Chemical recycling of treated mixed plastic waste streams.

Abstract

To provide chemical recycling facilities for processing mixed plastic waste.SOLUTION: Such facilities have the capability of processing mixed plastic waste streams and utilize a variety of recycling facilities, such as, for example, solvolysis facility, a pyrolysis facility, a cracker facility, a partial oxidation gasification facility, an energy generation / energy production facility, and a solidification facility. Streams from one or more of these individual facilities may be used as feed to one or more of the other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001]

[0001] Waste materials, especially non-biodegradable waste materials, can have a negative impact on the environment if disposed of in landfills after a single use. Therefore, from an environmental standpoint, it is desirable to recycle as much waste material as possible. However, there still exist low-value waste streams that are not possible or economically feasible to recycle using conventional recycling techniques. In addition, some conventional recycling processes themselves generate waste streams that are not economically feasible to recover or recycle, resulting in additional waste streams that must be disposed of or otherwise treated. Summary of the Invention [Problem to be solved by the invention]

[0002]

[0002] Thus, there is a need for a large-scale facility capable of chemically recycling a variety of waste materials, including various types of plastics, in an economically viable manner. Ideally, such a facility would provide commercially valuable end products while minimizing the generation of additional waste streams, promoting production efficiencies and minimizing environmental impacts. [Means for solving the problem]

[0003]

[0003] In one aspect, the present technology relates to a method for treating waste plastics, comprising introducing a polyolefin-containing by-product stream from a solvolysis facility to at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, (iii) a solidification facility, (iv) a cracker facility, and (v) an energy generation / energy production facility.

[0004]

[0004] In one aspect, the present technology relates to a solvolysis by-product composition comprising at least 90 weight percent polyolefin and no more than 1 weight percent PET, based on the total weight of the composition, and having a viscosity of at least 10 Pa·s (100 poise) at 10 radians per second and 250°C.

[0005]

[0005] In one aspect, the present technology relates to a method for treating waste plastics, comprising the steps of separating a mixed waste plastics (MWP) stream into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; subjecting at least a portion of the PET-rich stream to solvolysis in a solvolysis facility to form a major glycol product, a major terephthalyl product, and at least one by-product stream, wherein the by-product stream comprises a polyolefin-containing by-product stream; and introducing at least a portion of the by-product stream from the solvolysis facility to at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, (iii) a solidification facility, (iv) a cracker facility, and (v) an energy generation / energy production facility.

[0006]

[0006] In one aspect, the present technology relates to a method for treating waste plastics, comprising the steps of: (a) separating mixed plastic waste (MPW) into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) subjecting at least a portion of the PET-rich stream to solvolysis in a solvolysis facility; and (c) subjecting at least a portion of the PO-rich stream to (i) partial oxidation (POX) in a gasification facility, (ii) pyrolysis in a pyrolysis facility, or (iii) chemical conversion in an energy generation / energy production facility.

[0007] In one aspect, the present technology is a method for treating waste plastics, comprising the steps of: (a) separating mixed plastic waste (MPW) into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) subjecting at least a portion of the PO-rich stream to at least one of: (i) partial oxidation (POX) in a gasification facility; (ii) pyrolysis in a pyrolysis facility; and (iii) chemical conversion in an energy generation / energy production facility; (v) a mercury content of 1 ppm or less; (vi) an arsenic content of 100 ppm or less; and (vii) a melt viscosity of less than 2,500 Pa·s (25,000 poise) measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / s and a temperature of 250°C.

[0008]

[0008] In one aspect, the present technology relates to a method for treating waste plastics, comprising introducing a feedstream containing at least 50 weight percent polyolefins (PO) into at least one of: (i) a partial oxidation (POX) gasification facility; (ii) a pyrolysis facility; and (iii) an energy generation / energy production facility, wherein at least a portion of the feedstream contains plastics that are not classified as #3 to #7 plastics.

[0009]

[0009] In one aspect, the present technology relates to a method for processing waste plastics, comprising introducing a polyolefin (PO)-containing waste plastic stream and a solvolysis by-product stream into at least one of: (i) a partial oxidation (POX) gasification facility; (ii) a pyrolysis facility; and (iii) an energy generation / energy production facility.

[0010]

[0010] In one aspect, the present technology relates to a method for processing waste plastics, the method comprising the steps of: (a) introducing a polyethylene terephthalate (PET)-containing waste plastic stream into a solvolysis facility, thereby producing at least a major terephthalyl stream, a major glycol stream, and at least one solvolysis by-product stream; and (b) introducing at least a portion of the polyolefin-containing waste plastic stream and the solvolysis by-product stream into at least one of: (i) a partial oxidation (POX) gasification facility, (ii) a thermal cracking facility, and (iii) an energy generation / energy production facility.

[0011]

[0011] In one aspect, the present technology relates to a method for treating waste plastics, comprising the steps of: (a) separating a mixed plastic waste (MPW) stream into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) introducing at least a portion of the PET-rich stream into a solvolysis facility, thereby producing at least a major terephthalyl stream, a major glycol stream, and at least one solvolysis by-product stream; and (c) introducing at least a portion of the PO-rich stream and at least a portion of the solvolysis by-product stream into at least one of: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, and (iii) an energy generation / energy production facility.

[0012] In one aspect, the present technology provides a method for treating waste plastics, comprising: subjecting a bottoms by-product stream of a glycol column from a solvolysis facility to at least one of the following: One relates to a method including the steps of introducing the wastewater into: (i) a partial oxidation (POX) gasification facility; (ii) a pyrolysis facility; (iii) a solidification facility; (iv) a cracker facility; and (v) an energy generation / energy production facility.

[0013]

[0013] In one aspect, the present technology relates to a method for processing waste plastics, the method comprising: (a) withdrawing a glycol column bottoms by-product stream from a solvolysis facility used to process PET-containing waste plastics; and (b) introducing at least a portion of the by-product stream into at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, and (iii) a solidification facility, (iv) a cracker facility, and (v) an energy generation / energy production facility.

[0014]

[0014] In one aspect, the present technology relates to a method for treating waste plastics, comprising: (a) separating a mixed plastic waste (MPW) stream into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) subjecting at least a portion of the PET-rich stream to solvolysis in a solvolysis facility to form a major glycol product, a major terephthalyl product, and at least one by-product stream, wherein the by-product stream comprises a glycol column bottoms by-product stream; and (c) introducing at least a portion of the by-product stream from the solvolysis facility to at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, (iii) a solidification facility, (iv) a cracker facility, and (v) an energy generation / energy production facility.

[0015]

[0015] In one aspect, the present technology relates to a solvolysis by-product composition formed in a solvolysis facility for processing polyester terephthalate-containing waste plastics to form a major glycol, a major terephthalyl, and a major solvent, the composition comprising an oligomer containing at least 60 weight percent of a polyester portion, based on the total weight of the composition, a major glycol, and at least one glycol other than the major glycol, wherein the weight ratio of the at least one glycol other than the major glycol to the major glycol is at least 0.5:1.

[0016]

[0016] In one aspect, the present technology relates to a method for processing waste plastics, the method comprising introducing a reactor purge by-product stream from a solvolysis facility into at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, (iii) a cracker facility, and (iv) an energy generation / energy production facility.

[0017]

[0017] In one aspect, the present technology relates to a method for processing waste plastics, the method comprising: (a) withdrawing a reactor purge by-product stream from a solvolysis facility used to process PET-containing waste plastics; and (b) introducing at least a portion of the by-product stream into at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, and (iii) a cracker facility, (iv) an energy generation / energy production facility.

[0018] In one aspect, the present technology is a method for treating waste plastics, comprising the steps of: (a) separating a mixed plastic waste (MPW) stream into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; and (b) subjecting at least a portion of the PET-rich stream to solvolysis in a solvolysis facility to form a major glycol product, a major terephthalyl product, and at least one by-product stream, wherein the by-product stream is (c) introducing at least a portion of the by-product stream from the solvolysis facility into at least one of: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, (iii) a solidification facility, and (iv) a cracker facility, and (v) an energy generation / energy production facility.

[0019]

[0019] In one aspect, the present technology relates to a solvolysis by-product composition formed in a solvolysis facility for processing polyester-containing waste plastics into a major glycol, a major terephthalyl, and a major solvent, the composition comprising at least 25 weight percent of the major terephthalyl, based on the total weight of the composition, and one or more non-terephthalyl solids in an amount of 100 ppm by weight to 25 weight percent, based on the total weight of the composition.

[0020]

[0020] In one aspect, the present technology relates to a method for treating waste plastics, comprising introducing a terephthalyl column bottoms by-product stream from a solvolysis facility into at least one of the following: (i) a partial oxidation (POX) gasification facility, (ii) a pyrolysis facility, (iii) a solidification facility, (iv) a cracker facility, and (v) an energy generation / production facility 80.

[0021]

[0021] In certain embodiments, the present technology relates to a method for treating waste plastics, comprising: (a) withdrawing a terephthalyl column bottoms by-product stream from a solvolysis facility 30 used to process PET-containing waste plastics; and (b) introducing at least a portion of the by-product stream into at least one of the following: (i) a partial oxidation (POX) gasification facility 50, (ii) a pyrolysis facility 60, (iii) a solidification facility 40, (iv) a cracker facility, and (v) an energy generation / production facility 80.

[0022]

[0022] In certain embodiments, the present technology relates to a method for treating waste plastics, comprising: (a) separating a mixed plastic waste (MPW) stream into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) subjecting at least a portion 102 of the PET-rich stream to solvolysis in a solvolysis facility 30 to form a major glycol product, a major terephthalyl product, and at least one by-product stream, wherein the by-product stream comprises a terephthalyl column bottoms by-product stream; and (c) introducing at least a portion of the by-product stream from the solvolysis facility 30 to at least one of the following: (i) a partial oxidation (POX) gasification facility 50, (ii) a pyrolysis facility 60, (iii) a solidification facility 40, (iv) a cracker facility, and (v) an energy generation / energy production facility.

[0023]

[0023] In one aspect, the present technology relates to a solvolysis by-product composition formed in a solvolysis facility for processing polyester terephthalate-containing waste plastics to form a major glycol, a major terephthalyl, and a major solvent, the composition comprising oligomers containing at least 70 weight percent polyester moieties, based on the total weight of the stream, and at least 1 part per billion and / or 25 weight percent or less of substituted terephthalyl components, the mid-level boiling point of which is higher than the boiling point of the major terephthalyl.

[0024] In one aspect, the present technology provides a method for treating waste plastics, comprising: subjecting a solvolysis by-product stream from a solvolysis facility to at least one of the following: (i) a partial oxidation (POX) facility; (ii) a pyrolysis facility; (iii) a cracker facility; and (iv) a method comprising introducing the method into an energy generation / energy production facility.

[0025]

[0025] In one aspect, the present technology relates to a method for treating waste plastics, the method comprising: (a) withdrawing a solvolysis by-product stream from a solvolysis facility for treating PET-containing waste plastics; and (b) introducing at least a portion of the solvolysis by-product stream into at least one of the following: (i) a partial oxidation (POX) facility, (ii) a thermal cracking facility, (iii) a cracker facility, and (iv) an energy generation / energy production facility.

[0026]

[0026] In one aspect, the present technology relates to a method for treating waste plastics, comprising: (a) separating a mixed plastic waste (MPW) stream into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) subjecting at least a portion of the PET-rich stream to solvolysis in a solvolysis facility to form a major glycol product, a major terephthalyl product, and at least one by-product stream; and (c) introducing at least a portion of the solvolysis by-product stream from the solvolysis facility to at least one of the following: (i) a partial oxidation (POX) facility, (ii) a thermal cracking facility, (iii) a solidification facility, (iv) a cracker facility, and (v) an energy generation / energy production facility. [Brief explanation of the drawings]

[0027] [Figure 1]

[0027] FIG. 1 is a schematic block flow diagram illustrating the major steps of a chemical recycling facility in accordance with an embodiment of the present technology. [Figure 2]

[0028] FIG. 1 is a schematic block flow diagram illustrating the major steps of a solvolysis facility according to an embodiment of the present technology. [Figure 3]

[0029] FIG. 1 is a schematic block flow diagram illustrating the major steps of a methanolysis facility in accordance with an embodiment of the present technology. [Figure 4]

[0030] FIG. 1 is a schematic block flow diagram illustrating the major steps of a solidification facility in accordance with an embodiment of the present technology. [Figure 5]

[0031] FIG. 1 is a schematic block flow diagram illustrating the major steps of a pyrolysis facility in accordance with an embodiment of the present technology. [Figure 6]

[0032] 1 is a schematic block flow diagram illustrating the major steps of a cracking facility in accordance with an embodiment of the present technology; [Figure 7]

[0033] 1 is a schematic diagram of a cracker furnace constructed in accordance with an embodiment of the present technology; [Figure 8]

[0034] 1 is a schematic block flow diagram illustrating the major steps of a partial oxidation (POX) gasification facility in accordance with an embodiment of the present technology. [Figure 9]

[0035] FIG. 1 is a schematic block flow diagram illustrating the major steps of an energy generation / production facility in accordance with an embodiment of the present technology. DETAILED DESCRIPTION OF THE INVENTION

[0028]

[0036] Where a numerical sequence is given, each number is understood to be modified in the same way as the first or last number, and to be in an "or" relationship, i.e., each number is "at least" or "up to" or "less than," as the case may be. For example, "at least 10 weight percent, 20, 30, 40, 50, 75..." means "at least 10 weight percent, or at least 20 weight percent, or at least 30 weight percent, or at least 40 weight percent, or at least 50 weight percent, or at least 75 weight percent," etc.

[0029]

[0037] All concentrations or amounts are by weight unless otherwise stated. When used herein, the terms "containing" and "including" are open-ended and have the same meaning as "comprising."

