe(s) of the dual-pipe heat exchanger surrounded by the outer pipe. According to various embodiments, a dual-pipe heat exchanger is preferred.

[0230] As shown in FIG. 1A, according to various embodiments, the system 100 may include at least one gas separator unit 600 downstream of the at least one heat exchanger unit 500. According to various embodiments, the at least one gas separator unit 600 may be in fluid communication with the at least one heat exchanger unit 500. According to various embodiments, the at least one gas separator unit 600 may remove residual particulates or heavy hydrocarbons, or combinations thereof, from the pyrolysis gas product that may be generated in the continuous thermal processing arrangement 300 (e.g., the melting stage 310 and / or the thermal-catalytic pyrolysis stage 320 and / or the termination stage 330) and may pass through the at least one heat exchanger unit 500. The residual particulates removed by the at least one gas separator unit 600 may include solid particles, carbonized particles.

[0231] According to various embodiments, the at least one gas separator unit 600 may include any suitable type of gas separator unit 600. For example, according to various embodiments, the at least one gas separator unit 600 may include a cyclone separator or a drum separator, with a cyclone separator being preferred. Thus, the pyrolysis gas products entering the cyclone separator may be subjected to vortex separation, according to various embodiments.

[0232] According to various embodiments, the at least one gas separator unit 600 may be further connected (e.g., fluidly connected) to the thermal-catalytic pyrolysis stage 320, such as to an initial thermal pyrolysis zone 321 of the thermal-catalytic pyrolysis stage 320, so that residual fine particles and heavy hydrocarbons removed by the at least one gas separator unit 600 may be directed or re-entered into the thermal-catalytic pyrolysis stage 320, for example, for further melting, heating and / or pyrolysis.

[0233] According to various embodiments, prior to entering the at least one gas separator unit 600, the pyrolysis gas products may enter or pass through or be processed by other equipment, such as a distillation column(s) interconnected between and fluidly connected to the at least one heat exchanger unit 500 and the at least one gas separator unit 600.

[0234] As shown in FIG. 1A, according to various embodiments, the system 100 can include at least one product separation and purification unit 700. According to various embodiments, the at least one product separation and purification unit 700 can be located downstream of the at least one gas separator unit 600. According to various embodiments, the at least one product separation and purification unit 700 can be coupled or fluidly connected to the at least one gas separator unit 600. According to various embodiments, the at least one product separation and purification unit 700 can separate and purify the pyrolysis gas product into one or more hydrocarbon products or end products 701 (e.g., to obtain a desired hydrocarbon product or end product 701), including, but not limited to, hydrocarbons having carbon atoms in the range of C2 to C34, such as hydrocarbons suitable for petrochemical processes or fuels (e.g., naphtha, diesel, or other hydrocarbons, etc.). According to various embodiments, the pyrolysis gas products from the at least one gas separator unit 600 may be received or enter at least one product separation and purification unit 700 for separation and purification.

[0235] According to various embodiments, a method for converting waste plastic materials into useful products is provided, which may include any one or more of the steps described herein and any corresponding features described herein.

[0236] According to various embodiments, the method may include introducing waste plastic material into the system 100 .

[0237] According to various embodiments, the method may include compressing the waste plastic material, for example, via a waste material compaction unit 200 to form a compressed waste plastic feed. According to various embodiments, the method may include compressing the waste plastic material via the waste material compaction unit 200 with a compression ratio substantially in the range of 2.0-5.0. According to various embodiments, the compression of the waste plastic material via the waste material compaction unit 200 may remove air such that the compressed waste plastic feed output from the waste material compaction unit 200 may have an air (e.g., oxygen) content substantially in the range of 2%-16% by weight, preferably 5%-10% by weight. According to various embodiments, the compression of the waste plastic material via the waste material compaction unit 200 may remove moisture such that the compressed waste plastic feed output from the waste material compaction unit 200 may have a moisture content substantially in the range of 2%-16% by weight, preferably 5%-10% by weight.

[0238] According to various embodiments, if the waste material compaction unit 200 of the system 100 includes at least one moisture release port, the method can include releasing moisture from the waste material compaction unit 200 or from the system 100 through at least one moisture release port of the waste material compaction unit 200 of the system 100. For example, if a plurality of moisture release ports are provided and distributed along the waste material compaction unit 200 of the system 100 when moisture release is desired (e.g., when moisture increases in the following area(s) beyond a moisture volume threshold), the method can include selectively activating or opening any one or combination of the moisture release port(s) of the plurality of moisture release ports to release moisture from the area(s) of the waste material compaction unit 200 that is directly connected (e.g., fluidly connected) to the activated or opened moisture release port(s).

