Apparatus and method for depolymerization of polymers

Abstract

The apparatus (1) for depolymerization of polymers, particularly polyesters, polyamides, polyurethanes, and polycarbonates, comprises a microwave depolymerization reactor (2) having a reaction chamber (10); a microwave generation and transport system (5) for transmitting microwaves into the reaction chamber (10), the microwave generation and transport system (5) comprising a microwave generator (37) and a guiding device (38) housed within the reaction chamber (10) to convey and distribute the microwaves within the reaction chamber (10); a mixing device (3) configured to rotate about an axis (A) within the reaction chamber (10) and dynamically distribute within the reaction chamber (10) a mixture of liquids and solids housed within the reaction chamber (10); and a pressurization system (6) configured to vary the pressure within the reaction chamber (10).

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims priority to Italian Patent Application No. 102019000020784, filed November 11, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to an apparatus and method for the depolymerization of polymers, in particular polyesters, polyamides, polyurethanes and polycarbonates. [Background technology]

[0003] As is known, various polymeric materials that are widely used to manufacture various products can be recovered and reused at the end of their useful life instead of being sent to landfills.

[0004] In particular, some polymeric materials, such as, for example, polyesters, polyamides, polyurethanes, and polycarbonates, can be depolymerized, i.e., reduced to the monomeric (or oligomeric) form for subsequent repolymerization to produce new products.

[0005] Generally, these materials are first ground and reduced into granules and then undergo a depolymerization reaction under suitable processing conditions.

[0006] Various depolymerization reactions, especially of polyesters, polyamides, polyurethanes and polycarbonates, are known, but carrying out these reactions on an industrial scale with entirely satisfactory results, especially in terms of simplicity, yield, efficiency and processing speed, can be complicated.

[0007] Indeed, reactions described at the experimental or laboratory level are not always useful for practical industrial application; in certain cases, a given reaction can only be utilized by resorting to relatively complex and / or expensive industrial equipment and / or by processes that are not particularly advantageous overall or in any case require improvement.

[0008] US Pat. No. 5,399,633 describes a method and an apparatus for recycling polymeric materials, in particular polyesters and polyamides, by depolymerization, which is suitable for use on an industrial scale and is simple, effective and inexpensive. However, the method and apparatus of US Pat. No. 5,399,633 leaves room for further improvement, in particular in terms of simplicity of construction and use, as well as efficiency.

[0009] In particular, the solution of US Pat. No. 5,399,633 does not allow the fusion of both the chemical depolymerization reaction and at least part of the subsequent separation step of the reaction products in the same device. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] International Publication No. 2013 / 014650 Brochure Summary of the Invention [Problem to be solved by the invention]

[0011] It is an object of the present invention to provide an apparatus and a method for the depolymerization of polymers, in particular polyesters, polyamides, polyurethanes and polycarbonates, which is an improvement over the solutions of the state of the art, in particular it is an object of the present invention to provide an apparatus and a method which make it possible to carry out depolymerization reactions on an industrial scale in a simple, efficient and inexpensive manner. [Means for solving the problem]

[0012] In accordance with said object, the present invention relates to a method and an apparatus for the depolymerization of polymers, in particular polyesters, polyamides, polyurethanes and polycarbonates, as defined in the essential terms of claims 1 and 16, respectively, of the appended claims and for the preferred additional features of the dependent claims.

[0013] The device and the method according to the invention allow the effective recovery of the monomers constituting the treated polymers (in particular polyesters, polyamides, polyurethanes and polycarbonates) and their reintroduction into the production cycle of the corresponding polymer in a simple, efficient and inexpensive manner, even on an industrial scale.

[0014] In particular, the present invention allows for the merging of both the chemical depolymerization reaction and some of the subsequent reaction product separation steps in the same device.

[0015] Moreover, the present invention makes it possible to effectively overcome the inherent limitations of microwave electromagnetic radiation (especially at frequencies of interest for depolymerization reactions, which range from 300 MHz to 300 GHz), namely its limited liquid penetration power. In particular, the present invention makes it possible to effectively use microwave radiation within depolymerization reactions, such that the liquid components of the reaction are always in contact with the solid parts without intervening as an obstacle for the radiation.

[0016] The present invention uses the same elements that allow for the acceleration of reactions through microwaves to subsequently simplify the separation of liquid components from solid components within the reacted mixture.

[0017] Further features and advantages of the present invention will become apparent from the following description of non-limiting examples of embodiments, with reference to the accompanying drawings. [Brief description of the drawings]

[0018] [Figure 1] 1 is a schematic diagram illustrating an apparatus for depolymerization of a polymer according to a first embodiment of the present invention. [Diagram 2]2 is a schematic diagram showing an apparatus for depolymerization of polymers according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] In FIG. 1, the reference number 1 indicates as a whole an apparatus for the depolymerization of polymers, in particular polyesters (and in particular polyethylene terephthalate and its isomers, PET) or polyamides (nylon 6, nylon 6,6).

[0020] Typically (but not exclusively) the material to be treated by the apparatus 1 is PET or other polyesters, or polyamides, or polyurethanes, or polycarbonates, or composites containing said polymers. In the following description, by way of example, specific reference is made to the use of the apparatus 1 for the treatment of PET (said term also includes composites containing PET), thereby depolymerizing PET by alkaline hydrolysis.

[0021] It should be understood that the device 1 of the present invention can also be used for other reactions.