[0030]

[0038] The weight percentages expressed for plastic mixed waste (MPW) are the weight of MPW as fed to the first stage of separation and before the addition of any diluents / solutions, such as salt or caustic solutions.

[0031]

[0039] References throughout this specification to MPW also provide support for particulate plastics or MPW particulates or size-reduced plastics or plastics feedstock to the separation process. For example, references to weight percentages of feedstock components in MPW also describe and provide support for the same weight percentages for particulate plastics or size-reduced plastics or plastics fed to the first stage of separation before combining them with the caustic or salt solution.

[0032]

[0040] Referring now to FIG. 1 , a schematic overview of a chemical recycling facility 10 for processing a stream 100 containing mixed plastic waste is shown. The chemical recycling facility 10 generally illustrated in FIG. 1 includes a pre-treatment facility 20 in combination with one or more of a solvolysis facility 30, a solidification facility 40, a partial oxidation (POX) gasification facility 50, a pyrolysis facility 60, a cracker facility 70, an energy generation / production facility 80, and a reuse (recycling) facility 90. While each of these facilities is shown inclusive, it should be understood that a chemical recycling facility according to embodiments of the present technology need not include all of the above facilities, but may include two or more, three or more, or four or more of these facilities. Chemical recycling facilities such as those described herein can be used to convert mixed plastic waste into recycled component products or chemical intermediates used to form various end-use materials.

[0033]

[0041] As used herein, the term "chemical recycling" refers to a waste plastic recycling process that involves chemically converting waste plastic polymers into lower molecular weight polymers, oligomers, monomers, and / or non-polymer molecules (e.g., hydrogen and carbon monoxide) that are useful in their own right and / or as feedstocks to another chemical production process(es). A "chemical recycling facility" is a facility for producing recycled component products through the chemical recycling of waste plastics. As used herein, the term "recycled component" is used herein either i) as a noun referring to a physical component (e.g., a compound, molecule, or atom) that is derived, at least in part, directly or indirectly from recycled waste, or ii) as an adjective modifying a particular composition (e.g., a compound, polymer, feedstock, product, or stream) that is derived, at least in part, directly or indirectly from recycled waste.

[0034]

[0042] As used herein, the term "directly derived" means having at least one physical component that originates from waste plastic, while "indirectly derived" means having a designated recycled component that i) originates from waste plastic, but ii) is not based on having a physical component that originates from waste plastic.

[0035]

[0043] Chemical recycling facilities are not physical recycling facilities. As used herein, the term "physical recycling" (also known as "mechanical recycling") refers to the process of melting waste plastics and converting the melted plastics into new intermediate products (e.g., pellets or sheets) and / or new final products (e.g., bottles). and forming a waste stream from a physical recycling facility. Generally, physical recycling does not change the chemical structure of the plastic being recycled. In one embodiment or any combination of the described embodiments, the chemical recycling facility described herein can be configured to receive and process waste streams from physical recycling facilities and / or waste streams that cannot normally be processed at physical recycling facilities.

[0036] Preliminary Treatment Facility

[0044] Referring again to FIG. 1 , mixed plastic waste stream 100 may initially be introduced into pre-treatment facility 20. As used herein, the term “waste plastic” refers to used, dismantled, and / or discarded plastic materials, such as polyethylene terephthalate (PET), polyolefin (PO), and / or polyvinyl chloride (PVC). As used herein, “mixed plastic waste” or MPW refers to post-industrial (or pre-consumer) plastics, post-consumer plastics, or mixtures thereof. Examples of plastic materials include, but are not limited to, polyester, one or more polyolefins (PO), and polyvinyl chloride (PVC). Furthermore, as used herein, “waste plastic” refers to any post-industrial (or pre-consumer) and post-consumer plastics, such as, but not limited to, polyester, polyolefin (PO), and / or polyvinyl chloride (PVC). In one or more embodiments, the waste plastic may also contain minor amounts of other plastic components (other than PET and polyolefins) that may collectively amount to less than 50 weight percent, less than 40 weight percent, less than 30 weight percent, less than 20 weight percent, less than 15 weight percent, or less than 10 weight percent of the total amount of waste plastic in stream 100, and optionally, may individually represent less than 30 weight percent, less than 20 weight percent, less than 15 weight percent, less than 10 weight percent, or less than 1 weight percent.

[0037]

[0045] Plastics suitable for processing at recycling facility 10 can include any organic synthetic polymer that is solid at 25°C and 1 atm. The polymer can be a thermoplastic or thermosetting polymer. The number average molecular weight (Mn) of the polymer can be at least 300, or at least 500, or at least 1000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000. The weight average molecular weight (Mw) of the polymer can be at least 300, or at least 500, or at least 1000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000, or at least 150,000, or at least 300,000.

[0038]

[0046] In one embodiment or in combination with any of the described embodiments, the MPW processed at recycling facility 10 can include, but is not limited to, plastic components, such as polyesters, including, for example, those having aromatic or cyclic repeating units, such as those containing terephthalate or naphthalate repeating units, e.g., polyethylene terephthalate (PET) and / or polyethylene naphthalate (PEN). As used herein, "PET" refers to a homopolymer of polyethylene terephthalate, or polyethylene terephthalate modified with a modifier, or It refers to polyethylene terephthalate containing residues or moieties other than ethylene glycol and terephthalic acid, such as isophthalic acid, diethylene glycol, TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanedimethanol), propylene glycol, isosorbide, 1,4-butanediol, 1,3-propanediol, and / or NPG (neopentyl glycol), or polyesters having terephthalate repeat units (and whether or not they contain repeat units based on ethylene glycol) and one or more residues or moieties of TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanedimethanol), propylene glycol, or NPG (neopentyl glycol), isosorbide, isophthalic acid, 1,4-butanediol, 1,3-propanediol, and / or diethylene glycol, or combinations thereof.

[0039]

[0047] Alternatively or additionally, the polyester can include furanate repeat units. While within the definition of PET provided herein, it is important to reiterate that polyesters suitable for processing in chemical recycling facility 10 also include terephthalate repeat units and polyesters containing TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanedimethanol), propylene glycol, or NPG (neopentyl glycol), isosorbide, isophthalic acid, 1,4-butanediol, 1,3-propanediol, and / or diethylene glycol, or combinations thereof, as well as aliphatic polyesters such as PLA, polyglycolic acid, polycaprolactone, and polyethylene adipate; polyolefins (e.g., low density polyethylene, high density polyethylene, low density polypropylene, high density polypropylene, crosslinked polyethylene, amorphous polyolefins, and copolymers of any one of the aforementioned polyolefins), polyvinyl chloride (PVC), polystyrene, polytetrafluoroethylene, acrylic butadiene styrene (ABS), cellulosics such as cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, cellulose acetate butyrate, and regenerated cellulose such as viscose; epoxides, polyamides, phenolics, polyacetals, polycarbonates, polyphenylene-based alloys, poly(methyl methacrylate), styrenic-containing polymers, polyurethanes, vinyl-based polymers, styrene-acrylonitrile, thermoplastic elastomers other than tires, and urea-containing polymers and melamine.

[0040]

[0048] In one embodiment or in combination with any of the described embodiments, the MPW introduced to chemical recycling facility 10 can contain a thermosetting polymer. Example amounts of thermosetting polymer present in the MPW can be at least 1 weight percent, or at least 2 weight percent, or at least 5 weight percent, or at least 10 weight percent, or at least 15 weight percent, or at least 20 weight percent, or at least 25 weight percent, or at least 30 weight percent, or at least 40 weight percent, based on the weight of the MPW.

[0041]

[0049] In one embodiment or in combination with any of the described embodiments, the MPW introduced into chemical recycling facility 10 contains plastics, at least a portion of which is cellulosic, e.g., derived from cellulose derivatives having an acyl substitution degree of less than 3, or between 1.8 and 2.8. Examples include cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, and cellulose acetate butyrate.

[0042]

[0050] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into the chemical recycling facility 10 comprises at least a portion of the MPW stream being terephthalate. Examples of suitable polymers include polymers having repeating units of the methyl group, such as polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, and plastics obtained from copolyesters thereof.

[0043]

[0051] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastics at least a portion of which is derived from copolyesters having multiple dicyclohexanedimethanol moieties, 2,2,4,4-tetramethyl-1,3-cyclobutanediol moieties, or combinations thereof.

[0044]

[0052] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastics, at least a portion of which is derived from low density polyethylene, high density polyethylene, linear low density polyethylene, polypropylene, polymethylpentene, polybutene-1, and copolymers thereof.

[0045]

[0053] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastics, at least a portion of which are derived from eyeglass frames or cross-linked polyethylene.

[0046]

[0054] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastics, at least a portion of which is obtained from plastic bottles.

[0047]

[0055] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastics, at least a portion of which is derived from diapers.

[0048]

[0056] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains at least a portion of Styrofoam, or a plastic derived from expanded polystyrene.

[0049]

[0057] In one embodiment or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastic, at least a portion of which is derived from flash-spun high density polyethylene.

[0050]

[0058] In one embodiment, or in combination with any of the described embodiments, the MPW stream introduced into chemical recycling facility 10 contains plastics having or derived from plastics having Resin ID Code numbers 1-7 within the chasing arrow triangle established by SPI. In one embodiment, or in combination with any of the described embodiments, at least a portion of the MPW contains one or more plastics that are not typically mechanically recycled. These include plastics having numbers 3 (polyvinyl chloride), 5 (polypropylene), 6 (polystyrene), and 7 (other). In one embodiment, or in combination with any of the described embodiments, the MPW contains at least 0.1 weight percent, or at least 0.5 weight percent, or at least 1 weight percent, or at least 2 weight percent, or at least 3 weight percent, or at least 5 weight percent, or at least 7 weight percent, or at least 10 weight percent, or at least 12 weight percent, or at least 15 weight percent, or at least 20 weight percent, or at least 25 weight percent, based on the weight of plastics in the MPW. or at least 30 weight percent, or at least 40 weight percent, or at least 50 weight percent or more, or at least 65 weight percent, or at least 85 weight percent, or at least 90 weight percent of plastics having or corresponding to the numbers 3, 5, 6, 7, or combinations thereof.

[0051]

[0059] In one embodiment or in combination with any of the described embodiments, the MPW comprises at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent plastics having or derived from at least one, at least two, at least three, or at least four different types of Resin ID Codes.

[0052]

[0060] The MPW introduced into the chemical recycling facility 10 may contain recycled textiles. Textiles may include natural and / or synthetic fibers, rovings, yarns, nonwoven webs, fabrics, and products made from or containing any of the above-mentioned items. Textiles can be woven, knitted, knotted, sewn, or tufted, and may include compressed fibers, such as felt, embroidered, laced, crocheted, or braided, or may include nonwoven webs and materials. Textiles may include fabrics and fibers separated from textiles, or fibers, disassembled or non-standard fibers, or other products containing yarns or fabrics, or any other source of loose fibers and yarns. Textiles may also include staple fibers, continuous fibers, yarns, tow bands, twisted and / or spun yarns, greige fabrics made from yarns, processed fabrics produced by wet processing of greige fabrics, and garments made from processed fabrics or any other fabrics. Textiles include garments, interior furnishing materials, and industrial-type textiles. The textiles may include pre-consumer textiles or post-consumer textiles or both.

[0053]

[0061] In one embodiment or in combination with any of the described embodiments, textiles can include apparel, which can be generally defined as clothing worn by or made for the human body. Such textiles can include sport coats, suits, trousers and casual or work pants, shirts, socks, sportswear, dresses, underwear, outerwear such as rain jackets, winter jackets and coats, sweaters, protective clothing, uniforms, and accessories such as scarves, hats, and gloves. Examples of textiles in the interior materials category include upholstery and slipcovers, carpets and rugs, curtains, bedding such as sheets, pillowcases, duvets, comforters, mattress covers; linens, tablecloths, towels, washcloths, and blankets. Examples of technical textiles include transportation (automobile, airplane, train, bus) seats, floor mats, trunk liners, and ceilings; outdoor furniture and cushions, tents, backpacks, luggage, ropes, conveyor belts, calender roll felts, abrasive cloths, rugs, soil erosion control fabrics and geotextiles, agricultural mats and screens, personal protective equipment, bulletproof vests, medical bandages, sutures, tape, and the like.

[0054]

[0062] Nonwoven webs classified as textiles do not include the category of wet-laid nonwoven webs and articles made therefrom. Although various articles having the same function can be made from dry-laid or wet-laid processes, articles made from dry-laid nonwoven webs are classified as textiles. Examples of suitable articles that can be formed from dry-laid nonwoven webs as described herein include personal protective equipment. These nonwoven webs can include articles for commercial, consumer, industrial, food service, medical, and other end uses. Specific examples include, but are not limited to, neonatal wipes, flushable wipes, disposable diapers, training pants, feminine hygiene products such as sanitary napkins and tampons, adult incontinence pads, underwear, or briefs, and pet training pads. Other examples include a variety of different dry or wet wipes, including those for consumer (e.g., personal care or household) and industrial (e.g., food service, healthcare, or professional) uses. Nonwoven webs can also be used as pillow pads, mattresses, and upholstery, as well as filling for quilts and comforters. In the medical and industrial fields, the nonwoven webs of the present invention can be used in consumer, medical, and industrial face masks, protective clothing, caps, and shoe covers, disposable sheets, surgical gowns, drapes, bandages, and medical dressings.

[0055]

[0063] Additionally, nonwoven webs as described herein can be used in environmentally friendly fabrics, such as geotextiles and tarps, oil and chemical absorbent pads, and building materials, such as sound or heat insulation, tents, lumber and soil covers and sheeting. Nonwoven webs can also be used in other consumer end uses, such as carpet backing, packaging for consumer, industrial, and agricultural products, thermal or sound insulation, and various types of apparel.