[0239] According to various embodiments, the compression of the waste plastic material by the waste material compaction unit 200 may be carried out at a temperature substantially in the range of 80° C. to 170° C., or 90° C. to 140° C., or 90° C. to 160° C., or 110° C. to 120° C., or 130° C. to 150° C., or 120° C. to 155° C. According to various embodiments, the compression of the waste plastic material by the waste material compaction unit 200 may be substantially at a pressure in the range of 100 kPa to 190 kPa, preferably 100 kPa to 150 kPa, or more preferably 100 kPa to 110 kPa (or 0 bar gauge pressure to 0.9 bar gauge pressure, preferably 0 bar gauge pressure to 0.5 bar gauge pressure, more preferably 0 bar gauge pressure to 0.1 bar gauge pressure, or 1 bar to 1.9 bar, preferably 1 bar to 1.5 bar, or more preferably 1 bar to 1.1 bar). According to various embodiments, the compression of the waste plastic material by the waste material compaction unit 200 may be for a period of time (e.g., a retention time) that depends on or is based on the flow rate along the waste material compaction unit 200 or the dimensions of the waste material compaction unit 200. For example, according to various embodiments, the waste plastic material may be compressed by the waste material compaction unit 200 for a period of time (e.g., a retention time) of substantially 30 seconds to 120 seconds (or 0.5 minutes to 2.0 minutes), preferably 60 seconds to 78 seconds (or 1.0 minutes to 1.3 minutes).

[0240] According to various embodiments, the method can include melting the compressed waste plastic feed, e.g., via melting stage 310, by heating the compressed waste plastic feed at a temperature equal to or higher than the melting point of the compressed waste plastic feed to form a molten mixture. According to various embodiments, the temperature is substantially within the range of 110° C. to 350° C., or 110° C. to 160° C., or 120° C. to 140° C., or 200° C. to 350° C., or 240° C. to 320° C., or 250° C. to 300° C. According to various embodiments, the melting of the compressed waste plastic feed by melting stage 310 can be for a period of time (e.g., a retention time) depending on or based on the flow rate of the compressed waste plastic feed or the molten mixture along the melting stage 310, or the dimensions of the melting stage 310, or the reactor having the melting stage 310. For example, according to various embodiments, the melting of the compressed waste plastic feed via the melting stage 310 can be for a period (e.g., a retention time) of substantially between 10 seconds and 120 seconds, or between 18 seconds and 90 seconds (i.e., between 0.16 minutes and 2 minutes, between 0.3 minutes and 1.5 minutes), or between 48 seconds and 90 seconds, preferably between 48 seconds and 72 seconds (i.e., between 0.8 minutes and 1.5 minutes, or between 0.8 minutes and 1.2 minutes).

[0241] According to various embodiments, the method may include feeding catalyst at one or more of the various catalyst feed points (e.g., catalyst feed ports) 32 of the thermal-to-catalytic pyrolysis stage 320 of the system 100 to vary the proportion of thermal and catalytic pyrolysis processes in the thermal-to-catalytic pyrolysis stage 320 based on the desired end product 701 output from the system 100 or the characteristics of the waste plastic material or feed introduced into the system 100.

[0242] According to various embodiments, when the melting stage 310 of the system 100 includes at least one auxiliary catalyst feed point (e.g., an auxiliary catalyst feed port), the method may further include feeding the same or different type or composition, and / or the same or different amount of catalyst to one or more of the at least one auxiliary catalyst feed points in the melting stage 310 of the system 100, relative to the type or composition, and / or amount of catalyst fed at one or more of the catalyst feed points (e.g., catalyst feed ports) 32 located downstream of the melting stage 310.

[0243] According to various embodiments, the thermal pyrolysis process may be carried out at a temperature or temperature range suitable for breaking down or breaking down the waste plastic material into a size suitable for interaction with a catalyst and converting or modifying or switching or transforming to a catalytic pyrolysis process. According to various embodiments, the thermal pyrolysis process may be carried out or performed at a temperature or temperature range substantially within the range of 130°C to 380°C, or 130°C to 370°C, or 130°C to 280°C, or 150°C to 250°C, or 300°C to 380°C, or 310°C to 360°C, or 320°C to 350°C.

[0244] According to various embodiments, the catalytic pyrolysis process may be carried out or performed at a temperature or temperature range substantially within the range of 250°C to 440°C, or 250°C to 370°C, or 270°C to 320°C, or 300°C to 440°C, or 320°C to 420°C, or 350°C to 400°C.