[0022] The apparatus 1 comprises a microwave depolymerization reactor 2 equipped with an internal mixing device 3 , a thermal control system 4 , a microwave generation and delivery system 5 , and a pressurization system 6 .

[0023] The reactor 2 comprises a reactor vessel 9 which defines an internal reaction chamber 10 .

[0024] For example, vessel 9 having a substantially cylindrical shape extends along and about a longitudinal axis A which, for example, is linear during use (as in the illustrated example, but not necessarily so) and substantially horizontal. It will be appreciated that, during use, vessel 9 (i.e., reactor 2) can be oriented differently, whereby axis A can be vertical instead of horizontal, or can be variously inclined relative to the horizontal plane (i.e., relative to the ground).

[0025] The container 9 is made of a material that is substantially opaque to microwave electromagnetic radiation and resistant to corrosion, for example, the container 9 is made of steel or other metallic material.

[0026] The vessel 9 is designed to withstand both internal overpressure and internal underpressure relative to atmospheric pressure.

[0027] The vessel 9 has a transverse wall 11, for example cylindrical, which internally bounds a reaction chamber 10, and a pair of end walls 12 at respective opposite axial ends.

[0028] The reactor 2 comprises a number of inlets and outlets, which are defined by respective openings formed in the vessel 9 and associated with respective ducts so as to allow the introduction of reagents and auxiliary components required for the depolymerization reaction into the reaction chamber 10 and the withdrawal of reaction products and reaction residues from the reaction chamber 10.

[0029] In particular, Reactor 2 is - at least one solid phase inlet 15 connected to a polymer feed duct 16 for feeding the polymer material to be treated (for example PET in dispersed solid form, e.g. flakes, granules, etc.) to the reaction chamber 10; a first liquid phase inlet 17 connected to a reagent supply duct 18 for supplying a liquid reaction composition to the reaction chamber 10; a second liquid phase inlet 19 connected to an auxiliary supply duct 20 for supplying an auxiliary component to the reaction chamber 10; at least one reaction product outlet 21 connected to an outlet duct 22 for removing reaction products formed in the reaction chamber 10 from the reaction chamber 10; at least one liquid phase outlet 23 connected to an extraction duct 24 equipped with a filter 25 and optionally a withdrawal pump 26, for removing the liquid stream from the reaction chamber 10 and for retaining in the reaction chamber 10 any solid residues separated from the liquid stream; at least one gas phase outlet 27 connected to a gas outlet duct 28 equipped with a vacuum pump 29 and connected to a condenser 30 for extracting the gas phase from the reaction chamber 10; a service inlet 31 and a service outlet 32 ​​connected to respective ducts of the pressurization system 6 for introducing inert gas into the reaction chamber 10 and extracting inert gas from the reaction chamber 10;

[0030] The mixing device 3 is housed within the vessel 9, within the reaction chamber 10, said device being rotatable about an axis A, thereby also defining an axis of rotation of the mixing device 3, and configured through its rotational action to keep the mixture of liquids and solids (formed from the polymer and the reaction composition) contained within the vessel 9 stirred and dynamically distributed within the reaction chamber 10 both along the axis A and radially relative to the axis A.

[0031] In particular, the mixing device 3 includes a number of blades 33 that may be of various shapes, sizes and configurations.

[0032] In a preferred embodiment, the blade 33 is integrally supported by a support structure 34 housed within the reaction chamber 10 and is rotatable within the reaction chamber 10 about an axis A.

[0033] For example, the structure 34 comprises a basket housed within the container 9, the basket having an outer radial lateral surface facing the lateral wall 11 of the container 9 and an inner radial lateral surface from which the blades 33 project radially towards the axis A.

[0034] The blades 33 can have different shapes and sizes and can be arranged in various ways on the structure 34 .

[0035] It should be understood that the mixing device 3 may be of other types than those shown here by way of example only, and may include blades arranged in various configurations and having various shapes and sizes.

[0036] For example, blades 33 of various shapes, or even strip shapes, may extend from a support structure 34 centrally positioned within the reaction chamber 10 along an axis A.

[0037] In another embodiment, the mixing device 3 is integral with the container 9 and rotates therewith about axis A. The container 9 is then rotatably mounted on an external support, for example involving in the rotation a blade 33 extending from the lateral wall 11 of the container 9.

[0038] The mixing device 3 is driven by a motor 35, for example positioned outside the container 9 and connected to the structure 34 (or to the container 9, if the latter is rotatable).

[0039] The thermal control system 4 is configured to extract thermal energy (heat) from the reaction chamber 10 inside the vessel 9 or introduce thermal energy (heat) into the reaction chamber 10, thereby cooling or heating the vessel 9 and its contents. For example, the system 4 comprises at least one coil 36 wound around the lateral wall 11 of the vessel 9, inside which circulates a fluid designed to transfer heat, the heat coming from a thermal unit in which said fluid is heated or cooled as appropriate.

[0040] The microwave generation and transport system 5 comprises a microwave generator 37 preferably positioned outside the vessel 9, and a guiding device 38 associated with the generator 37 and housed within the reaction chamber 10 for conveying and distributing microwaves generated by the generator 37 within the reaction chamber 10 along and around the axis A. For example, the guiding device 38 comprises a pipe extending along the axis A of the vessel 9 between the end walls 12 and comprising a (leaky pipe type) waveguide 39 with lateral emission holes formed on a lateral wall of the pipe.