[0056]

[0064] Drylaid nonwoven webs as described herein can also be used for a variety of filtering applications, including transportation (e.g., automotive or aviation), commercial, residential, industrial, or other specialty applications. Examples include filter elements for consumer or industrial air or liquid filters (e.g., gasoline, oil, water), including nanofiber webs used for microfiltration, as well as end uses such as tea bags, coffee filters, and dryer sheets. Furthermore, nonwoven webs as described herein can be used to form various components for use in automobiles, including, but not limited to, brake pads, trunk liners, carpet tufting, and underpads.

[0057]

[0065] A woven fabric can include one or more types of natural fibers and / or one or more types of synthetic fibers. Examples of fiber combinations for a woven fabric include all natural, all synthetic, two or more types of natural fibers, two or more types of synthetic fibers, one type of natural fiber and one type of synthetic fiber, one type of natural fiber and two or more types of synthetic fibers, two or more types of natural fibers and one type of synthetic fiber, and two or more types of natural fibers and two or more types of synthetic fibers.

[0058]

[0066] Natural fibers include those of plant or animal origin. Natural fibers can be cellulosic, hemicellulose, and lignin. Examples of natural fibers of plant origin include hardwood pulp, softwood pulp, and wood flour, as well as other plant fibers, including wheat straw, rice straw, abaca, coir, cotton, flax, hemp, jute, bagasse, papyrus, ramie, rattan, vines, kenaf, abaca, henequen, sisal, soybean, grain straw, bamboo, reed, espermum gracilis, bagasse, saba grass, milkweed floss fiber, pineapple leaf fiber, switchgrass, and lignin-containing plants. Examples of fibers of animal origin include wool, silk, mohair, cashmere, goat hair, horse hair, bird fiber, camel hair, angora wool, and alpaca wool.

[0059]

[0067] Synthetic fibers are fibers that have been at least partially synthesized or derivatized through chemical reaction or that have been regenerated, including, but not limited to, rayon, viscose, mercerized fibers, or other types of regenerated cellulose (a soluble form of natural cellulose). and subsequent regeneration) of fibers such as lyocell (also known as TENCEL™), Cupro, Modal, acetates such as polyvinyl acetate, polyamides including nylon, polyesters such as PET, olefin polymers such as polypropylene and polyethylene, polycarbonates, polysulfones, polyethers such as polyether ureas known as Spandex or elastane, polyacrylates, acrylonitrile copolymers, polyvinyl chloride (PVC), polylactic acid, polyglycolic acid, sulfopolyester fibers, and combinations thereof.

[0060]

[0068] The textile may be in any of the forms described above and may be subjected to one or more pre-treatment steps in pre-treatment facility 20 before being processed in the remaining zones of chemical treatment facility 10 shown in FIG. 1. Examples of pre-treatment steps include, but are not limited to, size reduction via comminuted, chopped, crushed, powdered, pulverized, or cutting of the textile feedstock to produce a reduced-size textile. The textile may also be densified. Examples of densification processes include agglomerating the textile or particles produced by extrusion through heat generated by frictional forces, or applying other external heat to the textile to soften or melt some or all of the textile.

[0061]

[0069] In one embodiment or in combination with any of the described embodiments, the amount of textile (including textile fibers) in the MPW stream in line 100 is at least 0.1 weight percent, or at least 0.5 weight percent, or at least 1 weight percent, or at least 2 weight percent, or at least 5 weight percent, or at least 8 weight percent, or at least 10 weight percent, or at least 15 weight percent, or at least 20 weight percent material derived from textile or textile fibers, based on the weight of the MPW. In one embodiment or in combination with any of the described embodiments, the amount of textile (including textile fibers) in the MPW in stream 100 is 50 weight percent or less, 40 weight percent or less, 30 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 8 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less, 0.5 weight percent or less, 0.1 weight percent or less, 0.05 weight percent or less, 0.01 weight percent or less, or 0.001 weight percent or less, based on the weight of MPW stream 100. The amount of textile in MPW stream 100 can range from 0.1 to 50 weight percent, from 5 to 40 weight percent, or from 10 to 30 weight percent, based on the total weight of MPW stream 100.

[0062]

[0070] In one embodiment, or in combination with any of the described embodiments, the mixed plastic waste introduced into chemical recycling facility 10 (or into any of the subsequent processing facilities within chemical recycling facility 10) may include one or more inert ingredients that are typically present as additives in at least a portion of the mixed plastic waste. For example, such inert ingredients may be particularly present in plastics when they include textiles as described herein. Examples of such inert ingredients may include, but are not limited to, calcium carbonate, sand, titanium dioxide, and other hard, crystalline solids that are insoluble in water or other aqueous solvents.

[0063]

[0071] In one embodiment, or in combination with any of the described embodiments, the amount of inert ingredients present in the feedstream to chemical recycling facility 10 (or to any one of the facilities within chemical recycling facility 10) is at least 0.001 weight percent, at least 0.0025 weight percent, at least 0.005 weight percent, at least 0.0075 weight percent, at least 0.010 weight percent, at least 0.025 weight percent, at least 0.05 weight percent, based on the total weight of the feedstream. The amount of inerts present in the feed stream 100 to the chemical recycling facility 10 can be in the range of 0.002 to 0.5 weight percent, 0.005 to 0.40 weight percent, or 0.100 to 0.25 weight percent, based on the total weight of the stream 100.

[0064]

[0072] Alternatively, or in addition, the amount of inert components present in the feed stream to chemical recycling facility 10 (or to any one of the facilities within chemical recycling facility 10) can be at least 0.35 weight percent, at least 0.40 weight percent, at least 0.45 weight percent, at least 0.50 weight percent, at least 0.55 weight percent, at least 0.60 weight percent, at least 0.65 weight percent, at least 0.70 weight percent, or at least 0.75 weight percent, based on the total weight of the stream, and / or 3 weight percent or less, 2.5 weight percent or less, 2 weight percent or less, 1.5 weight percent or less, 1 weight percent or less, 0.75 weight percent or less, 0.60 weight percent or less, 0.55 weight percent or less, or 0.50 weight percent or less. The amount of inert components in feed stream 100 can range from 0.35 to 3 weight percent, 0.40 to 2.5 weight percent, or 0.50 to 2 weight percent, based on the total weight of feed stream 100. The mixed plastic waste feedstream 100 introduced into the chemical recycling facility 10 may include post-consumer and / or post-industrial (pre-consumer) plastic materials. As previously discussed, such plastics may include polyethylene terephthalate (PET), polyolefins (PO), and / or polyvinyl chloride (PVC).In one embodiment or in combination with any of the described embodiments, PET and PO, combined, constitute at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent of the mixed plastic waste, based on the total weight of the MPW, while PVC can constitute at least 0.001 weight percent, at least 0.01 weight percent, at least 0.05 weight percent, at least 0.1 weight percent, at least 0.25 weight percent, or at least 0.5 weight percent, and / or 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less, 0.75 weight percent or less, or 0.5 weight percent or less. The amount of PVC in the mixed plastic waste can range from 0.001 to 5 weight percent, 0.01 to 3 weight percent, or 0.1 to 2 weight percent, based on the total weight of the MPW stream 100.

[0065]

[0073] In one embodiment or in combination with any of the described embodiments, the mixed plastic waste comprises at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent PET, based on the total weight of the MPW stream or composition. may include:

[0066]

[0074] In one embodiment or in combination with any of the described embodiments, the mixed plastic waste can comprise at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, and / or no more than 75 weight percent, no more than 70 weight percent, no more than 65 weight percent, no more than 60 weight percent, no more than 55 weight percent, no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, or no more than 35 weight percent polyolefin (PO), based on the total weight of the MPW. The amount of PO in MPW stream 100 can range from 5 to 75 weight percent, 10 to 60 weight percent, or 20 to 35 weight percent, based on the total weight of stream 100.

[0067]

[0075] In one embodiment or in combination with any of the described embodiments, the MPW comprises a multicomponent polymer. As used herein, the term "multicomponent polymer" refers to an article and / or particulate comprising at least one synthetic or natural polymer combined with, attached to, or otherwise physically and / or chemically bonded to at least one other polymer and / or non-polymeric solid. The polymer can be a synthetic polymer or plastic, such as PET, olefin, and / or nylon. The non-polymeric solid can be a metal, such as aluminum. The multicomponent polymer can include a metallized plastic.

[0068]

[0076] In one embodiment or in combination with any of the described embodiments, the MPW comprises a multicomponent plastic in the form of a multilayer polymer. As used herein, the term "multilayer polymer" refers to a multicomponent polymer comprising PET and at least one other polymer and / or non-polymeric solid physically and / or chemically bonded together in two or more physically distinct layers. A polymer or plastic is considered a multilayered polymer even though a transition zone may exist between two layers, for example, in adhesively bonded or coextruded layers. The adhesive between two layers is not considered a layer. A multilayer polymer may include a layer comprising PET and one or more additional layers, at least one of which is a synthetic or natural polymer different from PET, or a polymer without ethylene terephthalate repeat units, or a polymer without alkylene terephthalate repeat units (a "non-PET polymer layer"), or another non-polymeric solid.

[0069]

[0077] Examples of non-PET polymer layers include nylon, polylactic acid, polyolefin, polycarbonate, ethylene vinyl alcohol, polyvinyl alcohol, and / or other plastics or plastic films bonded to PET-containing articles and / or particulates, as well as natural polymers such as whey protein. Multilayer polymers can include metal layers, such as aluminum, provided there is at least one additional polymer layer other than the PET layer. The layers may be adhered by adhesive or other means, physically adjacent (i.e., articles compressed against the film), tackified (i.e., plastics heated and stuck together), coextruded plastic films, or otherwise affixed to the PET-containing article. Multilayer polymers can include PET films bonded to articles containing other plastics in the same or similar manner. MPWs can include multicomponent polymers combining PET and at least one other plastic, such as polyolefins (e.g., polypropylene) and / or other synthetic or natural polymers, in a single physical phase. For example, MPWs can include a compatibilizer, PET, and at least one other synthetic or natural polymer. or natural polymer plastics (e.g., non-PET plastics) combined in a single physical phase. As used herein, the term "compatibilizer" refers to an agent capable of combining at least two otherwise immiscible polymers together in a physical mixture (i.e., a blend).

[0070]

[0078] In one embodiment, or in combination with any of the described embodiments, the MPW comprises 20 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.1 weight percent or less nylon, based on the dry-laid plastic. In one embodiment, or in combination with any of the described embodiments, the MPW comprises 0.01 to 20 weight percent, 0.05 to 10 weight percent, 0.1 to 5 weight percent, or 1 to 2 weight percent nylon, based on the dry-laid plastic.

[0071]

[0079] In one embodiment or in combination with any of the described embodiments, the MPW comprises 40 weight percent or less, 20 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of a multi-component plastic, based on the dry-laid plastic. In one embodiment or in combination with any of the described embodiments, the MPW comprises 0.1 to 40 weight percent, 1 to 20 weight percent, or 2 to 10 weight percent of a multi-component plastic, based on the dry-laid plastic. In one embodiment or in combination with any of the described embodiments, the MPW comprises 40 weight percent or less, 20 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of a multi-layer plastic, based on the dry-laid plastic. In one embodiment or in combination with any of the described embodiments, the MPW comprises 0.1 to 40 weight percent, 1 to 20 weight percent, or 2 to 10 weight percent of a multi-layer plastic, based on the dry-laid plastic.

[0072]

[0080] The plastic mixed waste can also include non-plastic solids, such as dirt, fillers, rocks, sand, food, cellulosics, such as paper and cardboard, and glass, which can comprise at least 0.1 weight percent, at least 1 weight percent, at least 2 weight percent, at least 4 weight percent, at least 5 weight percent, at least 6 weight percent, and / or no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 8 weight percent, no more than 5 weight percent, no more than 2.5 weight percent, or no more than 2 weight percent of the plastic mixed waste, based on the total weight of the MPW. The amount of non-plastic solids in the MPW feed stream 100 can range from 0.1 to 25 weight percent, 1 to 20 weight percent, or 2 to 8 weight percent, based on the total weight of the MPW stream 100.

[0073]

[0081] In one embodiment, or in combination with any of the described embodiments, the MPW may comprise at least 0.01 weight percent, at least 0.1 weight percent, at least 0.5 weight percent, or at least 1 weight percent, and / or no more than 25 weight percent, no more than 20 weight percent, no more than 25 weight percent, no more than 10 weight percent, no more than 5 weight percent, or no more than 2.5 weight percent liquid, based on the total weight of the MPW stream or composition. The amount of liquid in the MPW can range from 0.01 to 25 weight percent, 0.5 to 10 weight percent, or 1 to 5 weight percent, based on the total weight of the MPW stream 100.

[0074]

[0082] The mixed plastic waste may include plastics that are not classified as #3 to #7 plastics. In one embodiment or in combination with any of the described embodiments, The total amount of plastics in the MPW that are not classified as #3-#7 plastics can be at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, or at least 75 weight percent, and / or 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, or 35 weight percent or less, based on the total weight of the MPW stream. The total amount of plastics in the MPW that are not classified as #3-#7 plastics can range from 5 to 95 weight percent, 20 to 80 weight percent, or 25 to 75 weight percent, based on the total weight of the stream.

[0075]

[0083] The incoming plastic mixed waste (or pre-treated plastic stream withdrawn from pre-treatment facility 20) may be in several forms, including, but not limited to, whole articles or particulates that have been shredded, pelletized, or formed into fibers. As used herein, the term "plastic mixed waste particulates" or "MPW particulates" refers to plastic mixed waste having an average particle diameter of less than 2.54 cm (1 inch). MPW particulates can include, for example, chopped or shredded, shredded plastic particles, or plastic pellets. When whole or nearly whole articles are introduced into pre-treatment facility 20, one or more shredding or pelletizing steps can be used therein to convert the MPW into plastic mixed waste particulates. Alternatively, or in addition, at least a portion of the plastic mixed waste introduced into pre-treatment facility 20 may already be in particulate form.