[0245] According to various embodiments, the method includes heating the pyrolyzed solid residue for conversion to a solid product in a termination stage 330. According to various embodiments, the method can include heating the pyrolyzed solid residue via the termination stage 330 to a temperature suitable for any one or combination of: (i) breaking any remaining C-H bonds in the pyrolyzed solid residue, (ii) removing any hydrogen from the pyrolyzed solid residue, and / or (iii) drying the pyrolyzed solid residue. According to various embodiments, the heating of the pyrolyzed solid residue in the termination stage 330 can be performed or carried out at a temperature of at least substantially 350° C., preferably at least substantially 400° C., and more preferably at least or about 410° C. According to various embodiments, the method can include heating the pyrolyzed solid residue through the termination stage 330 for a period of time (e.g., retention time) depending on or based on the flow rate of the pyrolyzed solid residue along the termination stage 330, or the amount of pyrolyzed solid residue, or the amount of solid product produced, or the dimensions of the termination stage 330, or the reactor having the termination stage 330. For example, the heating of the pyrolyzed solid residue through the termination stage 330 can be for a period of time (e.g., retention time) of substantially 18 seconds to 210 seconds (i.e., 0.3 minutes to 3.5 minutes), or 42 seconds to 180 seconds (i.e., 0.7 minutes to 3.0 minutes), or 84 seconds to 144 seconds (i.e., 1.4 minutes to 2.4 minutes). According to various embodiments, the method can include a step of heating the pyrolysis solid residue to remove moisture (i.e., from the pyrolysis solid residue) via termination step 330 such that the solid product (i.e., produced in termination step 330) has a moisture content substantially in the range of 5% to 35% by weight, preferably 10% to 30% by weight, and a solids content substantially in the range of 60% to 95% by weight, preferably 70% to 90% by weight, and more preferably at least 90% by weight.

[0246] According to various embodiments, the melting of the compacted waste plastic feed, the thermal pyrolysis process and / or the catalytic pyrolysis process, and the heating of the pyrolysis solid residue in the termination stage 330 may be carried out at the same pressure. According to various embodiments, the pressure may be substantially within the range of 100 kPa to 110 kPa, or 120 kPa to 180 kPa, or 140 kPa to 160 kPa (0 bar gauge to 0.1 bar gauge, or 0.2 bar gauge to 0.8 bar gauge, or 0.4 bar gauge to 0.6 bar gauge, or 1 bar to 1.1 bar, or 1.2 bar to 1.8 bar, or 1.4 bar to 1.6 bar).

[0247] According to various embodiments, the method can include removing the solid product from the termination stage 330.

[0248] According to various embodiments, removal of solid products from the termination stage 330 may include waiting for and / or allowing solid products to increase in the termination stage 330 so that the increasing (or remaining) solid products in the termination stage 330 do not unintentionally overflow or leak from the termination stage 330, and blocking the pyrolysis solids outlet 332 of the termination stage 330 to prevent gas leakage from the termination stage 330 via the pyrolysis solids outlet 332.

[0249] According to various embodiments, removing the solid product from the termination stage 330 can include continuously removing the solid product from the termination stage 330 .

[0250] According to various embodiments, the method may include monitoring a characteristic of the final product 701 (i.e., obtained from at least one product separation and purification unit 700) output from the system 100 to determine whether adjustment of the ratio of thermal pyrolysis and catalytic pyrolysis processes within the thermal-catalytic pyrolysis stage 320 is necessary to produce a desired final product 701 output from the system 100. For example, according to various embodiments, the final product 701 in the form of one or more hydrocarbon products output from the at least one product separation and purification unit 700 may be an initial sample or an initial iteration of the final product 701 initially output from the system 100. The monitored characteristic may be or may include the specific gravity and / or any other suitable characteristic(s) of such final product 701 initially output from the system 100. According to various embodiments, based on monitored or determined property(s) (e.g., specific gravity) of such end product(s) 701 initially output from the system 100, a determination may be made as to whether to add catalyst to at least one intermediate variable zone 322 and / or the final catalytic pyrolysis zone 324 to obtain the desired end product 701. Thus, the determination of the required adjustment of the ratio of thermal pyrolysis to catalytic pyrolysis processes may be based on an iterative process until the desired end product 701 is achieved.

[0251] For example, upon start-up of the system 100 or at the beginning of the method, catalyst may be fed into one of the catalyst feed points of the system 100 ("initial catalyst feed point"). According to various embodiments, the initial catalyst feed point may be any selection, such as the feed port 32b of the final catalytic pyrolysis zone 324. The property(s) of the first output final product 701 from the system 100, which may be an initial sample or an initial iteration of the final product 701, may then be monitored to determine whether the first output final product 701 from the system 100 has the same property(s) (e.g., specific gravity, etc.) as the desired final product 701. If not, the point(s) at which the catalyst is fed into the system 100 may be adjusted to correspondingly change the final product 701 output from the system 100. The point(s) at which the catalyst is fed may be adjusted until the corresponding output final product 701 from the system 100 matches the desired final product 701. If a longer catalytic cracking time for the waste plastic material is required to produce the desired end product 701, the catalyst may be added earlier to the system 100 (e.g., at a catalyst feed point 32 closer to the melting stage 310). According to various embodiments, the regulated point(s) at which catalyst is fed into the system 100 may include or may be different from the initial catalyst feed point.

[0252] According to various embodiments, adjusting the ratio of the thermal pyrolysis process to the catalytic pyrolysis process can include adjusting the hold time of the thermal pyrolysis process and / or the hold time of the catalytic pyrolysis process.

[0253] According to various embodiments, the determination of the ratio or adjustment of the ratio of thermal pyrolysis process to catalytic pyrolysis process required may be based on the composition of the waste plastic material and / or the type of catalyst used.