[0041] Typically (but not necessarily), microwaves are transmitted into the reaction chamber 10 at a frequency in the range of 300 MHz to 300 GHz.

[0042] The pressurization system 6 is configured to introduce and extract inert gas into and from the reaction chamber 10 through a service inlet 31 and a service outlet 32, respectively. The inert gas is, for example, contained in a storage tank 40, and for circulation of the inert gas, a dedicated pump can be used or the same pump 29 utilized to extract the gas phase from the reaction chamber 10 through the gas phase outlet 27 can be used.

[0043] For example, the tank 40 is connected via a recovery line 41 to the condenser 30 from which it receives the gas (nitrogen) phase separated in the condenser 30 and to a duct 28 equipped with a pump 29 .

[0044] A separate recovery line 42 leaves the condenser 30 for removing therefrom the liquid phase condensed by the condenser 30 and optionally joins the extraction duct 24 downstream of the pump 26 .

[0045] A recycle duct 43 connects the extraction duct 24 to the reagent supply duct 18 .

[0046] The gas outlet duct 28 equipped with the pump 29, the condenser 30 and the recovery lines 41, 42 thus define a recovery circuit 44 configured to recover the gas phase from the reaction chamber 10 and separate therefrom the recovered condensate (comprising essentially HO and MEG), for example by distillation, and the gas (nitrogen) sent to the pressurization system.

[0047] The apparatus 1 is optionally connected to a polishing unit for preliminary mechanical treatment of the material to be recycled and / or to a mixing unit in which a reactive composition is prepared, i.e. a reactive composition is prepared with defined amounts of various components.

[0048] The device 1 is preferably used in a method for the depolymerization of polymers, in particular (but not exclusively) polyesters, polyamides, polyurethanes or polycarbonates.

[0049] The use of the device 1 to carry out said method is described below.

[0050] In the following examples, the operation of the apparatus 1 is essentially discontinuous (batch mode), but it should be understood that the apparatus 1 can also be operated in a continuous mode, in particular since the liquid phase (reactant composition) and / or the solid phase (polymer to be treated) can be fed continuously.

[0051] Step a) Reagent loading and reaching reaction conditions At the beginning of a production cycle, the polymeric material to be treated (e.g., PET) and the reactant composition (e.g., an aqueous solution of NaOH or other alkaline hydroxide and ethylene glycol) are fed separately into the reaction chamber 10 through respective feed ducts 16, 18 in a ratio appropriate for efficient execution / initiation of the depolymerization reaction.

[0052] In the loading step, the mixing device 3 is at rest and the microwave generation and delivery system 5 is stopped.

[0053] In view of the inherent structural stability of the apparatus 1 and in particular the reactor 2, and since the solid-liquid mixture does not have to be circulated in ducts of narrow diameter, the solid component (polymer material) does not require any particular preparatory treatment.

[0054] The liquid components (reactant compositions) are introduced at an elevated temperature (close to the reaction temperature) to accelerate the transient onset time.

[0055] First, the polymer material (PET) is preferably introduced at atmospheric pressure, for example by a pneumatic conveying system (or the like). The polymer is introduced through a duct 16 having a diameter such as to avoid any clogging problems.

[0056] The duct 16 can also be connected to a branch of the polymer material transport system (e.g. a pneumatic system) or, in case of high flows, directly to a dosing hopper, to prevent excessive accumulation of material in certain areas of the reaction chamber 10 (in all cases where the mixing device 3 operates to homogenize the components).

[0057] The reactor 2 is then pressurized, introducing nitrogen (or other inert gas) via a pressurization system 6 to bring the reaction chamber 10 to a specified pressure.

[0058] For example, in the case of the depolymerization of PET, the pressure is above 7 barg to prevent boiling of the reactant compositions at high temperatures; in this way, liquid components can be introduced without the risk of evaporation.

[0059] In view of the high structural tolerances that can be obtained with the configuration of reactor 2, it is advantageous to operate at even higher pressures, for example 10 barg or more. In this way, it is possible to operate with a wider margin in terms of reaction temperature and, moreover, a higher overpressure can be utilized during the extraction step of the filtered liquid components, as described below.

[0060] It is preferable to use nitrogen as the pressurized gas since it contains glycol in its vapor state, which would create an explosive atmosphere inside the reactor 2 .

[0061] Once a predetermined pressure has been reached, the reaction composition is fed into the reaction chamber 10 through the inlet 17 and duct 18 .

[0062] The reactant composition constitutes the liquid components of the reagents of the depolymerization reaction. For example, in the case of the depolymerization of PET, the reactant composition essentially consists of sodium hydroxide (NaOH) dissolved in water and ethylene glycol (MEG), mixed together in the appropriate proportions.

[0063] The reactant composition is, according to the invention, progressively introduced into the reaction chamber 10, extracting the liquid contents of the reaction chamber 10 when the NaOH is consumed, and then reintroducing subsequent doses of the reactant composition to continue the depolymerization of the polymer (which is conversely introduced in one single initial loading batch).

[0064] The overall number of introductions, and therefore the division of the reaction composition into doses, is established to minimize reaction time.

[0065] At the beginning of the depolymerization cycle, and following the introduction of the polymeric material and pressurization of the reaction chamber 10, a first dose of the reactant composition is introduced.