[0076]

[0084] In one embodiment, or in combination with any of the described embodiments, the MPW feedstock comprises 20 weight percent or less, 15 weight percent or less, 12 weight percent or less, 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less of biowaste materials, based on 100 weight percent of the total weight of the MPW feedstock on a dry basis. In one embodiment, or in combination with any of the described embodiments, the MPW feedstock comprises 0.01 to 20 weight percent, 0.1 to 10 weight percent, 0.2 to 5 weight percent, or 0.5 to 1 weight percent of biowaste materials, based on 100 weight percent of the total weight of the MPW feedstock on a dry basis. As used herein, the term "biological waste" refers to materials of living organisms or organic origin. Exemplary biowaste materials include, but are not limited to, cotton, wood, sawdust, food waste, animals and animal parts, plants and plant parts, and manure.

[0077]

[0085] In one embodiment, or in combination with any of the described embodiments, the MPW feedstock comprises 20 weight percent or less, 15 weight percent or less, 12 weight percent or less, 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less manufactured cellulosic products, based on 100 weight percent of the total weight of the MPW feedstock on a dry basis. In one embodiment, or in combination with any of the described embodiments, the MPW feedstock comprises 0.01 to 20 weight percent, 0.1 to 10 weight percent, based on 100 weight percent of the total weight of the MPW feedstock on a dry basis. The term "manufactured cellulose products" as used herein refers to non-natural (i.e., man-made or machine-made) articles containing cellulosic fibers, and scrap thereof. Exemplary manufactured cellulose products include, but are not limited to, paper and cardboard.

[0078]

[0086] As noted above, in one embodiment, or in combination with any of the described embodiments, the MPW may contain non-plastic solids. In one embodiment, or in combination with any of the described embodiments, a separate separation process to remove the non-plastic solids from the MPW is not required or included. However, in one embodiment, or in combination with any of the described embodiments, at least a portion of the non-plastic solids in the MPW may be separated before the MPW feedstock is fed to the separation process(es), particularly the initial density separation stage. Nevertheless, in one embodiment, or in combination with any of the described embodiments, the MPW feedstock contains 20 weight percent or less, 15 weight percent or less, 12 weight percent or less, 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less of non-plastic solids, based on 100 weight percent of the total weight of the MPW feedstock on a dry basis. In one embodiment or in combination with any of the described embodiments, the MPW feedstock comprises 0.01 to 20 weight percent, 0.1 to 10 weight percent, 0.2 to 5 weight percent, or 0.5 to 1 weight percent non-plastic solids, based on 100 weight percent total weight of the MPW feedstock on a dry basis.

[0079]

[0087] Once introduced into the pre-treatment facility 20, the mixed plastic waste may be prepared for chemical recycling through one or more steps. As used herein, the term "pre-treatment" refers to preparing the waste plastic for chemical recycling using one or more of the following steps: (i) shredding, (ii) pulverizing, (iii) washing, (iv) drying, and / or (v) separating. As used herein, the term "pre-treatment facility" refers to a facility that includes all the equipment, lines, and controls required to pre-treat the waste plastic. Pre-treatment facilities as described herein can utilize any suitable method for carrying out the preparation of mixed plastic waste for chemical recycling.

[0080]

[0088] In one embodiment, or in combination with any of the described embodiments, the pre-treatment facility 20 shown in Figure 1 can include a separation zone (not shown) for separating the mixed plastic waste into two or more streams rich in a particular type of plastic. For example, the separation zone can separate the mixed plastic waste into a PET-rich stream 102 and a PO-rich stream 104, as generally shown in Figure 1. Additionally, non-plastic, non-soluble components 105a and non-plastic soluble components 105b streams can also be removed from the pre-treatment facility 20 and routed to various locations within or outside the chemical recycling facility 10.

[0081]

[0089] Examples of suitable types of separation techniques that can be used in separation facility 20 of chemical recycling facility 10 include mechanical separation and density separation, which may include sedimentation flotation and / or centrifugal density separation. As used herein, the term "sedimentation flotation" refers to a density separation process in which separation of materials is primarily caused by floating or settling a selected liquid medium, while the term "centrifugal density separation" refers to a density separation process in which separation of materials is primarily caused by centrifugal forces. Generally, the term "density separation process" refers to a process in which separation of materials is primarily caused, at least in part, by centrifugal forces. refers to a process for separating material based on its density into at least a higher density product and a lower density product.

[0082]

[0090] If a sedimentation / flotation method is used in the preliminary treatment facility 20, the liquid medium can include water. For example, salts, sugars, and / or other additives can be added to the liquid medium to increase the density of the liquid medium and adjust the target separation density for the sedimentation / flotation separation stage. In one embodiment, or in combination with any of the described embodiments, the liquid medium includes a concentrated salt solution. In one or more such embodiments, the salt is sodium chloride. However, in one or more other embodiments, the salt is a non-halogenated salt, such as acetate, carbonate, citrate, nitrate, nitrite, phosphate, and / or sulfate.

[0083]

[0091] It should be understood that the target separation density referenced herein refers to the target plastic density as opposed to the density of the salt-enriched solution used in the separation process, which may or may not be the same as the target separation density for the plastic material. For example, in a typical settling / flotation separation stage, the densities of the plastic and salt-enriched solution are the same or substantially the same. However, in a typical hydrocyclone separation stage, the density of the salt-enriched solution is generally equal to or less than the target plastic density, although the density of the salt-enriched solution may be lower than the target plastic density. In one embodiment, or in combination with any of the described embodiments, the hydrocyclone separator is configured to separate plastics with a density of 1.25 to 1.35 g / cm. 3 (1.25-1.35g / cc) and a salt-concentrated solution with a target plastic separation density of 1.25-1.35g / cm 3 (1.25-1.35 g / cc). Such embodiments generally allow for higher PET purity, but result in significant yield losses. In one embodiment, or in combination with any of the described embodiments, the hydrocyclone separator is used at a 1.00-1.20 g / cc concentration. 3 (1.00~1.20g / cc), or 1.10~g / cm 3 Salt-concentrated solution with a density of (1.10-g / cc) and target plastic separation density of 1.25-1.35 g / cm 3 (1.25-1.35 g / cc). Such embodiments generally result in lower PET purity, but higher PET yields.

[0084]

[0092] In one embodiment, or in combination with any of the described embodiments, the liquid medium comprises a concentrated salt solution containing sodium bromide, sodium dihydrogen phosphate, sodium hydroxide, sodium iodide, sodium nitrate, sodium thiosulfate, potassium acetate, potassium bromide, potassium carbonate, potassium hydroxide, potassium iodide, calcium chloride, cesium chloride, iron chloride, strontium chloride, zinc chloride, manganese sulfate, zinc sulfate, and / or silver nitrate. In one embodiment, or in combination with any of the described embodiments, the liquid medium comprises a sugar, e.g., sucrose. In one embodiment, or in combination with any of the described embodiments, the liquid medium comprises carbon tetrachloride, chloroform, dichlorobenzene, dimethyl sulfate, and / or trichloroethylene. The specific components and concentrations of the liquid medium can be selected depending on the desired target separation density of the separation stage.

[0085]

[0093] In one embodiment, or in combination with any of the described embodiments, after separation in pre-treatment facility 20, the separated waste plastic stream (or, in one embodiment, or in combination with any of the described embodiments, the mixed plastic waste stream) may optionally be washed to remove inorganic, non-plastic solids, such as dirt, glass, fillers, and other non-plastic solids, and / or to remove biological elements, such as bacteria and / or food. The resulting waste plastic (whether separated or not) may also be dried to a moisture content of 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less, 0.5 weight percent or less, 0.25 weight percent or less water (or liquid), based on the total weight of the stream.

[0086]

[0094] Also shown in FIG. 1, a stream of non-plastic components 105 may be withdrawn from pre-treatment facility 20. Non-plastic component stream 105 may include soluble and non-soluble components and may originate from one or more locations within the pre-treatment facility. A soluble component may be one that is substantially soluble in water, e.g., has a solubility of at least 50 g, at least 55 g, at least 60 g, at least 65 g, at least 70 g, at least 75 g, at least 80 g, at least 85 g, at least 90 g, at least 95 g, or at least 99 g per 100 grams of water, measured at 25° C. and 1 atm (1 atm) pressure. Examples of soluble components include, but are not limited to, salts, sugars, and combinations thereof.

[0087]

[0095] 1, after separation in preliminary treatment facility 20, a stream of non-plastic, soluble components 105b can be withdrawn from facility 20 and routed to a wastewater treatment facility (not shown). The stream of non-plastic, soluble components 105b can include at least 1 weight percent, at least 2 weight percent, at least 3 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, and / or no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 7 weight percent, or no more than 5 weight percent soluble, non-plastic components, based on the total weight of the stream. The water stream of non-plastic, soluble components 105b can include soluble, non-plastic components in an amount ranging from 1 to 50 weight percent, 2 to 45 weight percent, or 5 to 25 weight percent, based on the total weight of the stream. The remainder of the stream can be or include water.

[0088]

[0096] 1, a stream of non-plastic, non-soluble components may also be withdrawn from pre-treatment facility 20 via line 105a. The non-plastic, non-soluble components withdrawn from pre-treatment facility 20 may include organic matter (e.g., food or cellulosic, such as paper or cardboard), as well as dirt, glass, metal, rock, TEFLON®, filled polyolefins such as polypropylene and polyethylene, silicon, and combinations thereof. At least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 75 weight percent, 70 weight percent, 60 weight percent, 55 weight percent, 50 weight percent, 45 weight percent, 40 weight percent, 35 weight percent, 30 weight percent, or 25 weight percent of the non-plastic, non-soluble components can comprise biomass or other organic matter, or the amount of non-plastic, non-soluble components can range from 5 to 75 weight percent, 10 to 60 weight percent, or 20 to 50 weight percent, based on the total weight of the stream.

[0089]

[0097] In one embodiment or combination with any of the described embodiments, the non-plastic, non-soluble components in stream 105b can comprise at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, or at least 80 weight percent, and / or no more than 95 weight percent, no more than 90 weight percent, no more than 85 weight percent, no more than 80 weight percent, no more than 75 weight percent, no more than 70 weight percent, or no more than 65 weight percent metal, based on the total weight of the stream; or the non-plastic, non-soluble components can comprise 45-95 weight percent, 50-85 weight percent, Alternatively, the metal may be present in an amount ranging from 60 to 80 weight percent.

[0090]

[0098] In one embodiment or in combination with any of the described embodiments, non-plastic, non-soluble component stream 105b can include at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent organic compounds, based on the total weight of the stream. Additionally or in alternative embodiments, non-plastic, non-soluble component stream 105b can comprise 99 weight percent or less, 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, or 5 weight percent or less of organic compounds, based on the total weight of the stream, or the stream can comprise organic compounds in an amount between 5 and 95 weight percent, between 15 and 85 weight percent, between 25 and 75 weight percent, or between 30 and 50 weight percent, based on the total weight of the stream.

[0091]

[0099] In one embodiment or in combination with any of the described embodiments, non-plastic, non-soluble component stream 105b can include at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent inorganic compounds, based on the total weight of the stream. Additionally or alternatively, non-plastic, non-soluble component stream 105b can comprise 99 weight percent or less, 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, or 5 weight percent or less of inorganic compounds, based on the total weight of the stream, or stream 105b can comprise inorganic compounds in an amount of 5 to 80 weight percent, 10 to 60 weight percent, or 15 to 40 weight percent, based on the total weight of the stream. Examples of inorganic compounds include metals, metalloids (e.g., silicon), rock, dirt, glass, and combinations thereof.

[0092]

[0100] In one embodiment, or in combination with any of the described embodiments, the non-plastic, non-soluble stream 105a removed from the preliminary treatment facility 20 may be sent to a subsequent treatment facility where one or more types of constituents may be removed from the stream and further utilized. For example, in one embodiment, or in combination with any of the described embodiments, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent, at least 80 weight percent, at least 90 weight percent, at least 10 ... 0 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent of the non-plastic, non-soluble components in stream 105a may be further processed, recycled, and / or sold. For example, metal components may be removed and sold to a metals recycling facility (not shown). Alternatively, less than 20 weight percent, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 3 weight percent or less, or 1 weight percent or less of the non-plastic, non-soluble components may be further processed, recycled, and / or sold.

[0093]

[0101] In one embodiment, or in combination with any of the described embodiments, as shown in Figure 1, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the non-plastic, non-soluble components from pre-treatment facility 20 may be introduced into partial oxidation (POX) gasifier 50. Alternatively, less than 20 weight percent, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 3 weight percent or less, or 1 weight percent or less of the non-plastic, non-soluble components may be introduced into POX gasifier 50. In one embodiment, or in combination with any of the described embodiments, at least a portion of the components may be transported to an industrial landfill or other treatment facility (not shown).

[0094]

[0102] As generally shown in FIG. 1 , the PO-rich plastic stream 104 withdrawn from pre-treatment facility 20 (or a PO-rich waste plastic stream from an external source) can be routed to one or more of several facilities within chemical recycling facility 10. In one embodiment, or in combination with any of the described embodiments, at least a portion or all of the polyolefin-rich (PO-rich) plastic stream 104 may be sent directly or indirectly to at least one of: (i) a partial oxidation (POX) gasification facility 50, (ii) a pyrolysis facility 60, (iii) a cracker facility 70, (iv) an energy generation / production facility 80, and (v) a recycling facility 90. Various embodiments of each of these types of facilities are discussed below with reference to the figures, along with specific examples of how two or more of the above facilities may be integrated with each other within chemical recycling facility 10.