[0254] According to various embodiments, the method can include withdrawing the pyrolysis gas products from the continuous thermal processing arrangement 300. In particular, according to various embodiments, the method can include withdrawing the pyrolysis gas products from the thermal-catalytic pyrolysis stage 320 of the system 100 and / or the termination stage 330 of the continuous thermal processing arrangement 300.

[0255] According to various embodiments, the method can include condensing (e.g., a portion of) the long-chain carbon compounds from the pyrolysis gas product by at least one heat exchanger unit 500. According to various embodiments, condensing the long-chain carbon compounds in the pyrolysis gas product by at least one heat exchanger unit 500 can occur after withdrawing the pyrolysis gas product from the thermal-catalytic pyrolysis stage 320. According to various embodiments, the method can include returning or recycling the condensed long-chain carbon compounds to the thermal-catalytic pyrolysis stage 320. For example, the condensed long-chain carbon can be directed or flowed back to the thermal-catalytic pyrolysis stage 320, for example, by gravity, as recycled wax.

[0256] According to various embodiments, the method may include removing particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product, for example, by at least one gas separator unit 600. According to various embodiments, the removal of particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product by at least one gas separator unit 600 may be performed on the pyrolysis gas product after passing through at least one heat exchanger unit 500. According to various embodiments, the method may include returning or recycling the particulates and / or heavy hydrocarbons removed by the at least one gas separator unit 600 to the thermal-catalytic pyrolysis stage 320. For example, the removed particulates and / or heavy hydrocarbons may be directed or re-entered into the thermal-catalytic pyrolysis stage 320 after the pyrolysis gas product has been treated by the at least one gas separator unit 600. According to various embodiments, the method may include a step of treating (e.g., melting them and / or subjecting them to a pyrolysis process and / or heating them) the particulates and / or heavy hydrocarbons that are returned to the thermal-catalytic pyrolysis stage 320.

[0257] According to various embodiments, prior to entering the at least one gas separator unit 600, the pyrolysis gas products may enter, pass through, or be processed by other equipment, such as a distillation column that is interconnected and fluidly connected between the at least one heat exchanger unit 500 and the at least one gas separator unit 600.

[0258] According to various embodiments, the method may include separating and purifying the pyrolysis gas product from at least one gas separator unit 600 into one or more hydrocarbon products or end products 701, such as hydrocarbons having carbon atoms in the range of C2 to C34, such as hydrocarbons suitable for petrochemical processes or fuels, such as naphtha, diesel, or other hydrocarbons. Thus, after the pyrolysis gas product is processed by at least one gas separator unit 600, the processed pyrolysis gas product may be directed to at least one product separation and purification unit 700 for separating and purifying the pyrolysis gas product into one or more end products 701 (e.g., hydrocarbons having carbon atoms in the range of C2 to C34, such as hydrocarbons suitable for petrochemical processes or fuels, such as naphtha, diesel, or other hydrocarbons).

[0259] Some operational examples of the systems and methods according to various embodiments are described below by reference to Examples (A) and (B).

[0260] The examples described below (i.e., Examples (A) and (B)) may be performed or operated in a pilot system (or test system or experimental system) constructed in accordance with the system 100 of various embodiments, whereby the melting stage, the thermal-catalytic pyrolysis stage, and the termination stage of the pilot system may be performed in a multi-zone reactor. According to various embodiments, the total length of the reactor may be 16 m, whereby the length from the first end of the reactor (e.g., at the melting stage) to the first catalyst feed port (e.g., closest to the melting stage) may be 3 m, the length from the first end of the reactor to the second catalyst feed port may be 6 m, and the length from the first end of the reactor to the third catalyst feed port may be 9 m.

[0261] Example (A): The feed used for the pilot system may comprise a mixture of waste plastics, containing 50% by weight of 'PVC 7%, PE 55%, PP 31%, PS 4% and others 3%', 20-30% by weight of moisture, and 20-30% by weight of sand and stones. The feed may be compressed in a compression stage (e.g., a waste material compression unit) at a temperature of about 115°C (or in another example, about 140°C). The compressed feed may be introduced into the reactor at the first end of the reactor, where a melting stage is carried out at a temperature of about 130°C (or in another example, about 300°C) to form a molten mixture. The molten mixture may then be transferred to a thermal-catalytic pyrolysis stage, where the thermal pyrolysis is first carried out at a temperature of about 270°C (or in another example, about 330°C) before adding catalyst through a second catalyst feed port (i.e., 6 m from the first end of the reactor). After adding the catalyst, the thermal pyrolysis process can be converted to a catalytic pyrolysis process at a temperature of about 330° C. (or, in another example, about 400° C.) in a thermal-catalytic pyrolysis stage. The pyrolysis gas product produced in the reactor can be withdrawn from the reactor in a termination stage and put into a double-pipe heat exchanger to condense the long-chain carbon compounds in the pyrolysis gas product, and then into a cyclone separator to remove fine particles or heavy hydrocarbons in the pyrolysis gas product. The pyrolysis solid residue produced in the reactor can be transferred to a termination stage, which can be operated at 350° C. (or, in another example, about 410° C.) to break any residual carbon-hydrogen (CH) bonds in the pyrolysis solid residue, remove any hydrogen from the pyrolysis solid residue, and / or dry the pyrolysis solid residue to generate (or produce) a solid product. The solid product may be removed by a solid product compression unit, whereby the rotational speed of the second screw of the solid product compression unit may be about 90% of the rotational speed of the first screw and the rotational speed of the third screw of the solid product compression unit may be about 80% of the rotational speed of the first screw. The diesel selectivity of the pyrolysis gas product may be 50.10% and the naphtha selectivity of the pyrolysis gas product may be 7.40%. The bulk density of the solid product may be 1.91 g / cm 3 It can be said that:

[0262] Example (B): Example (B) can be operated according to the same conditions as Example (A) except that the catalyst can be added through the first catalyst feed port (i.e., 3 m from the first end of the reactor) using the same feed. The diesel selectivity of the pyrolysis gas product can be 7.40% and the naphtha selectivity of the pyrolysis gas product can be 57.40%. The bulk density of the solid product can be 1.97 g / cm 3 It can be said that:

[0263] By comparing Example (A) and Example (B), it can be observed that feeding catalyst at various catalyst feed ports can result in various product selectivities. Thus, individual catalyst feed ports may be selected to feed catalyst to the system based on the required product (i.e., the desired end product) or the properties or composition of the waste plastic material or feed introduced into the system. Thus, various types of waste plastic material can be converted into useful products by using the system and methods according to various embodiments.

[0264] Various embodiments provide systems and methods for converting waste plastic materials into useful products. In various embodiments, the systems and methods can include selectively varying points along the system, where catalyst is added through at least two catalyst feed ports and / or at least one auxiliary catalyst feed port at various points (i.e., stages) along the system. Thus, catalyst can be selectively added only at certain points in the system, where the system can perform its function optimally without catalyst waste.

[0265] Additionally, in various embodiments, the present systems and methods provide a versatile and efficient pyrolysis process. In various embodiments, a wide range of crude feedstocks can be used with the present systems and methods. For example, in various embodiments, contaminated crude feedstocks can be used with the present systems and methods to achieve desired results. In various embodiments, the present systems and methods can be easy to control to obtain the desired end products and can be safe to operate.