[0066] Advantageously, the reaction composition is introduced already at a high temperature (shown at about 180° C.) to avoid the need for preheating inside the reactor 2. Also, for this reason, the reaction chamber 10 is already pressurized prior to the introduction of the reaction composition.

[0067] Step b) Microwave accelerated reaction After introducing the reagents (all polymeric material to be processed, e.g., PET, and the first dose of the reaction composition) and pressurizing the reaction chamber 10, the thermal control system 4 is activated to maintain a specified reaction temperature within the reaction chamber 10.

[0068] The first reaction step (depolymerization) of N successive reaction steps is then initiated.

[0069] In the reaction step, - the mixing system 3 is started to keep the mixture formed of the reaction composition (liquid) and the polymer (solid) stirred and distributed inside the reaction chamber 10 so that the polymer is always wetted by the reaction composition and to facilitate the separation of the sodium terephthalate from the polymer flakes, ensuring that the polymer is always exposed to the reaction composition; - a microwave generation and delivery system 5 operates to accelerate the depolymerization reaction; The pressure in the reaction chamber 10 is regulated around a defined set point by the introduction / extraction of nitrogen by the pressurization system 6.

[0070] In further detail, the mixing device 3 is started and rotates to mix and stir the contents of the reaction chamber 10 (the solid polymeric material and the liquid reaction composition) and the microwave generation system 5 is operated to send microwaves into the reaction chamber 10.

[0071] The mixing device 3 rotates at a defined speed which can be varied as required over time after a given cycle.

[0072] Mixed system 3 is - ensuring a constant and uniform mixing of the liquid and solid components contained within the reaction chamber 10, in particular ensuring that pieces (flakes, fibres etc.) of polymers (e.g. PET) are always wetted by the reagents, avoiding their accumulation in certain areas of the reaction chamber 10; - dynamically distributing the polymer within the reaction chamber 10 by a lifting action and subsequent drop due to gravity exerted by the blade 33; - configured to avoid dynamic accumulation of liquid portions having characteristic dimensions greater than the penetration capacity of microwaves;

[0073] The blades 33 are thereby configured (i.e., shaped, sized and distributed) to ensure high mixing and stirring capacity without introducing too many metal elements into the reaction chamber 10 that could block the transmission of the electromagnetic field.

[0074] The depolymerization reaction thereby essentially results in alkaline hydrolysis in the reaction chamber 10 which leads to the progressive transformation of PET into ethylene glycol (MEG), which in the case of the depolymerization of PET, is added to that already present in the reaction composition as a co-solvent, and sodium terephthalate (NaPTA), which tends to precipitate under reaction conditions.

[0075] The operating conditions of the depolymerization reaction (particularly temperature, pressure and amounts of reagents) are established by the polymeric material being treated.

[0076] As already emphasized, the method of the present invention involves a series of reaction steps alternating with liquid phase extraction steps and subsequent recombination of the liquid components of the reaction composition, ie, the reagents.

[0077] In each reaction step, a minimum amount of liquid reagent is dispensed at a given time interval. In this way, a minimum amount of reagent can be dispensed and the high transparency of PET, and generally other polymers, to microwaves is exploited to optimize the use of radiation.

[0078] Before feeding new reactant composition, the liquid phase is withdrawn from the reaction chamber 10 so as to increase the amount of PET processed at the same time without risking accumulation of too many liquid portions which would impair microwave penetration (inducing "grey areas" where the reaction is not accelerated).

[0079] Through experimental characterization of the process, optionally also supported by a pH sensor, it is determined when the depolymerization reaction is slowing down due to excessive marking reduction in the NaOH concentration, exceeding a defined threshold, which determines the transition to a subsequent liquid phase extraction and recoalescence step, or, if complete depolymerization has been achieved, to a drying step (described below).

[0080] Step c) Liquid phase extraction and refusion As described above, each reaction step is followed by a liquid phase extraction and recombination step in which the liquid phase present in the reaction chamber 10 is extracted from the reaction chamber 10 and a new reaction composition is introduced into the reaction chamber 10.

[0081] The extraction of the liquid phase serves to avoid the formation of excess accumulation of liquid inside the reaction chamber 10 and is advantageously carried out by utilizing a pressure inside the reaction chamber 10 that is well above atmospheric pressure (e.g., 7 bar or more).

[0082] After a defined reaction period during which the depolymerization reaction takes place, the extraction duct 24 equipped with a filter 25 is opened (it remains closed during the reaction step) and the pressure in the reaction chamber 10 pushes the liquid present out of the reactor 2, which is separated in the filter 25 from all the solid residues therein, in particular the not yet reacted PET, the solid undissolved terephthalate and any other solid material present in the reactor 2 (cotton, other plastics, solid contaminants, etc.). A liquid stream is obtained which essentially contains H2O and MEG and which can be sent by pump 26, for example, to a distillation column for recovery.

[0083] Since the liquid stream flowing from reactor 2 contains NaOH in addition to H2O and MEG, a portion of this liquid stream may be sent through a recycle duct 43 which merges into duct 18 for re-incorporation into the feed of the reaction composition.

[0084] At each liquid phase extraction and re-fusion step, a new dose of the reaction composition is introduced into the reaction chamber 10 through the duct 18 .

[0085] Step d) Drying of the solid components after the reaction Once the polymer has been completely depolymerized, after a series of N reaction steps alternating with N-1 liquid phase extraction / refusion steps, a final liquid phase extraction step is again carried out through the extraction duct 24 and the filter 25 so as to retain the terephthalate present in the reaction chamber 10. All the liquid phase removed is sent to a distillation step.