[0095]

[0103] In one or more embodiments, as previously described, the plastic mixed waste stream 100 may be separated into a PET-rich stream 102 and a PO-rich stream 104 within the preliminary treatment facility 20. As used herein, the term "rich" means having a concentration (on a dry weight basis) of a particular component that is higher than the concentration of that component in a reference material or stream. As used herein, all weight percentages are given on a dry weight basis unless otherwise specified. Thus, the PET-rich stream 102 of waste plastics formed within and / or withdrawn from the preliminary treatment facility 20 may have a higher PET concentration than the PET concentration in the mixed waste feed stream 100 introduced to the preliminary treatment facility 20. Similarly, the PO-rich waste plastics formed within and / or withdrawn from the preliminary treatment facility 20 may have a higher PET concentration than the PET concentration in the mixed waste feed stream 100 introduced to the preliminary treatment facility 20. The sticks stream 104 may have a higher PO concentration than the PO concentration in the plastic mixed waste stream 100 introduced into the pretreatment facility 20 .

[0096]

[0104] In one embodiment, the PET-rich stream 102 is enriched in PET concentration on an undiluted dry solids basis relative to the PET concentration in the MPW stream, or the PET-depleted stream, or both. For example, if the PET-rich stream 102 is diluted with liquid or other solids after separation, the enrichment is relative to the concentration in the undiluted PET-rich stream and is on a dry basis. In one embodiment, or in combination with any of the described embodiments, the PET-rich stream 102 is enriched in PET concentration relative to the PET concentration in the MPW stream, the PET-depleted stream, or both, based on the formula:

[0105]

[0097]

number

[0098] where PETe is the PET concentration in the PET-rich stream 102 on a neat dry weight basis; at least 10 percent, at least 20 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 80 percent, at least 100 percent, at least 125 percent, at least 150 percent, at least 175 percent, at least 200 percent, at least 225 percent, at least 250 percent, at least 300 percent, at least 350 percent, at least 400 percent, at least 500 percent, at least 600 percent, at least 700 percent, at least 800 percent, at least 900 percent, or at least 1000 percent enriched in PET as determined by (PETm is the PET concentration in the MPW stream on a dry weight basis, and PETd is the PET concentration in the PET-depleted stream on a dry weight basis).

[0099]

[0106] In one embodiment or in combination with any of the described embodiments, the PET-rich stream 102 is also enriched in halogens, e.g., fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, e.g., PVC, relative to the concentration of halogens in the MPW stream, or the PET-depleted stream, or both. In one embodiment or in combination with any of the described embodiments, the PET-rich stream 102 is enriched in halogens, e.g., fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, e.g., PVC, relative to the concentration of PVC in the MPW stream, by a ratio of:

[0100]

number

[0101] where PVCe is the PVC concentration in the PET-rich stream 102 on a neat dry weight basis; PVCm is the PVC concentration in the MPW stream on a neat dry weight basis; at least 1 percent, at least 3 percent, at least 5 percent, at least 7 percent, at least 10 percent, at least 15 percent, at least 20 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 80 percent, at least 100 percent, at least 125 percent, at least 150 percent, at least 175 percent, at least 200 percent, at least 225 percent, at least 250 percent, at least 300 percent, at least 350 percent, at least 400 percent, or at least 500 percent enriched in PVC concentration as determined by DIAS (where PVCd is the PVC concentration in the PET-depleted stream on an undiluted dry weight basis).

[0102]

[0107] Upon separation of the polyolefins from the PET, the PET-depleted stream is enriched in polyolefins on a neat dry solids basis relative to the polyolefin concentration in the MPW feedstock, or the PET-rich stream, or both. In one embodiment or in combination with any of the described embodiments, the PET-depleted stream is enriched in polyolefins relative to the polyolefin concentration in the MPW stream, or relative to the PET-rich stream 102, or both, based on the formula:

[0103]

number

[0104] where POd is the polyolefin concentration in the PET-depleted stream on a neat dry weight basis; POm is the concentration of PO in the MPW stream on a dry weight basis; at least 10 percent, at least 20 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 80 percent, at least 100 percent, at least 125 percent, at least 150 percent, at least 175 percent, at least 200 percent, at least 225 percent, at least 250 percent, at least 300 percent, at least 350 percent, at least 400 percent, at least 500 percent, at least 600 percent, at least 700 percent, at least 800 percent, at least 900 percent, at least 100 percent, at least 125 percent, at least 150 percent, at least 175 percent, at least 200 percent, at least 225 percent, at least 250 percent, at least 300 percent, at least 350 percent, at least 400 percent, at least 500 percent, at least 600 percent, at least 700 percent, at least 8 ...100 percent, at least 100 percent, at least 10 0 percent, at least 900 percent, or at least 1000 percent abundant.

[0105]

[0108] In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream is also depleted in halogens, such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, such as PVC, relative to the concentration of halogens in the MPW stream, the PET-rich stream, or both. In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream is depleted in halogens, such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, such as PVC, relative to the concentration of PVC in the MPW stream, the PET-rich stream 102, or both, by the formula:

[0106]

number

[0107] where PVCm is the PVC concentration in the MPW stream on a neat dry weight basis, PVCd is the PVC concentration in the PET-depleted stream on a neat dry weight basis, at least 1 percent, at least 3 percent, at least 5 percent, at least 7 percent, at least 10 percent, at least 15 percent, at least 20 percent, at least 25 percent, at least 30 percent, at least 35 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 65 percent, at least 70 percent, at least 75 percent, at least 80 percent, at least 85 percent, or at least 90 percent depleted in PVC concentration as determined by (PVCe is the PVC concentration in the PET-rich stream 102 on an undiluted dry weight basis).

[0108]

[0109] In one embodiment, or in combination with any other described embodiment, the PET-depleted stream is also depleted in PET relative to the PET concentration in the MPW stream, the PET-rich stream, or both. In one embodiment, or in combination with any described embodiment, the PET-depleted stream is depleted in PET relative to the PET concentration in the MPW stream or the PET-rich stream 102, or both, by the formula:

[0109]

number

[0110] where PETm is the PET concentration in the MPW stream on a neat dry weight basis, PETd is the PET concentration in the PET-depleted stream on a neat dry weight basis, At least 1 percent, at least 3 percent, at least 5 percent, at least 7 percent, at least 10 percent, at least 15 percent, at least 20 percent, at least 25 percent, at least 30 percent, at least 35 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 65 percent, at least 70 percent, at least 75 percent, at least 80 percent, at least 85 percent, or at least 90 percent depleted in PET concentration as determined by (PETe is the PET concentration in the PET-rich stream 102 on an undiluted dry weight basis).

[0111] The percentage of enrichment or depletion in any of the above embodiments can be measured as an average over a week, or over three days, or over a day, and measurements can be made to take into account the residence time of the MPW flowing from the inlet to the outlet so that samples taken at the outlet of the process reasonably correlate to the bulk of the MPW from which the MPW sample is taken. For example, if the average residence time of the MPW in the pre-treatment facility 20 (or a separation zone within the pre-treatment facility 20) is two minutes, then the outlet sample is taken two minutes after the sample input so that the samples correlate to each other.

[0112] In one embodiment, or in combination with any of the described embodiments, the PET-rich stream 102 exiting the separation zone or preliminary treatment facility 20 can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, at least 97 weight percent, at least 99 weight percent, or at least 99.5 weight percent PET, based on the total weight of the PET-rich stream 102. The PET-rich stream 102 can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the total amount of PET introduced into the preliminary treatment facility 20.

[0113] PET-rich stream 102 may also be rich in PVC, and may contain, for example, at least 0.1 weight percent, at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 3 weight percent, at least 5 weight percent, and / or 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 3 weight percent or less of halogens including PVC, based on the total weight of PET-rich stream 102, or stream 102 may contain halogens (including PVC) in an amount of 0.1 to 10 weight percent, 0.5 to 6 weight percent, or 0.5 to 3 weight percent, based on the total weight of the stream.

[0114] The PET-rich stream 102 withdrawn from the preliminary treatment facility 20 (or separation zone) may also be depleted in PO. As used herein, the term "depleted" means having a concentration of a particular component (on a dry weight basis) that is lower than the concentration of that component in a reference material or stream. In one embodiment, or in combination with any of the described embodiments, the PET-rich stream 102 may have a concentration of PO of 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less, 0.5 weight percent or less, based on the total weight of the PET-rich stream 102. It may contain PO.

[0115]

[0114] However, it should be understood that the halogen concentration in the PET-rich stream (and PET-depleted stream) is based at least in part on the halogen content in the MPW feedstock, and thus even lower amounts of halogen may be present in the PET-rich stream. In one embodiment, or in combination with any of the described embodiments, PET-rich stream 20 contains, on a dry basis, 1000 ppm or less, 500 ppm or less, 100 ppm or less, 50 ppm or less, 15 ppm or less, 10 ppm or less, 5 ppm or less, or 1 ppm or less of halogen and / or halogen-containing compounds.

[0116] PET-rich stream 102 may comprise 10 weight percent or less, 8 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less of the total amount of PO introduced into pre-treatment facility 20. In one embodiment, or in combination with any of the described embodiments, PET-rich stream 102 may also comprise 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less of components other than PET, based on the total weight of PET-rich stream 102.

[0117] Similarly, PO-rich stream 104 can contain at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, at least 97 weight percent, at least 99 weight percent, or at least 99.5 weight percent PO, based on the total weight of PO-rich stream 104. PO-rich stream 104 can also be PVC-depleted, e.g., contain no more than 5 weight percent, no more than 4 weight percent, no more than 3 weight percent, no more than 2 weight percent, no more than 1 weight percent, no more than 0.5 weight percent, or no more than 0.1 weight percent halogen or PVC, based on the total weight of PO-rich stream 104. The PO-rich stream 104 can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the total amount of PO introduced into pre-treatment facility 20.

[0118] The PO-rich stream 104 withdrawn from preliminary treatment facility 20 may also be depleted in PET. For example, in one embodiment or in combination with any of the described embodiments, PO-rich stream 104 can contain no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent, or no more than 0.5 weight percent PET, based on the total weight of PO-rich stream 104.

[0119] The PO-rich stream 104 may comprise 10 weight percent or less, 8 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less of the total amount of PET introduced into the pre-treatment facility 20. In one embodiment or in combination with any of the described embodiments, the PO-rich stream The PO-rich stream 104 can also contain up to 45 weight percent, up to 40 weight percent, up to 35 weight percent, up to 30 weight percent, up to 25 weight percent, up to 20 weight percent, up to 15 weight percent, up to 10 weight percent, up to 5 weight percent, up to 2 weight percent, or up to 1 weight percent of components other than PO, based on the total weight of the PO-rich stream 104.

[0120] In one embodiment or in combination with any of the described embodiments, the PO-rich stream 104 also has the following characteristics: an ash content of not more than 5 weight percent, not more than 4.5 weight percent, not more than 4 weight percent, not more than 3.5 weight percent, not more than 3 weight percent, not more than 2.5 weight percent, not more than 2 weight percent, not more than 1.5 weight percent, not more than 1 weight percent, or not more than 0.5 weight percent; Halogen content of 250 ppm by weight or less, 225 ppm by weight or less, 200 ppm by weight or less, 175 ppm by weight or less, 150 ppm by weight or less, 125 ppm by weight or less, 100 ppm by weight or less, 75 ppm by weight or less, 50 ppm by weight or less, 25 ppm by weight or less, 10 ppm by weight or less, or 5 ppm by weight or less (on a dry basis); Nitrogen-containing compounds of 5 weight percent or less, 4.5 weight percent or less, 4 weight percent or less, 3.5 weight percent or less, 3 weight percent or less, 2.5 weight percent or less, 2 weight percent or less, 1.5 weight percent or less, 1 weight percent or less, 0.75 weight percent or less, 0.5 weight percent or less, 0.25 weight percent or less; oxygen-containing compounds of 5 weight percent or less, 4.5 weight percent or less, 4 weight percent or less, 3.5 weight percent or less, 3 weight percent or less, 2.5 weight percent or less, 2 weight percent or less, 1.5 weight percent or less, 1 weight percent or less, 0.75 weight percent or less, 0.5 weight percent or less, 0.25 weight percent or less; not more than 10 weight percent, not more than 8 weight percent, not more than 6 weight percent, not more than 4 weight percent, not more than 2 weight percent, not more than 1 weight percent, not more than 0.5 weight percent polyethylene terephthalate; Mercury content of 1 ppm or less, 0.75 ppm or less, 0.50 ppm or less, 0.25 ppm or less, 0.10 ppm or less, or 0.05 ppm or less; Arsenic content of 100 ppm or less, 75 ppm or less, 50 ppm or less, 25 ppm or less, 10 ppm or less, and 5 ppm or less a melt viscosity of less than 2,500 Pa·s (25,000 poise), less than 1,500 Pa·s (15,000 poise), less than 1,000 Pa·s (10,000 poise), or less than 500 Pa·s (5000 poise), or between 0.1 and 500 Pa·s (1 and 5000 poise), or between 500 and 300 Pa·s (500 and 3000 poise), as measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / s and a temperature of 250°C; and all weights are based on the total weight of the PO-rich stream 104. In one embodiment, or in combination with any of the described embodiments, the PO-rich stream 104 can include one, two, three, four, five, six, seven, or all of the above characteristics.

[0121] Ash content can be determined by thermally evaporating non-ash components and weighing the ash gravimetrically according to ASTM D5630-13. Halogen content can be determined via Uniquant X-ray fluorescence or combustion ion chromatography. Nitrogen-containing compounds can be measured using nitrogen analysis or a CHN analyzer. Mercury and arsenic content can be determined using ICP-OES.