[0266] Although the present invention has been particularly shown and described with reference to certain embodiments, it should be understood by those skilled in the art that various changes, modifications and variations in form and details can be made therein without departing from the scope of the invention as defined by the appended claims. The scope of the present invention is therefore indicated by the appended claims, and it is therefore intended to embrace all changes that come within the meaning and range of equivalence of the claims. (Appendix 1) 1. A system for converting waste plastic materials into useful products, comprising: a melting step for melting the compressed waste plastic feed produced from the waste plastic material to form a molten mixture; a thermal-catalytic pyrolysis stage downstream of the melting stage for subjecting the molten mixture to a thermal pyrolysis process and then a catalytic pyrolysis process to produce a pyrolysis gas product and a pyrolysis solid residue, the thermal-catalytic pyrolysis stage comprising at least two catalyst feed points distributed along the thermal-catalytic pyrolysis stage and operable to selectively feed catalyst via any one or more of the at least two catalyst feed points to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal-catalytic pyrolysis stage in a manner to provide a variation in the proportion of the thermal pyrolysis process to the catalytic pyrolysis process within the thermal-catalytic pyrolysis stage; Downstream of the thermal-catalytic pyrolysis stage is a termination stage, in which the pyrolysis solid residue is heated for conversion into solid products. A continuous heat treatment arrangement having A system comprising: (Appendix 2) a waste material compaction unit upstream of the continuous heat treatment arrangement, the waste material compaction unit operable to compact the waste plastic material and remove air and moisture to generate a compressed waste plastic feed for feeding the continuous heat treatment arrangement; 2. The system of claim 1, further comprising: (Appendix 3) Thermal to catalytic pyrolysis stage: a first thermal pyrolysis zone for heating the molten mixture received from the melting stage at or above the pyrolysis temperature of the molten mixture; one or more intermediate variable zones, each of which has a catalyst feed port at the beginning of the intermediate variable zone, the catalyst feed port serving as one of at least two catalyst feed points along the thermal-catalytic pyrolysis stage; and a final catalytic pyrolysis section having a catalyst feed port at the beginning of the final catalytic pyrolysis section that serves as the final catalyst feed point of at least two catalyst feed points along the thermal-catalytic pyrolysis stage for receiving catalyst; Equipped with 3. The system of claim 1 or 2, wherein the catalyst is fed from one or more intermediate variable zone catalyst feed ports or a final catalytic pyrolysis zone catalyst feed port for converting the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal to catalytic pyrolysis stages. (Appendix 4) 4. The system of any one of claims 1 to 3, wherein the melting stage comprises at least one auxiliary catalyst feed point for feeding catalyst in the melting stage. (Appendix 5) 5. The system of claim 3 or 4, wherein the continuous heat treatment arrangement comprises at least one pyrolysis gas outlet for discharging pyrolysis gas products, the at least one pyrolysis gas outlet being in a final catalytic pyrolysis zone of the thermal-catalytic pyrolysis stage or the termination stage, or both, and the at least one pyrolysis gas outlet being equipped with a vacuum pump. (Appendix 6) 6. The system of claim 5, further comprising at least one heat exchanger unit coupled to the at least one pyrolysis gas outlet for condensing long-chain carbon compounds in the pyrolysis gas product. (Appendix 7) 7. The system of claim 6, further comprising at least one gas separator unit downstream of the at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product. (Appendix 8) 8. The system of any one of claims 1 to 7, wherein the termination stage comprises at least one solid product outlet for removing the solid product. (Appendix 9) 9. The system of any one of claims 1 to 8, wherein the continuous heat treatment arrangement comprises a reactor comprising any one or combination of a melting stage, a thermal to catalytic pyrolysis stage, or a termination stage. (Appendix 10) 10. The system of claim 9, wherein the reactor is inclined at a rise rate per horizontal distance of 1:250 to 1:20. (Appendix 11) 11. The system of any one of claims 2 to 10 in combination with claim 2, wherein the waste material compaction unit comprises at least two rotating screws arranged in series from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit, and the direction of solids transport is from the inlet of the waste material compaction unit to the outlet of the waste material compaction unit. (Appendix 12) 12. The system of claim 11, wherein the volumetric flow rate produced by each of the at least two rotating screws of the waste material compaction unit decreases successively from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit to compress the waste plastic material into a compressed waste plastic feed. (Appendix 13) 13. The system of any one of claims 1 to 12, further comprising at least one solid product compression unit for compressing a solid product take-up from a termination stage of the continuous heat treatment arrangement, the solid product compression unit being downstream of the termination stage of the continuous heat treatment arrangement. (Appendix 14) 14. The system of claim 13, wherein the solid product compression unit comprises at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, and the direction of solids transport is from the inlet of the solid product compression unit to the outlet of the solid product compression unit. (Appendix 15) 15. The system of claim 14, wherein the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit decreases successively from an inlet of the solid product compression unit to an outlet of the solid product compression unit to compress the solid product. (Appendix 16) 16. The system of claim 14 or 15, wherein the rotational speed of each of the at least two rotating screws of the solid product compression unit is successively reduced one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit. (Appendix 17) 17. The system of any one of claims 14 to 16, wherein the solid product compression unit further comprises at least three rotating screws. (Appendix 18) 1. A method for converting waste plastic materials into useful products, comprising: introducing a compressed waste plastic feed produced from the waste plastic material into a melting stage of a continuous heat processing arrangement of a system for converting waste plastic material into a useful product, the melting stage melting the compressed waste plastic feed to form a molten mixture; selectively feeding catalyst to vary the ratio of thermal and catalytic pyrolysis processes within the thermal-catalytic pyrolysis stage through any one or more of at least two catalyst feed points of the thermal-catalytic pyrolysis stage of the continuous heat treatment configuration of the system, the thermal-catalytic pyrolysis stage being downstream of the melting stage, and subjecting the molten mixture to a thermal pyrolysis process and then a catalytic pyrolysis process to produce pyrolysis gas products and a pyrolysis solid residue; and removing the solid product from a termination stage of the continuous heat treatment arrangement of the system, the termination stage being downstream of the thermal-catalytic pyrolysis stage and heating the pyrolysis solid residue for conversion to a solid product; A method comprising: (Appendix 19) monitoring at least one characteristic of an end product output from the system to determine whether adjustment of the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage is necessary to produce a desired end product output from the system; and selectively feeding catalyst through any one or more of the at least two catalyst feed points based on the proportion of thermal pyrolysis process and catalytic pyrolysis process determined to be required. 19. The method of claim 18, further comprising: (Appendix 20) feeding catalyst through at least one auxiliary catalyst feed point in a melting stage of a continuous heat treatment configuration of the system; 19. The method of claim 18 or 19, further comprising: (Appendix 21) 21. The method of any one of claims 18 to 20, further comprising withdrawing pyrolysis gas products from the continuous heat treatment arrangement via at least one pyrolysis gas outlet of the continuous heat treatment arrangement. (Appendix 22) condensing long-chain carbon compounds from the pyrolysis gas product by at least one heat exchanger unit connected to the at least one pyrolysis gas outlet; and A step to return long-chain carbon compounds to the thermal-catalytic pyrolysis stage 22. The method of claim 21, further comprising: (Appendix 23) removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product by at least one gas separator unit downstream of the at least one heat exchanger unit; and Returning the residual fines or heavy hydrocarbons, or a combination thereof, to the thermal-catalytic pyrolysis stage. 23. The method of claim 22, further comprising: (Appendix 24) 24. The method of any one of claims 18 to 23, further comprising compressing the waste plastic material through a waste material compression unit, the waste material compression unit being upstream of the continuous thermal processing arrangement of the system for converting the waste plastic material into a useful product. (Appendix 25) removing solid product from a termination stage of the continuous heat treatment arrangement of the system through a solid product compression unit, the solid product compression unit comprising at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, the direction of solid transport being from the inlet of the solid product compression unit to the outlet of the solid product compression unit; The method according to any one of claims 18 to 24, further comprising: (Appendix 26) 26. The method of claim 25, wherein the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit is successively decreased from an inlet of the solid product compression unit to an outlet of the solid product compression unit to compress the solid product. (Appendix 27) 26. The method of claim 25, wherein the rotational speed of each of the at least two rotating screws of the solid product compression unit is successively decreased one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit. (Appendix 28) 1. A solid compression unit comprising at least two rotating screws arranged in series from an inlet of the solid compression unit to an outlet of the solid compression unit, wherein the at least two rotating screws are cooperatively operable to compress the solid material as the solid material moves from the inlet of the solid compression unit to the outlet of the solid compression unit. (Appendix 29) 29. The solid compression unit of claim 28, wherein the volumetric flow rates produced by each of the at least two rotating screws of the solid compression unit decrease successively from the inlet of the solid compression unit to the outlet of the solid compression unit so as to operate in cooperation to compress the solid material as the solid material is moved from the inlet of the solid compression unit to the outlet of the solid compression unit. (Appendix 30) 30. The solid compression unit of claim 28 or 29, wherein the rotational speed of each of the at least two rotatable screws of the solid compression unit decreases successively from one to the other from the inlet of the solid compression unit to the outlet of the solid compression unit. (Appendix 31) 30. The solid compression unit of claim 28 or 29, wherein the diameter of the screw shaft of each of the at least two rotating screws of the solid compression unit increases successively from one to the other from the inlet of the solid compression unit to the outlet of the solid compression unit. (Appendix 32) 30. The solid compression unit of claim 28 or 29, wherein the pitch range of each of the at least two rotatable screws of the solid compression unit decreases successively from one rotatable screw to another rotatable screw from an inlet of the solid compression unit to an outlet of the solid compression unit. (Appendix 33) 33. The solid compression unit of any one of claims 28 to 32, further comprising at least three rotating screws. (Appendix 34) 34. The solid compression unit according to any one of claims 28 to 33, further comprising a cooling jacket around at least one rotating screw.