[0086] In the reaction chamber 10, the wet sludge of sodium terephthalate forms containing contaminants and unreacted solid residues. Before sending this material to a subsequent purification step to separate and recover terephthalic acid (PTA), humidity due to the presence of residual water and glycol must be minimized.

[0087] The recovery of water and glycol primarily serves to keep the overall production efficiency intact, since excess MEG during the subsequent PTA purification process could cause electrode problems in the chlorine soda plant responsible for the process.

[0088] Downstream of the final liquid phase extraction, a drying step begins in which the solid components after the reaction, in particular sodium terephthalate, are dried.

[0089] The drying step envisages drying the solid residue contained in the reactor 2 under the desired conditions, which expediently occurs using the same reactor 2, thereby without removing or transferring the product to be treated to another unit.

[0090] The terephthalate drying step is in fact carried out according to the invention inside the same reactor 2 in which the depolymerization reaction takes place.

[0091] The drying step advantageously comprises: a vacuum pump 29 for extracting gas from the reaction chamber 10 until an operating pressure is reached that is well below atmospheric pressure, for example below 0.05 atm, and provided that the final boiling temperature of the residual mixture at said pressure is clearly lower than the operating pressure during depolymerization, a first "flash" evaporation phenomenon occurs, extracting from the reaction chamber 10 both the nitrogen and the water vapor and glycol, which are condensed and sent back to the distillation column, while the nitrogen is sent back to the pressurization system 6; a thermal control system 4 operating in heating mode and supplying heat to the vessel 9 and subsequently to the reaction chamber 10; - a microwave generation and transport system 5 which transmits microwaves into the reaction chamber 10 with a power not necessarily equal to that used for the depolymerization and optionally modulated during drying, in order to introduce energy directly into the residual liquid components inside the reaction chamber 10, exploiting the fact that sodium terephthalate is substantially transparent to microwaves, so that most of the microwaves are absorbed by the liquid residues; - a mixing device 3 that remains rotating in order to facilitate the evacuation of steam and to prevent the formation of scale; This is done through joint use of the following:

[0092] Since the contents of the reactor 2 are at the reaction temperature (e.g., about 190° C. for PET), the extraction of pressurized nitrogen from inside the reactor 2 by the pressurization system 6 until a very low pressure (also clearly lower than 1 bar) is reached automatically causes evaporation of part of the mixture still contained in the terephthalate in the form of humidity.

[0093] At the same time, the mixing device 3 is kept rotating to agitate the contents of the reaction chamber 10, thereby facilitating evaporation of liquid residues, while nitrogen is thereby extracted, reducing the internal pressure.

[0094] By keeping the microwave generation and delivery system 5 active, radiation is utilized to complete the evaporation of the liquid residue which is only usefully absorbing the microwaves.

[0095] The MEG and H2O vapors extracted from reactor 2 through outlet 27 and gas outlet duct 28 are recondensed in condenser 30 and then sent to the distillation column by recovery line 42. Nitrogen extracted from reactor 2 for pressure control is recovered to repressurize reactor 2 in a new production cycle.

[0096] Optionally, the gas outlet duct 28 and / or the pressurization system 6 may be equipped with a filter to collect any dust that is sucked in during the drying step.

[0097] Step e) Decomposition of post-reaction solid components in water Once the terephthalate drying step in reactor 2 is completed, clean water is introduced into reaction chamber 10 through duct 20 and inlet 19 in an amount equal to that required to ensure total decomposition of the PTA salt. An aqueous solution containing solid residues but in reduced amounts and easy to filter is obtained outside reactor 2. At the same time, the pressure in reactor 2 is reset to atmospheric conditions or conditions of slight overpressure.

[0098] Using an outlet duct 22, the mixture is extracted from the reactor 2 and directed to a purification process of the terephthalic acid, which is carried out in a known manner.

[0099] In the embodiment of FIG. 2, in which similar or equal details as already described are indicated with the same numerals, the apparatus 1 always comprises a microwave depolymerization reactor 2 equipped with an internal mixing device 3, a thermal control system 4, a microwave generation and transport system 5 and a pressurization system 6.

[0100] With respect to the embodiment previously described with reference to FIG. 1, in this embodiment the reactor 2 and associated vessel 9 extend along and around a longitudinal axis A which, in use, is substantially vertical.

[0101] The axis A again defines the axis of rotation of the mixing device 3, whereby in this case the axis of rotation is substantially vertical.

[0102] Also in this case, the mixing device 3 is configured to keep the mixture of liquids and solids (polymer and reaction composition) contained in the container 9 stirred through its own rotational action and dynamically distribute it inside the reaction chamber 10 both along the axis A and radially relative to the axis A.

[0103] Advantageously, a filter 25 designed to separate the liquid phase from the solid residues (non-reacted PET, non-decomposed solid terephthalate, any other solid materials present) is housed in the bottom of the container 9, in the lower end wall 12, below the mixing device 3.

[0104] In particular, the filter 25 is positioned below the blade 33 (however configured) of the mixing device 3 .

[0105] The filter 25 is configured to retain within the chamber 10 solid components that intersect with the liquid phase present in the chamber 10 and form a filter cake above the filter 25 .