[0122] In one embodiment or in combination with any of the described embodiments, the PO-rich stream 104 has a solubility of at least 0.1 Pa·s (1 poise), at least 0.5 Pa·s (1 poise), ·s (5 poise), at least 5 Pa·s (50 poise), at least 10 Pa·s (100 poise), at least 20 Pa·s (200 poise), at least 30 Pa·s (300 poise), at least 40 Pa·s (400 poise), at least 50 Pa·s (500 poise), at least 60 Pa·s (600 poise), at least 70 Pa·s (700 poise), at least 80 Pa·s (800 poise), at least 90 Pa·s (900 poise), at least 100 Pa·s (1000 poise), at least 150 Pa·s (1500 poise), at least 200 Pa·s (2000 poise), at least 250 Pa·s (2500 poise), at least 300 Pa·s (3000 poise), at least 3 50 Pa·s (3500 poise), at least 400 Pa·s (4000 poise), at least 450 Pa·s (4500 poise), at least 500 Pa·s (5000 poise), at least 550 Pa·s (5500 poise), at least 600 Pa·s (6000 poise), at least 650 Pa·s (6500 poise), at least 700 Pa·s (7 000 poise, at least 7500 poise, at least 8000 poise, at least 8500 poise, at least 9000 poise, at least 9500 poise, or at least 10,000 poise. Alternatively, or in addition, the PO-rich stream 104 may be melted using a Brookfield V80-40 vane spindle operating at a shear rate of 10 rad / sec and a temperature of 250°C. It may have a melt viscosity of 2,500 Pa·s (25,000 poise) or less, 2,400 Pa·s (24,000 poise) or less, 2,300 Pa·s (23,000 poise) or less, 2,200 Pa·s (22,000 poise) or less, 2,100 Pa·s (21,000 poise) or less, 2,000 Pa·s (20,000 poise) or less, 1,900 Pa·s (19,000 poise) or less, 1,800 Pa·s (18,000 poise) or less, or 1,700 Pa·s (17,000 poise) or less, as measured using an R / S rheometer.The melt viscosity of the PO-rich stream can range from 0.1 to 2,500 Pa·s (1 to 25,000 poise), 10 to 2,000 Pa·s (100 to 20,000 poise), or 200 to 1,700 Pa·s (2000 to 17,000 poise).

[0123]

[0122] In one embodiment or in combination with any of the described embodiments, the PO-rich stream 104 contains less than 4 weight percent, less than 2 weight percent, less than 1 weight percent, less than 0.5 weight percent, or less than 0.1 weight percent adhesive, based on the total weight of the stream.

[0124] In one embodiment, or in combination with any of the described embodiments, the treatment of the PET polymers in PET-rich stream 20 in a downstream chemical recycling process results in at least 50 weight percent, at least 75 weight percent, at least 90 weight percent, at least 95 weight percent, at least 99 weight percent, or at least 100 weight percent of the PVC in PET-rich stream 20 remaining in PET-rich stream 20. In one embodiment, or in combination with any of the described embodiments, the treatment of the PET polymers in PET-rich stream 20 in a downstream chemical recycling process results in 50-100 weight percent, or 75-99 weight percent, or 90-95 weight percent of the PVC in PET-rich stream 20 remaining in PET-rich stream 20.

[0125] In one embodiment, or in combination with any of the described embodiments, PET-rich stream 20 is depleted in multi-layer plastics relative to MPW 10, PET-depleted stream 30, or both. In one embodiment, or in combination with any of the described embodiments, PET-rich stream 20 has a dry basis content of 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less or 0.1 weight percent or less of multi-layer plastic. In one embodiment or in combination with any of the described embodiments, PET-rich stream 20 includes, on a dry basis, 0.01 to 10 weight percent, 0.05 to 5 weight percent, or 0.1 to 2 weight percent, or 0.5 to 1 weight percent of multi-layer plastic.

[0126] In one embodiment, or in combination with any of the described embodiments, the PET-rich stream 20 is depleted in multi-component plastics relative to the MPW 10, the PET-depleted stream 30, or both. In one embodiment, or in combination with any of the described embodiments, the PET-rich stream 20 comprises, on a dry basis, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.1 weight percent or less multi-component plastics. In one embodiment, or in combination with any of the described embodiments, the PET-rich stream 20 comprises, on a dry basis, 0.01 to 10 weight percent, 0.05 to 5 weight percent, or 0.1 to 2 weight percent, or 0.5 to 1 weight percent multi-component plastics.

[0127] As shown in FIG. 1 , both the PET-rich stream 102 and the PO-rich stream 104 may be introduced to one or more downstream processing facilities within a chemical recycling facility. In one embodiment, or in combination with any of the described embodiments, at least a portion of the PET-rich stream 102 may be introduced to the solvolysis facility 30, while at least a portion of the PO-rich stream 104 may be introduced directly or indirectly to one or more of the pyrolysis facility 60, cracking (cracker) facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, and energy generation / production facility 80. Alternatively, or in addition, all or a portion of the streams may be sent to an industrial landfill and / or further processed and / or sold. Additional details of each type of facility, as well as the integration of each of these facilities with one or more of the other facilities, are discussed in more detail below, in accordance with one or more embodiments of the present technology.

[0128] In one embodiment or in combination with any of the described embodiments, the pre-treatment step(s) and / or separation process(es) described herein are particularly effective in separating nylon and other plastics that are bonded to PET in the form of multi-layer plastics or other multi-component plastics. Regardless of the mode of bonding, the pre-treatment and / or separation process(es) can effectively debond and separate the nylon and / or other plastics from the PET, thereby increasing the efficiency of separation of these components.

[0129] In one embodiment, or in combination with any of the described embodiments, PET-rich stream 20 comprises, on a dry basis, 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less, 0.5 weight percent or less, or 0.1 weight percent or less of bound PET-nylon. In one embodiment, or in combination with any of the described embodiments, PET-rich stream 20 comprises, on a dry basis, 0.001 to 5 weight percent, 0.01 to 2 weight percent, or 0.1 to 1 weight percent of bound PET-nylon.

[0130] In one embodiment or in combination with any of the described embodiments, the PET-rich stream 20 comprises, on a dry basis, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of the MPW and / or MPW fed to the first separation stage. In one embodiment or in combination with any of the described embodiments, PET-rich stream 20 comprises, on a dry basis, 0.01 to 20 weight percent, 0.1 to 10 weight percent, or 1 to 5 weight percent of the MPW and / or bound PET-nylon present in the MPW feed stream fed to the first separation stage.

[0131] In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 is enriched in multilayer plastics relative to the MPW 10, the PET-rich stream 20, or both. However, in one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 is depleted in multilayer plastics relative to the MPW 10. In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 contains at least 0.001 weight percent, at least 0.01 weight percent, at least 0.1 weight percent, or at least 1 weight percent, and / or 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, or 4 weight percent or less, multilayer plastics, based on the dry plastics. In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 contains 0.001 to 10 weight percent, 0.01 to 8 weight percent, 0.1 to 6 weight percent, or 1 to 4 weight percent, multilayer plastics, based on the dry plastics. In one embodiment or in combination with any of the described embodiments, the weight ratio of the multi-layer plastic in the PET-depleted stream to the multi-layer plastic in the PET-rich stream is at least 1:1, at least 2:1, at least 5:1, at least 10:1, at least 50:1, or at least 100:1.

[0132] In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 is enriched in multicomponent plastics relative to the MPW 10, the PET-rich stream 20, or both. However, in one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 is depleted in multicomponent plastics relative to the MPW 10. In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 contains at least 0.001 weight percent, at least 0.01 weight percent, at least 0.1 weight percent, or at least 1 weight percent, and / or 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, or 4 weight percent or less multicomponent plastics, based on the dry plastics. In one embodiment, or in combination with any of the described embodiments, the PET-depleted stream 30 contains 0.001 to 10 weight percent, 0.01 to 8 weight percent, 0.1 to 6 weight percent, or 1 to 4 weight percent multicomponent plastics, based on the dry plastics. In one embodiment or in combination with any of the described embodiments, the weight ratio of multi-component plastics in the PET-depleted stream to multi-component plastics in the PET-rich stream is at least 1:1, at least 2:1, at least 5:1, at least 10:1, at least 50:1, or at least 100:1.

[0133] In one embodiment, or in combination with any of the described embodiments, the PO-rich stream 104 may be further processed in pre-treatment facility 20 before being routed to one or more downstream facilities. For example, at least a portion, or all, of the PO-rich stream 104 may optionally be pulverized and pelletized (or micropelletized), or all or a portion of the stream may be sent directly to one or more of the downstream facilities listed above. In one embodiment, or in combination with any of the described embodiments, all or a portion of the solids may be sent directly from the separation zone, either directly or after pulverization and / or pelletization, It may be combined with other solids or may be combined with a liquid to form a slurry.

[0134]

[0133] If milled, the PO-rich flakes from within the pre-treatment facility 20 can be passed through a mill where the flakes (or other solids) contact a number of cutting blades or disks to reduce the particle size of the incoming material. The number and size of the blades can be selected to achieve a desired final particle size. After size reduction, the resulting material can be screened to obtain a final solids stream having a specified particle size distribution.

[0135] If pelletized, the feedstream can also be introduced into a melt extruder, where it is heated and melted to form a molten polymer at a temperature of at least 240°C, at least 245°C, at least 250°C, at least 255°C, at least 260°C, and / or no greater than 310°C, no greater than 305°C, no greater than 300°C, no greater than 290°C, no greater than 280°C, no greater than 275°C, no greater than 270°C, no greater than 265°C, or no greater than 260°C. The molten polymer then passes through a die plate having multiple holes, and the resulting polymer strands are cut, optionally under water, to form pellets. The resulting pellets can have an average particle size, measured along their longest dimension, of at least 0.5 mm, at least 0.75 mm, at least 0.90 mm, at least 1 mm, at least 1.1 mm, at least 1.25 mm, and / or no greater than 2.25 mm, no greater than 2.1 mm, no greater than 2 mm, no greater than 1.75 mm, or no greater than 1.6 mm.

[0136]

[0135] Although described herein as part of a single chemical recycling facility 10, it should be understood that one or more of the pre-treatment facility 20, solvolysis facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, energy generation / production facility 80, and recycling facility 90 may be located in different geographic locations and / or operated by different commercial entities. In one embodiment, or in combination with any of the described embodiments, each of the pre-treatment facility 20, solvolysis facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, energy generation / production facility 80, and recycling facility 90 may be operated by the same entity, while in other cases, one or more of the pre-treatment facility 20, solvolysis facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, energy generation / production facility 80, and recycling facility 90 may be operated by different entities.

[0137] In one embodiment, or in combination with any of the described embodiments, the chemical recycling facility 10 may be an industrial-scale facility capable of processing significant quantities of mixed plastic waste. As used herein, the term "industrial-scale facility" refers to a facility that has an average annual feed rate of at least 500 pounds per hour, averaged over a year. In one embodiment, or in combination with any of the described embodiments, the average feed rate to the chemical recycling facility (or any one of the pre-treatment facility 20, solvolysis facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, energy generation / production facility 80, and reclaim facility 90) may be at least 1000 pounds per hour, at least 1500 pounds per hour, at least 2000 pounds per hour, or at least 3000 pounds per hour. ), at least 2,500 lbs (1,133.981 kg), at least 3,000 lbs (1,360.777 kg), at least 3,500 lbs (1,587.573 kg), at least 4,000 lbs (1,814.369 kg), at least 4,500 lbs (2,041.166 kg), at least 5,000 lbs (2,267.962 kg), at least 5,500 lbs (2,494.758 kg), at least 6,000 lbs (2,721.554 kg), at least 6,500 lbs (2,948.35 kg) , at least 3,401.943 kg (7,500 lbs), at least 4,535.924 kg (10,000 lbs), at least 5,669.9046 kg (12,500 lbs), at least 6,803.8855 kg (15,000 lbs), at least 7,937.8665 kg (17,500 lbs), at least 9,071.8474 kg (20,000 lbs), at least 10,205.828 kg (22,500 lbs), at least 11,339.809 kg (2 5,000 lbs), at least 12,473.79 kg (27,500 lbs), at least 13,607.771 kg (30,000 lbs), or at least 14,741.752 kg (32,500 lbs), and / or not more than 226,796.185 kg (500,000 lbs), not more than 204,116.567 kg (450,000 lbs), not more than 181,436.948 kg (400,000 lbs), not more than 158,757.33 kg (350,000 lbs) per hour , 136,077.711 kg (300,000 lbs) or less, 113,398.092 kg (250,000 lbs) or less, 90,718.474 kg (200,000 lbs) or less, 68,038.8555 kg (150,000 lbs) or less, 45,359.237 kg (100,000 lbs) or less, 34,019.428 kg (75,000 lbs) or less, 22,679.619 kg (50,000 lbs) or less, or 18,143.695 kg (40,000 lbs) or less The annual average supply volume can be less than or equal to 1000 lbs / hr (453.592 kg / hr) and 500,000 lbs / hr (226,796.185 kg / hr), 3500 lbs / hr and 250,000 lbs / hr, or 10,000 lbs / hr and 100,000 lbs / hr. If a facility includes more than one feed stream, the annual average supply volume will be determined based on the higher volume feed stream.

[0138] Additionally, in one embodiment or in combination with any of the described embodiments, the chemical recycling facility 10 (or any one of the pre-treatment facility 20, solvolysis facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, energy generation / production facility 80, and reuse facility 90) may also be operated in a continuous manner.

[0139] In addition, or in an alternative embodiment, at least a portion of the chemical recycling facility (or any of the pre-treatment facility 20, solvolysis facility 30, pyrolysis facility 60, cracking facility 70, partial oxidation (POX) gasification facility 50, solidification facility 40, and energy generation / production facility 80) may be operated in a batch or semi-batch mode. In some cases, the facility may include multiple tanks between or among portions of the facility to manage inventory and ensure consistent flow rates to each facility.