Claims

1. 1. A system for converting waste plastic materials into useful products, comprising: a melting step for melting the compressed waste plastic feed produced from the waste plastic material to form a molten mixture; a thermal-to-catalytic pyrolysis stage downstream of the melting stage for subjecting the molten mixture to a thermal pyrolysis process and then a catalytic pyrolysis process to produce a pyrolysis gas product and a pyrolysis solid residue, the thermal-to-catalytic pyrolysis stage comprising at least two catalyst feed points distributed along the thermal-to-catalytic pyrolysis stage and operable to selectively feed catalyst via any one or more of the at least two catalyst feed points to convert the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal-to-catalytic pyrolysis stage in a manner to have a variation in the proportion of the thermal pyrolysis process to the catalytic pyrolysis process within the thermal-to-catalytic pyrolysis stage; Downstream of the thermal-catalytic pyrolysis stage is a termination stage, in which the pyrolysis solid residue is heated for conversion into solid products. A continuous heat treatment arrangement having A system comprising:

2. a waste material compaction unit upstream of the continuous heat treatment arrangement, the waste material compaction unit operable to compact the waste plastic material and remove air and moisture to generate a compressed waste plastic feed for feeding the continuous heat treatment arrangement; The system of claim 1 further comprising:

3. The thermal to catalytic pyrolysis stage a first thermal pyrolysis zone for heating the molten mixture received from the melting stage at or above the pyrolysis temperature of the molten mixture; one or more intermediate variable zones, each of which has a catalyst feed port at the beginning of the intermediate variable zone, the catalyst feed port serving as one of at least two catalyst feed points along the thermal to catalytic pyrolysis stage; and a final catalytic pyrolysis section having a catalyst feed port at the beginning of the final catalytic pyrolysis section which serves as the final catalyst feed point of the at least two catalyst feed points along the thermal to catalytic pyrolysis stages for receiving catalyst; Equipped with 3. The system of claim 1 or 2, wherein the catalyst is fed from one or more intermediate variable zone catalyst feed ports or the final catalytic pyrolysis zone catalyst feed port for converting the thermal pyrolysis process to a catalytic pyrolysis process at various points along the thermal to catalytic pyrolysis stages.

4. The system according to any one of claims 1 to 3, wherein the melting stage comprises at least one auxiliary catalyst feed point for feeding catalyst in the melting stage.

5. 5. The system according to claim 3 or claim 4, wherein the continuous heat treatment arrangement comprises at least one pyrolysis gas outlet for discharging pyrolysis gas products, the at least one pyrolysis gas outlet being present in a termination stage or in the final catalytic pyrolysis zone of the thermal to catalytic pyrolysis stage, or in both, and the at least one pyrolysis gas outlet is equipped with a vacuum pump.