[0106] As previously described, the liquid stream (containing substantially H2O and MEG) that traverses filter 25 is removed from reactor 2 through liquid phase outlet 23 and sent to recovery via extraction duct 24.

[0107] Advantageously, the mixing device 3 driven by a motor 35 is configured such that the structure 34 with the blades 33 not only rotates about the axis A but is also axially movable along the axis A to apply pressure on the filter cake produced on the filter 25.

[0108] In the embodiment of FIG. 2, the reactor 2 thus substantially integrates a Nutsche filter dryer.

[0109] Obviously, and in this embodiment, the mixing device 3 can assume various configurations, with the blades 33 being of various shapes and organisations and positioned on several rotors.

[0110] Also in this case, the mixing device 3 is used during the depolymerization step to mix the polymer (PET) and keep it sufficiently "wet" with the reaction composition to diffuse inside the reaction chamber 10, so that the polymer can be sufficiently irradiated by the microwaves, and similar to a conventional Nutsche filter dryer, the mixing device 3 serves to maintain a smooth upper surface of the dried cake (during the filtration step) and to agitate the material (during the drying step).

[0111] In this embodiment, the reactor 2 is cooled or heated by a thermal control system 4 .

[0112] In addition to or as an alternative to the coils 36 previously described, the thermal control system 4 can also include heating / cooling devices acting directly on the mixing device 3 (i.e., structures 34 and / or blades 33), which is particularly useful in the vacuum drying step.

[0113] Also in this case, the microwave generation and delivery system 5 introduces the microwaves required for the depolymerization reaction directly into the chamber 10 through a waveguide 39 .

[0114] The configuration described next makes it possible to adopt a modified form of use of the device 1, in particular during the depolymerization step: instead of a series of reaction steps alternating with liquid phase extraction / recombination steps, it is in fact possible to work with a continuous liquid phase recycle flow on the reactor 2.

[0115] To this end, the apparatus 1 includes a recirculation tank 45 which contains the reaction composition that is fed to the reactor 2 .

[0116] The tank 45 has an inlet 46 connected to a mixing unit (not shown) in which the reaction composition is prepared, and a reagent supply duct 18 optionally equipped with a supply pump 48 and thereby a transport outlet 47 connected to the liquid phase inlet 17 of the reactor 2.

[0117] The tank 45 also has a return inlet 49 connected to a recirculation duct 50 equipped with a control valve 51 , which branches off from the extraction duct 24 by a branch valve 52 .

[0118] The tank 45 is then pressurized by the same pressurization system 6 of the reactor 2, for example with a nitrogen atmosphere and at a controlled pressure (in particular above 7 barg, for example about 10 barg).

[0119] Advantageously, the tank 45 further comprises a separate thermal control system 54, e.g. a liner 55 externally encasing the tank 45 and within which a heating / cooling fluid circulates to maintain a controlled temperature of the reaction composition supplied to the reactor 2, ensuring better regulation compared to the sole use of a thermal control system 4 directly integrated within the reactor 2.

[0120] At the beginning of a production cycle of the apparatus 1, the tank 45 is supplied with the reactant composition in an amount calculated for the entire production batch of the reactor 2.

[0121] Tank 45 continuously supplies the reactant composition to reactor 2 .

[0122] It is possible to maintain a suitable pressure differential (representing at least 3 bar) between the reactor 2 and the tank 45 to extract a controlled flow of the filtered mixture from the reactor 2 .

[0123] This approach allows precise amounts (i.e., levels) of reactant compositions to be maintained within reactor 2 (after the initial loading step) while ensuring that the concentrations of reagents involved in the depolymerization reaction (e.g., sodium hydroxide for PET) decay gradually in parallel as the overall reaction occurs (as opposed to the separate step operating mode).

[0124] Furthermore, the outer liner of the tank makes it possible to maintain a well-controlled temperature of the reaction mixture within the reactor, ensuring better regulation compared to the use of a single cooling / heating system directly integrated within the reactor.

[0125] Obviously, the solutions described with reference to each of the above embodiments can be combined with each other.

[0126] Finally, further modifications and variations may be made to the devices and methods described and illustrated herein without departing from the scope of the appended claims. [Explanation of symbols]

[0127] 1. Apparatus for depolymerization 2. Microwave depolymerization reactor 3 Internal Mixing Device 4. Thermal Control System 5. Microwave Generation and Delivery Systems 6 Pressurized System 9. Reactor vessel 10 Inner Reaction Chamber 11 Side Wall 12 End wall 15 Solid phase inlet 16 Polymer supply duct 17 First liquid phase inlet 18 Reagent supply duct 19 Second liquid phase inlet 20 Auxiliary Supply Duct 21 Reaction product outlet 22 Exit Duct 23 Liquid phase outlet 24 Extraction duct 25 Filters 26 Extraction pump 27 Gas phase outlet 28 Gas outlet duct 29 Vacuum Pump 30 Condenser 31 Service Entrance 32 Service Exit 33 Blade 34 Support structure 35 Motor 36 Coil 37 Generator 38 Guidance Device 39 Waveguide 40 Tank 41 Recovery Line 42 Recovery Line 43 Recycling Duct 44 Recovery Circuit 45 Recirculation Tank 46 Entrance 47 Transport Exit 48 Supply Pump 49 Return Entrance 50 Recirculation Duct 51 Control valve 52 Branch valve A Longitudinal axis

Claims

1. An apparatus (1) for the depolymerization of polymers, in particular polyesters, polyamides, polyurethanes, polycarbonates, comprising a microwave depolymerization reactor (2) having a reactor vessel (9), said reactor vessel (9) extending along and around a longitudinal axis (A) and defining an internal reaction chamber (10) in which a depolymerization reaction of said polymer treated with a liquid reaction composition takes place, and a microwave generation and transport system (5) for transmitting microwaves into said internal reaction chamber (10), said microwave generator (37) being preferably arranged outside said reactor vessel (9), and a guiding device (38) associated with said microwave generator (37) and housed within said internal reaction chamber (10) for conveying and distributing said microwaves generated by said microwave generator (37) within said internal reaction chamber (10) along and around said longitudinal axis (A).