[0140] In addition, two or more of the facilities shown in FIG. 1 may also be co-located with one another. In one embodiment, or in combination with any of the described embodiments, at least two, three, four, five, six, or all of the facilities may be co-located. As used herein, the term "co-located" refers to a facility in which at least a portion of a process or auxiliary equipment or service is shared between two facilities. In one embodiment, or in combination with any of the described embodiments, when two or more of the facilities shown in FIG. 1 are co-located, the facilities may meet at least one of the following criteria (i)-(v): (i) the facilities share at least one utility, (ii) the facilities share at least one service group, (iii) the facilities are owned and / or operated by parties that share at least one boundary, (iv) the facilities are connected by at least one conduit, and (v) the facilities are within the geographical boundaries of these facilities. Within 40 miles, 35 miles, 30 miles, 20 miles, 15 miles, 12 miles, 10 miles, 8 miles, 5 miles, 2 miles, or 1 mile of each other, as measured from their respective centers. At least one, two, three, four, or all of the above may be true.

[0141]

[0140] With regard to (i), examples of suitable utilities include, but are not limited to, steam systems (co-generation and distribution systems), cooling water systems, heat transfer fluid systems, plant or plant air systems, nitrogen systems, hydrogen systems, power generation and distribution, wastewater / sewer systems including power distribution above 8000V, storage facilities, transportation lines, flare systems, and combinations thereof.

[0142] With respect to (ii), examples of service groups and facilities include, but are not limited to, emergency service personnel (fire and / or medical personnel), third-party vendors, government oversight groups, and combinations thereof. Government oversight groups can include, for example, regulatory or environmental agencies, as well as municipal and tax agencies at the city, county, and state levels.

[0143]

[0142] With regard to (iii), the boundary may be, for example, a fence line, a property line, a gate, or a boundary common with at least one boundary of land or facilities owned by a third party.

[0144] Regarding (iv), the conduit may be a fluid conduit, such as a gas-filled or liquid-filled conduit, or an electrical conduit. In some cases, two units may share one or more conduits selected from the list above. The fluid conduit may be used to transport a process stream or utility between two units. For example, the inlet of one facility (e.g., solvolysis facility 30) may be fluidly connected to the inlet of another facility (e.g., POX gasification facility 50) via a conduit. In some cases, the interim storage between the outlet of one facility and the inlet of another facility may be 90 days or less, 75 days or less, 60 days or less, 40 days or less, 30 days or less, 25 days or less, 20 days or less, 15 days or less, 10 days or less, 5 days or less, 2 days or less, or 1 day or less.

[0145] In one embodiment or in combination with any of the described embodiments, one or more of the streams withdrawn from pre-treatment facility 20, including non-plastic, non-soluble stream 105a, PO-rich stream 104, and PET-rich stream 102, can be solids or can include solids. Examples of such streams can include solid particles transportable by solid transport devices and systems, as well as melts and slurries.

[0146]

[0145] Additional embodiments of specific facilities within a chemical recycling facility such as that shown in Figure 1 are described in further detail below. Solvolysis Facility In one embodiment or in combination with any of the described embodiments, at least a portion of the PET-rich stream 102 may be introduced into a solvolysis facility 30. As used herein, the terms "solvolysis" or "ester solvolysis" refer to the reaction in which an ester-containing feed is chemically decomposed in the presence of a solvent to form a major carboxyl product and a major glycol product. A "solvolysis facility" refers to all the equipment, lines, and processes necessary to carry out the solvolysis of waste plastics and feedstocks derived therefrom. As used herein, the term "major carboxyl" refers to the main or principal carboxyl product recovered from the solvolysis facility. As used herein, the term "major glycol" refers to the main glycol product recovered from the solvolysis facility.

[0147]

[0147] When the ester subjected to solvolysis comprises PET, the solvolysis performed in the solvolysis facility may be PET solvolysis. As used herein, the term "PET solvolysis" refers to a reaction in which a polyester terephthalate-containing feed is chemically decomposed in the presence of a solvent to form a major terephthalyl product and a major glycol product. As used herein, the term "major terephthalyl" refers to the main or primary terephthalyl product recovered from the solvolysis facility. As used herein, the term "glycol" refers to a component containing two or more -OH functional groups per molecule. As used herein, the term "terephthalyl" refers to a molecule containing the following group:

[0148] [ka]

[0149]

[0148] In one embodiment or in combination with any of the described embodiments, the predominant terephthalyl formed during solvolysis comprises terephthalyl, e.g., terephthalic acid or dimethyl terephthalate (or oligomers thereof), while the predominant glycol formed during solvolysis comprises glycols, e.g., ethylene glycol and diethylene glycol. The main steps of a PET solvolysis facility according to one or more embodiments of the present technology are generally shown in Figure 2, and are described in detail hereinafter.

[0150] In one embodiment or in combination with any of the described embodiments, the primary solvent used in solvolysis comprises a chemical compound having at least one -OH group. Examples of suitable solvents include, but are not limited to, water (in which case solvolysis can be referred to as "hydrolysis"), alcohol (in which case solvolysis can be referred to as "alcoholysis"), such as methanol (in which case solvolysis can be referred to as "methanolysis") or ethanol (in which case solvolysis can be referred to as "ethanolysis"), glycol, such as ethylene glycol or diethylene glycol (in which case solvolysis can be referred to as "glycolysis"), or ammonia (in which case solvolysis can be referred to as "ammonolysis").

[0151] In one embodiment, or in combination with any of the described embodiments, the solvent can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent of the primary solvent, based on the total weight of the solvent stream. In one embodiment, or in combination with any of the described embodiments, the solvent can comprise no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, or no more than 1 weight percent of other solvents or components.

[0152]

[0151] When the solvolysis facility 30 utilizes methanol as the primary solvent, the facility can be referred to as a methanolysis facility. In one embodiment, or in combination with any of the described embodiments, the chemical recycling facility 10 of Figure 1 can include a methanolysis facility.

[0153] 2 and 3, block flow diagrams are presented that provide a schematic representation of the main steps of the PET solvolysis facility 230 (FIG. 2) and the PET methanolysis facility 330 (FIG. 3). During solvolysis, PET can be chemically decomposed to form major glycols and major terephthalyl. When the feedstock to the solvolysis facility 230 includes mixed plastic waste, the major glycols and major terephthalyl include recycled components, as shown in FIG. 2, including recycled component glycol (r-glycol) 206 and recycled component terephthalyl (r-terephthalyl) 208. In addition, several solvolysis by-product streams are also produced, which are discussed in more detail below.

[0154] Similarly, during methanolysis, PET can be chemically decomposed to form ethylene glycol (EG) as the major glycol and dimethyl terephthalate (DMT) as the major terephthalyl. When PET contains waste plastics, both EG and DMT can contain recycled content, with the major glycol stream comprising r-EG stream 306 and the major terephthalyl stream comprising r-DMT stream 308, as shown in Figure 3. In addition, several by-product streams are also produced, which are discussed in more detail below.

[0155] 2, in one embodiment or in combination with any of the described embodiments, the r-glycol stream 206 withdrawn from the solvolysis facility 230 can comprise at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the major glycols formed in the solvolysis facility 30. The r-glycol stream 206 can also comprise up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, or up to 75 weight percent of the major glycols, or can comprise an amount in the range of 45 to 99 weight percent, 50 to 95 weight percent, or 55 to 90 weight percent, based on the total weight of the stream.

[0156] In one embodiment, or in combination with any of the described embodiments, r-glycol stream 206 can include at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 7 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, or no more than 15 weight percent components other than the major glycols, based on the total weight of the stream, or can include components other than the major glycols in an amount from 0.5 to 45 weight percent, from 1 to 40 weight percent, or from 2 to 20 weight percent, based on the total weight of the stream. In one embodiment, or in combination with any of the described embodiments, the components other than the major glycols can include other modifying glycols used in forming the PET. Examples of such glycols include, but are not limited to, cyclohexanedimethanol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, Examples of suitable glycerols include glycerol, neopentyl glycol, and combinations thereof.

[0157] In one embodiment or in combination with any of the described embodiments, the recycle component major terephthalyl (r-terephthalyl) stream 208 withdrawn from the solvolysis facility 230 can comprise at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the major terephthalyl formed in the solvolysis facility 30. Stream 208 can also comprise up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, or up to 75 weight percent major terephthalyl, or can comprise an amount in the range of 45 to 99 weight percent, 50 to 95 weight percent, or 55 to 90 weight percent, based on the total weight of the stream.

[0158]

[0157] The r-terephthalyl stream 208 may contain at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 7 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, or 15 weight percent or less of components other than the major terephthalyl, based on the total weight of the stream, or may contain components other than the major terephthalyl in an amount of 0.5 to 45 weight percent, 1 to 40 weight percent, or 2 to 20 weight percent, based on the total weight of the stream.

[0159] 2, in one embodiment or in combination with any of the described embodiments, one or more streams of solvent 202, 204 may be withdrawn from a solvolysis facility 230. The solvent may comprise at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the major solvent used in the solvolysis facility 30. The solvent may also comprise up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, or up to 75 weight percent of the major solvent, based on the weight of one of the solvent streams, or may comprise an amount of solvent in the range of 45 to 99 weight percent, 50 to 95 weight percent, or 55 to 90 weight percent, based on the total weight of the streams.

[0160] One of the solvent streams 202, 204 withdrawn from the solvolysis facility 230 may also contain at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 7 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, or no more than 1 weight percent of components other than the primary solvent, based on the total weight of the stream, or between 0.5 and 45 weight percent, between 1 and 40 weight percent, based on the total weight of the stream. percent, or 2 to 20 weight percent, of ingredients other than the primary solvent.

[0161] In one embodiment or combination with any of the described embodiments, at least one of the solvent streams 202, 204 (or 302, 304) contains at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, or at least 40 weight percent, and / or 75 weight percent or less, based on the total weight of the stream. The primary glycol (or EG) may be present in an amount of 0 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, or 5 weight percent, or the primary glycol (or EG) may be present in an amount ranging from 1 to 75 weight percent, 5 to 65 weight percent, or 15 to 50 weight percent, based on the total weight of the stream.

[0162] 3, when the solvolysis facility is a methanolysis facility 330, the recycled component glycol stream 306 withdrawn from the solvolysis facility 30 comprises recycled component ethylene glycol (r-EG) and can include at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent EG. Glycol stream 306 can also include up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, or up to 75 weight percent EG, or can include an amount of EG in the range of 45 to 99 weight percent, 50 to 95 weight percent, or 55 to 90 weight percent, based on the total weight of the stream.

[0163] In one embodiment, or in combination with any of the described embodiments, the r-EG stream can contain at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 7 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, or no more than 15 weight percent of components other than EG, based on the total weight of the stream, or can contain these components in amounts ranging from 0.5 to 45 weight percent, from 1 to 25 weight percent, or from 2 to 15 weight percent, based on the total weight of the stream. Components other than EG can include other modifying glycols used in forming PET. Examples of such glycols can include one or more of those previously described.

[0164] Additionally, when the solvolysis facility is a methanolysis facility, the r-terephthalyl may contain DMT, and the recycled component DMT (r-DMT) stream 308 withdrawn from the methanolysis facility 330 may comprise at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least The DMT stream 308 may comprise up to 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent dimethyl terephthalate (DMT). The DMT stream 308 may also comprise up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, or 75 weight percent DMT, or an amount of DMT in the range of 45 to 99 weight percent, 50 to 95 weight percent, or 55 to 90 weight percent, based on the total weight of the stream.

[0165] In one embodiment, or in combination with any of the described embodiments, the r-DMT stream can contain at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 7 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, or no more than 15 weight percent of components other than DMT, based on the total weight of the stream, or the r-DMT stream can contain these components in amounts ranging from 0.5 to 45 weight percent, from 1 to 25 weight percent, or from 2 to 15 weight percent, based on the total weight of the stream.

[0166] As shown in the diagram of methanolysis facility 330 in Figure 3, one or more of the methanol streams 306, 308 may be formed within or withdrawn from methanolysis facility 330. The solvent can comprise at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent methanol. The solvent can also comprise up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, or up to 75 weight percent methanol, or can comprise an amount of methanol in the range of 45 to 99 weight percent, 50 to 95 weight percent, or 55 to 95 weight percent, based on the total weight of the streams.

[0167] Methanol streams 306, 308 can also contain at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 7 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, or no more than 1 weight percent, or these components can be present in amounts ranging from 0.5 to 45 weight percent, 1 to 25 weight percent, or 2 to 15 weight percent, based on the total weight of the stream. The solvent stream compositions described herein can refer to in-process solvent streams withdrawn from and / or added to the process at methanolysis facility 330.

[0168] In addition to providing streams including the recycled component primary glycol, recycled component primary terephthalyl, and primary solvent streams, one or more solvolysis (or methanolysis) by-product streams are also provided to solvolysis facility 230 (or methanolysis facility 330). ) may be withdrawn from one or more locations within the solvolysis facility. As used herein, the term "by-product" or "solvolysis by-product" refers to any compound withdrawn from the solvolysis facility that is not the primary carboxyl (or primary terephthalyl) product of the solvolysis facility, the primary glycol product of the solvolysis facility, or the primary solvent fed to the solvolysis facility. When the solvolysis facility is a methanolysis facility, the by-product may be referred to as a methanolysis by-product. As used herein, the term "methanolysis by-product" refers to any compound withdrawn from the methanolysis facility that is not DMT, EG, or methanol.

[0169] In one embodiment, or in combination with any of the described embodiments, one or more by-product streams withdrawn from the solvolysis (or methanolysis) facility can include heavy organic by-products and / or light organic by-products. As used herein, the term "heavy organic solvolysis by-product" refers to a solvolysis by-product having a boiling point higher than that of the primary terephthalyl product of the solvolysis facility, while the term "light organic solvolysis by-product" refers to a solvolysis by-product having a boiling point lower than that of the primary terephthalyl product of the solvolysis facility. As used herein, the term "heavy organic methanolysis by-product" refers to a methanolysis by-product having a boiling point higher than DMT, while the term "light methanolysis by-product" refers to a methanolysis by-product having a boiling point lower than DMT. Examples of specific by-products from both the methanolysis and solvolysis facilities are described in more detail below.