6. 6. The system of claim 5, further comprising at least one heat exchanger unit coupled to the at least one pyrolysis gas outlet for condensing long-chain carbon compounds in the pyrolysis gas product.

7. 7. The system of claim 6, further comprising at least one gas separator unit downstream of the at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product.

8. The system according to any one of claims 1 to 7, wherein the termination stage comprises at least one solid product outlet for removing the solid product.

9. 9. The system of any one of claims 1 to 8, wherein the continuous heat treatment arrangement comprises a reactor comprising any one or combination of a melting stage, a thermal to catalytic pyrolysis stage or a termination stage.

10. 10. The system of claim 9, wherein the reactor is inclined at a rise rate per horizontal distance of 1:250 to 1:

20.

11. A system as claimed in claim 2 or any one of claims 3 to 10 which cites claim 2, wherein the waste material compaction unit comprises at least two rotating screws arranged in series from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit, and the direction of solids transport is from the inlet of the waste material compaction unit to the outlet of the waste material compaction unit.

12. 12. The system of claim 11, wherein the volumetric flow rate produced by each of the at least two rotating screws of the waste material compaction unit decreases successively from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit to compress the waste plastic material into a compressed waste plastic feed.

13. 13. The system according to any one of claims 1 to 12, further comprising at least one solid product compression unit for compressing a solid product take-off from a termination stage of the continuous heat treatment arrangement, the solid product compression unit being downstream of the termination stage of the continuous heat treatment arrangement.

14. 14. The system of claim 13, wherein the solid product compression unit comprises at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, and the direction of solid transport is from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

15. 15. The system of claim 14, wherein the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit decreases successively from the inlet of the solid product compression unit to the outlet of the solid product compression unit to compress the solid product.

16. 16. The system according to claim 14 or 15, wherein the rotational speed of each of the at least two rotating screws of the solid product compression unit decreases successively from one to the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

17. The system according to any one of claims 14 to 16, wherein the solid product compression unit further comprises at least three rotating screws.

18. 1. A method for converting waste plastic materials into useful products, comprising: introducing a compressed waste plastic feed produced from the waste plastic material into a melting stage of a continuous heat processing arrangement of a system for converting waste plastic material into a useful product, the melting stage melting the compressed waste plastic feed to form a molten mixture; selectively feeding catalyst through any one or more of at least two catalyst feed points of a thermal-catalytic pyrolysis stage of a continuous heat treatment configuration of the system to vary the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage, the thermal-catalytic pyrolysis stage being downstream of the melting stage, and subjecting the molten mixture to a thermal pyrolysis process and then a catalytic pyrolysis process to produce pyrolysis gas products and a pyrolysis solid residue; and removing the solid product from a termination stage of the continuous heat treatment arrangement of the system, the termination stage being downstream of the thermal to catalytic pyrolysis stage and heating the pyrolysis solid residue for conversion to a solid product; A method comprising:

19. monitoring at least one characteristic of an end product output from the system to determine whether adjustment of the ratio of thermal pyrolysis process to catalytic pyrolysis process within the thermal-catalytic pyrolysis stage is necessary to produce a desired end product output from the system; and selectively feeding catalyst through any one or more of the at least two catalyst feed points based on the proportion of thermal pyrolysis process and catalytic pyrolysis process determined to be required.

20. The method of claim 18, further comprising:

20. feeding catalyst through at least one auxiliary catalyst feed point in a melt stage of a continuous heat treatment configuration of the system.

20. The method of claim 18 or claim 19, further comprising:

21. The method according to any one of claims 18 to 20, further comprising the step of withdrawing pyrolysis gas products from the continuous heat treatment arrangement via at least one pyrolysis gas outlet of the continuous heat treatment arrangement.

22. condensing long-chain carbon compounds from the pyrolysis gas product by at least one heat exchanger unit connected to the at least one pyrolysis gas outlet; and Returning long-chain carbon compounds to the thermal to catalytic pyrolysis stage 22. The method of claim 21 further comprising:

23. removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product by at least one gas separator unit downstream of the at least one heat exchanger unit; and Returning the residual fines or heavy hydrocarbons, or a combination thereof, to the thermal to catalytic pyrolysis stage.

23. The method of claim 22, further comprising:

24. 24. The method according to any one of claims 18 to 23, further comprising compressing the waste plastic material through a waste material compaction unit, the waste material compaction unit being upstream of the continuous heat treatment arrangement of the system for converting the waste plastic material into useful products.

25. removing solid product from a termination stage of the continuous heat treatment arrangement of the system through a solid product compression unit, the solid product compression unit comprising at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, the direction of solid transport being from the inlet of the solid product compression unit to the outlet of the solid product compression unit; The method of any one of claims 18 to 24, further comprising:

26. 26. The method of claim 25, wherein the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit decreases successively from the inlet of the solid product compression unit to the outlet of the solid product compression unit to compress the solid product.

27. 26. The method according to claim 25, wherein the rotational speed of each of the at least two rotating screws of the solid product compression unit decreases successively from one to the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit.

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