1. An apparatus comprising: a generation and transport system (5); a mixing device (3) contained within said internal reaction chamber (10) and rotating about said longitudinal axis (A), said mixing device (3) configured to keep a mixture of liquids and solids contained in said internal reaction chamber (10) stirred, configured to dynamically distribute said mixture inside said internal reaction chamber (10) both along said longitudinal axis (A) and radially relative to said longitudinal axis (A) and ensure a constant and uniform mixing of liquid and solid components contained in said internal reaction chamber (10), ensure that the pieces of polymer being depolymerized are always wetted by the liquid reaction composition and avoid accumulation in certain areas of said internal reaction chamber (10), and avoid dynamic accumulation of liquid portions having characteristic dimensions larger than the penetration capacity of the microwaves; and a pressurization system (6) configured to regulate the pressure inside said internal reaction chamber (10) both above and below atmospheric pressure.

2. 2. The apparatus according to claim 1, wherein the guiding device (38) comprises a pipe extending along the longitudinal axis (A) of the reactor vessel (9) and including a waveguide (39) with lateral emission holes formed on a lateral wall of the pipe.

3. 3. Apparatus according to claim 1 or 2, wherein the mixing device (3) comprises a plurality of blades (33) supported together by a support structure (34) housed within the internal reaction chamber (10).

4. 3. Apparatus according to claim 1 or 2, wherein the reactor vessel (9) is made of a material that is substantially opaque to microwave electromagnetic radiation, for example steel or another metallic material.

5. 3. The apparatus of claim 1 or 2, comprising a thermal control system (4) configured to selectively extract heat from or provide heat to the internal reaction chamber (10).

6. 6. The apparatus according to claim 5, wherein the thermal control system (4) comprises at least one coil (36) wound around the reactor vessel (9), inside which a heat transfer fluid circulates, the heat transfer fluid coming from a thermal unit where the heat transfer fluid is heated or cooled, and / or a heating / cooling device acting directly on the mixing device (3).

7. 3. The apparatus of claim 1 or 2, wherein the pressurization system (6) is configured to selectively inject and extract inert gas into and from the internal reaction chamber (10).

8. 3. Apparatus according to claim 1 or 2, comprising a vacuum pump (29) for extracting the gas phase from the internal reaction chamber (10) through a gas phase outlet (27).

9. 3. Apparatus according to claim 1 or 2, comprising a recovery circuit (44) configured to recover a gas phase from the internal reaction chamber (10) and subsequently separate condensate and gases from said gas phase.

10. 3. The apparatus of claim 1 or 2, comprising a filter (25) configured to separate a liquid stream from the mixture of liquids and solids contained in the internal reaction chamber (10) and to retain solid residue separated from the liquid stream in the internal reaction chamber (10).

11. 11. Apparatus according to claim 10, wherein the filter (25) is positioned below the mixing device (3) at the lower end wall (12) of the reactor vessel (9).

12. Said microwave depolymerization reactor (2) comprises at least one solid phase inlet (15) connected to a polymer supply duct (16) for supplying the polymeric material to be treated to said internal reaction chamber (10), a first liquid phase inlet (17) connected to a reagent supply duct (18) for supplying a liquid reaction composition to said internal reaction chamber (10), a second liquid phase inlet (19) connected to an auxiliary supply duct (20) for supplying auxiliary components to said internal reaction chamber (10), at least one reaction product outlet (21) connected to an outlet duct (22) for removing reaction products formed in said internal reaction chamber (10) from said internal reaction chamber (10), and at least one reaction product outlet (22) connected to an outlet duct (23) for removing a liquid stream from said internal reaction chamber (10) and removing said liquid 3. The apparatus according to claim 1 or 2, comprising at least one liquid phase outlet (23) connected to an extraction duct (24) equipped with a filter (25) and optionally a withdrawal pump (26) for retaining in the internal reaction chamber (10) solid residues separated from the flow, at least one gas phase outlet (27) connected to a gas outlet duct (28) equipped with a vacuum pump (29) and connected to a condenser (30) for extracting a gas phase from the internal reaction chamber (10), and a service inlet (31) and a service outlet (32) connected to respective ducts of the pressurization system (6) for introducing an inert gas into the internal reaction chamber (10) and extracting an inert gas from the internal reaction chamber (10).

13. 3. Apparatus according to claim 1 or 2, comprising a recirculation tank (45) for containing the liquid reaction composition to be fed to the microwave depolymerization reactor (2), the recirculation tank (45) having a delivery outlet (47) connected via a reagent supply duct (18) to a liquid phase inlet (17) of the microwave depolymerization reactor (2) and a return inlet (49) connected via a recirculation duct (50) to a liquid phase outlet (23) of the microwave depolymerization reactor (2).

14. 14. The apparatus according to claim 13, wherein the recirculation tank (45) is pressurized to a controlled pressure higher than the internal pressure of the microwave depolymerization reactor (2) and comprises an additional thermal control system (54), e.g. a liner (55) externally encasing the recirculation tank (45), in which a heating / cooling fluid circulates to maintain a controlled temperature of the liquid reaction composition in the recirculation tank (45).

15. 15. Use of a device according to any one of claims 1 to 14 in a process for the depolymerization of polymers, in particular polyesters, polyamides, polyurethanes or polycarbonates.

16. A method for the depolymerization of polymers, in particular polyesters, polyamides, polyurethanes or polycarbonates, comprising a reagent supply step in which a reaction chamber (10) defined inside a reactor vessel (9) of a reactor (2) and extending along and around an axis (A) is supplied with the polymer to be treated and with a liquid reaction composition for the depolymerization reaction of said polymer, and a depolymerization reaction step in which microwaves are directed into said reaction chamber (10) by a guiding device (38) contained in said reaction chamber (10) to distribute said microwaves in said reaction chamber (10) along and around said axis (A) and to activate said depolymerization reaction, said polymer and said liquid reaction composition contained in said reaction chamber (10) being supplied with said polymer and said liquid reaction composition. a depolymerization reaction step, wherein the material is kept mixed and stirred by a mixing device (3) which rotates about said axis (A) so as to dynamically distribute within said reaction chamber (10) both along said axis (A) and radially relative to said axis (A) and to ensure a constant and uniform mixing of the liquid and solid components contained in said reaction chamber (10), to ensure that the pieces of polymer to be depolymerized are always wetted by said liquid reaction composition and accumulation in certain areas of said reaction chamber (10) is avoided, and to avoid dynamic accumulation of liquid portions having characteristic dimensions larger than the penetration capacity of the microwaves, a mixture being formed by said polymer and said liquid reaction composition, and wherein said reaction chamber (10) is pressurized at a defined pressure during said depolymerization reaction step.

17. 17. The method according to claim 16, wherein the polymer is first introduced into the reaction chamber (10) at atmospheric pressure and then the liquid reaction composition is introduced into the reaction chamber (10) after pressurizing the reaction chamber (10), in particular by introducing nitrogen or another inert gas into the reaction chamber (10).

18. 18. The method according to claim 16 or 17, wherein the pressure in the reaction chamber (10) when feeding the liquid reaction composition and during the depolymerization reaction step is equal to or greater than 7 barg.

19. 18. The method according to claim 16 or 17, wherein the method comprises an initial feeding step in which the reaction chamber (10) is fed with the entire amount of the polymer to be treated and a first dose of a reaction composition, and a number of reaction steps alternating with liquid phase extraction and refusion steps, in which in each liquid phase extraction and refusion step a liquid phase comprising reaction residues is extracted from the reaction chamber (10) and a new dose of a new reaction composition is introduced into the reaction chamber (10).

20. 20. The method according to claim 19, wherein in each liquid phase extraction and re-merger step, an extraction duct (24) equipped with a filter (25) is opened, whereby the pressure in the reaction chamber (10) pushes the liquid phase contained in the reaction chamber (10) out of the reaction chamber (10) and the filter (25) separates the solid residues retained in the reaction chamber (10) from the liquid flow.

21. 20. The method according to claim 19, comprising a final liquid phase extraction step, after a series of reaction steps alternating with liquid phase extraction and recombination steps, in which the entire liquid phase present in the reaction chamber (10) is removed from the reaction chamber (10).

22. 18. The method according to claim 16 or 17, wherein the method comprises a drying step for drying the post-reaction solid components remaining in the reaction chamber (10) after the depolymerization reaction step, the drying step being carried out in the reaction chamber (10) using one or more of the following steps: extracting gas from the reaction chamber (10) by a vacuum pump (29) until an operating pressure well below atmospheric pressure is reached, for example 0.05 atm or less; providing heat to the reaction chamber (10) by a thermal control system (4) operating in heating mode; sending microwaves into the reaction chamber (10) with a power not necessarily equal to that used for the depolymerization reaction and optionally modulated during the drying step, in order to directly provide energy to the remaining liquid components in the reaction chamber (10); and mixing the contents of the reaction chamber (10) by the mixing device (3).

23. 23. The method according to claim 22, comprising a hydrolysis step of the reacted solid components, in which, after the drying step, water is introduced into the reaction chamber (10) in order to decompose the solid components still present in the reaction chamber (10) and to obtain an aqueous solution containing solid residues which is subsequently removed from the reaction chamber (10) in a new production cycle by returning the pressure inside the reaction chamber (10) to atmospheric conditions or to a slight overpressure condition.

24. 18. The method according to claim 16 or 17, comprising the step of drawing a gas phase from the reaction chamber (10) by means of a vacuum pump (29) and sending said gas phase to a condenser (30) for separating condensate and gas.

25. 18. The method according to claim 16 or 17, wherein the depolymerization reaction step is carried out by feeding a continuous flow of liquid phase to the reactor (2), the method comprising the step of recycling to the reactor (2) a liquid phase recovery stream taken from the reactor (2).

26. 26. The method of claim 25, comprising controlling the temperature of the liquid reaction composition supplied to the reactor (2) upstream of the reactor (2).

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