[0170] 2 and 3, several by-product streams may be withdrawn from the solvolysis facility 230 and the methanolysis facility 330. In one embodiment, or in combination with any of the described embodiments, at least one by-product stream can comprise at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of organic compounds having a boiling point higher than the boiling point of the primary glycol (or EG) produced from the solvolysis (or methanolysis) facility, based on the total weight of organics in the stream. In addition, or in alternative embodiments, the by-products may include 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less of components having a boiling point lower than that of the primary glycol (or EG), based on the total weight of organics in the stream.

[0171] In one embodiment or in combination with any of the described embodiments, at least one by-product stream withdrawn from the solvolysis (or methanolysis) facility can contain at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of organic compounds having a boiling point higher than the boiling point of the primary glycol (or EG) and lower than the boiling point of the primary terephthalyl (or DMT) produced from the solvolysis (or methanolysis) facility, based on the total weight of organics in the stream. In addition, or in an alternative embodiment, the by-product can contain no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, based on the total weight of organics in the stream. The glycol (or EG) may contain up to 10 weight percent, up to 5 weight percent, up to 2 weight percent, up to 1 weight percent of a component having a boiling point below that of the major glycol (or EG) and above that of the major terephthalyl (or DMT).

[0172] In one embodiment or in combination with any of the described embodiments, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the organic compounds in one or more by-product streams from the solvolysis (or methanolysis) facility can have a boiling point higher than the boiling point of the primary terephthalyl (or DMT) produced from the solvolysis (or methanolysis) facility, based on the total weight of organics in the streams. In addition, or in alternative embodiments, the by-products may contain no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent of components having boiling points lower than the boiling point of the primary terephthalyl (or DMT), based on the total weight of organics in the stream.

[0173] In one embodiment or in combination with any of the described embodiments, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, and / or no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent of the organic compounds in one or more by-product streams from the solvolysis (or methanolysis) facility have a boiling point lower than the boiling point of the major glycol (or EG) produced from the solvolysis (or methanolysis) facility, based on the total weight of organics in the stream. In addition or alternative embodiments, the by-products may contain no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent of components having a boiling point higher than the boiling point of the major glycol (or EG), based on the total weight of organics in the stream.

[0174]

[0173] Referring again to Figures 2 and 3, the operation of the solvolysis facility 230 and the methanolysis facility 330 is described in detail. For clarity, unless otherwise specified, the following description is generally applicable to both the solvolysis and methanolysis facilities. As shown in Figures 2 and 3, a stream of mixed plastic waste 210 and solvent 212 (or methanol 312) may be introduced (separately or together) into the solvolysis facility 230 (or methanolysis facility 330). The stream may first pass through an optional non-PET separation zone 220, where at least 50 percent of the total amount of components other than PET is separated from the stream. In one embodiment, or in combination with any of the described embodiments, the non-PET components may have a lower boiling point (or density) than PET and may be removed from the zone as a vapor. In one embodiment, or in combination with any of the described embodiments, these non-PET components may enter facility 230 or 330 as a liquid. Alternatively, or in addition, at least a portion of the non-PET components can have a density slightly higher or lower than that of PET and can separate as a liquid. Finally, in one embodiment or in combination with any of the described embodiments, the non-PET components can also separate as a solid from the PET-containing liquid phase.

[0175]

[0174] One example of a non-PET component that may be separated from non-PET separation zone 220 is polyolefin. In one embodiment or in combination with any of the described embodiments, the non-PET components separated from at least 50 percent, at least 55 percent, at least 60 percent, at least 65 percent, at least 70 percent, at least 75 percent, at least 80 percent, at least 85 percent, at least 90 percent, or at least 95 percent of the PET-containing stream comprise polyolefins, e.g., polyethylene and / or polypropylene. As generally indicated by dashed lines in FIG. 2, all or a portion of non-PET separation zone 220 in solvolysis facility 230 can be upstream of solvolysis reaction zone 240, while all or a portion of non-PET separation zone 220 can be downstream of reaction zone 240. As shown in FIG. 3, in methanolysis facility 330, non-PET separation zone 220 can be located upstream of methanolysis reaction zone 340.

[0176] Separation techniques used in non-PET separation zone 220 can include, but are not limited to, extraction, filtering, decanting, cyclone or centrifugation, manual removal, magnetic removal, chemical decomposition, evaporation and degassing, distillation, and combinations thereof. One or more of these techniques can be used in non-PET separation zone 220 before and / or after solvolysis reaction zone 240 or before methanolysis reaction zone 340 to separate non-PET components from the PET-containing stream.

[0177] Here, PET-rich stream 214 exiting non-PET separation zone 220 can contain 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.5 weight percent of components other than PET (or their oligomeric and monomeric degradation products) and solvent, based on the total weight of PET-containing stream 214. PET-containing stream 214 exiting non-PET separation zone 220 upstream of solvolysis reaction zone 240 or methanolysis reaction zone 340 can contain 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent of other types of plastics (e.g., polyolefins). In one embodiment or in combination with any of the described embodiments, the PET-containing stream 214 exiting the non-PET separation zone 220 may comprise 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 10 weight percent or less, 5 weight percent or less, or 2 weight percent or less of the total amount of non-PET components introduced to the non-PET separation zone 220 via the plastic mixed waste stream 210.

[0178] 2 and 3, non-PET components may be purged from the solvolysis facility 230 (or methanolysis facility 330) via polyolefin-containing by-product stream 216a,b (or 316). The resulting polyolefin-containing by-product stream 216a,b (or 316) can comprise at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 92 weight percent, at least 95 weight percent, at least 97 weight percent, at least 99 weight percent, or at least 99.5 weight percent polyolefin, based on the total weight of the polyolefin-containing by-product stream.

[0179] The polyolefins present in the polyolefin-containing by-product stream 216a, b (or 316) may be primarily polyethylene, primarily polypropylene, or polyethylene and polypropylene. and pyrene combinations. As used herein, the term "predominantly" means at least 50 weight percent of a given component, based on the total weight of the stream or composition. In one embodiment, or in combination with any of the described embodiments, the polyolefin in the polyolefin-containing by-product stream comprises at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 92 weight percent, at least 94 weight percent, at least 95 weight percent, at least 97 weight percent, at least 98 weight percent, or at least 99 weight percent polyethylene, based on the total weight of polyolefins in the polyolefin-containing by-product stream.

[0180] Alternatively, the polyolefin in the polyolefin-containing by-product stream 216a, b (or 316) comprises at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 92 weight percent, at least 94 weight percent, at least 95 weight percent, at least 97 weight percent, at least 98 weight percent, or at least 99 weight percent polypropylene, based on the total weight of polyolefin in the polyolefin-containing by-product stream.

[0181]

[0180] In one embodiment or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b comprises less than or equal to 10 weight percent, less than or equal to 5 weight percent, less than or equal to 2 weight percent, less than or equal to 1 weight percent, less than or equal to 0.75 weight percent, less than or equal to 0.50 weight percent, less than or equal to 0.25 weight percent, less than or equal to 0.10 weight percent, or less than or equal to 0.05 weight percent PET, based on the total weight of the polyolefin-containing by-product stream 216a, b. Additionally, in one embodiment or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b comprises at least 0.01 weight percent, at least 0.05 weight percent, at least 0.10 weight percent, at least 0.50 weight percent, at least 1 weight percent, or at least 1.5 weight percent, and / or no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, or no more than 2 weight percent of non-polyolefin components, based on the total weight of the polyolefin-containing by-product stream, or can contain non-polyolefin components in an amount ranging from 0.01 to 40 weight percent, 0.10 to 15 weight percent, or 0.5 to 5 weight percent, based on the total weight of the stream.

[0182] Overall, the polyolefin-containing by-product stream 216a,b (or 316) comprises at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent organic compounds, based on the total weight of the polyolefin-containing by-product stream 216a,b. The polyolefin-containing by-product stream 216a,b (or 316) comprises at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 3 weight percent, at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent, and / or no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 ... It may contain no more than, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of non-organic components, or may contain amounts ranging from 0.5 to 40 weight percent, 1 to 15 weight percent, or 2 to 5 weight percent of non-organic components, based on the total weight of the stream.

[0183] In one embodiment or combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b (or 316) comprises at least 0.1 weight percent, at least 0.5 weight percent, at least 1 weight percent, at least 1.5 weight percent, at least 2 weight percent, at least 2.5 weight percent, at least 3 weight percent, at least 3.5 weight percent, at least 4 weight percent, at least 4.5 weight percent, at least 5 weight percent, at least 8 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, based on the total weight of the polyolefin-containing by-product stream. The non-reactive solids may comprise at least 18 weight percent, at least 20 weight percent, at least 22 weight percent, or at least 25 weight percent, and / or no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, or no more than 2 weight percent of one or more non-reactive solids, or may contain an amount in the range of 0.1 to 50 weight percent, 2 to 25 weight percent, or 3 to 15 weight percent, based on the total weight of the stream.

[0184] Non-reactive solids refer to solid components that do not chemically react with PET. Examples of non-reactive solids include, but are not limited to, sand, dirt, glass, plastic fillers, and combinations thereof. In one embodiment, or in combination with any of the described embodiments, one or more of the by-product streams, including polyolefin-containing by-product stream 216a, b (or 316), can contain non-reactive solids in an amount of 100 ppm by weight to 50 weight percent, 500 ppm by weight to 10 weight percent, or 1000 ppm by weight to 5 weight percent, based on the total weight of the stream.

[0185] In one embodiment or combination with any of the described embodiments, the polyolefin-containing by-product stream has at least 100 ppm by weight, at least 250 ppm by weight, at least 500 ppm by weight, at least 750 ppm by weight, at least 1000 ppm by weight, at least 1500 ppm by weight, at least 2000 ppm by weight, at least 2500 ppm by weight, at least 5000 ppm by weight, at least 7500 ppm by weight, or at least 1 percent by weight, at least 1.5 percent by weight, at least 2 percent by weight, at least 5 percent by weight, at least 10 percent by weight, or at least The stream may comprise at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent, and / or no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent, or the stream may comprise fillers in an amount ranging from 100 ppm to 50 weight percent, 500 ppm to 20 weight percent, or 2500 ppm to 2 weight percent, based on the total weight of the stream.

[0186] Examples of fillers include, but are not limited to, thixotropic agents such as fume silica and clay (kaolin), pigments, colorants, flame retardants such as alumina trihydrate, bromine, chlorine, borate, and phosphorus, inhibitors such as wax-based materials, UV inhibitors. Examples of suitable additives include adhesives or stabilizers, conductive additives such as metal particles, carbon particles, or conductive fibers, release agents such as zinc stearate, wax, and silicone, calcium carbonate, and calcium sulfate.

[0187] The polyolefin-containing by-product stream may be primarily liquid, but may further include at least some vapor and / or solids. In one embodiment, or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b (or 316) has a viscosity of at least 1 poise, at least 10 poise, at least 25 poise, at least 50 poise, at least 75 poise, at least 90 poise, at least 100 poise, at least 125 poise, at least 150 poise, at least 20 poise, as measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / sec and a temperature of 250°C. a·s (200 poise), at least 25 Pa·s (250 poise), at least 30 Pa·s (300 poise), at least 35 Pa·s (350 poise), at least 40 Pa·s (400 poise), at least 45 Pa·s (450 poise), at least 50 Pa·s (500 poise), at least 55 Pa·s (550 poise), at least 60 Pa·s (600 poise), at least 65 Pa·s (650 poise), at least 70 Pa·s ( 700 poise), at least 75 Pa·s (750 poise), at least 80 Pa·s (800 poise), at least 85 Pa·s (850 poise), at least 90 Pa·s (900 poise), or at least 95 Pa·s (950 poise), and / or not more than 2,500 Pa·s (25,000 poise), not more than 2,400 Pa·s (24,000 poise), not more than 2,300 Pa·s (23,000 poise), not more than 2,200 Pa·s (22,000 poise), 2,100 Pa·s (21,000 poise) or less, 2,000 Pa·s (20,000 poise) or less, 1,900 Pa·s (19,000 poise) or less, 1,800 Pa·s (18,000 poise) or less, 1,700 Pa·s (17,000 poise) or less, 1,600 Pa·s (16,000 poise) or less, 1,500 Pa·s (15,000 poise) or less, 1,400 Pa·s (14,000 poise) or less, 1,300 Pa·s (13,000 poise), 1,200 Pa·s (12,000 poise), 1,100 Pa·s (11,000 poise), 1,000 Pa·s (10,000 poise), 900 Pa·s (9000 poise), 800 Pa·s (8000 poise), 700 Pa·s (7000 poise), 600 Pa·s (6000 poise), 500 Pa·s (5000 poise), 450 Pa·s (4500 poise), 400 Pa·s (4000 poise), 350 Pa·s (3500 poise), 300 Pa·s (3000 poise), 250 Pa·s (25 It can have a viscosity of 00 poise or less, 200 Pa·s (2000 poise) or less, 175 Pa·s (1750 poise) or less, 150 Pa·s (1500 poise) or less, 125 Pa·s (1250 poise) or less, 120 Pa·s (1200 poise) or less, 115 Pa·s (1150 poise) or less, 110 Pa·s (1100 poise) or less, 105 Pa·s (1050 poise) or less, 100 Pa·s (1000 poise) or less, 95 Pa·s (950 poise) or less, 90 Pa·s (900 poise) or less, 80 Pa·s (800 poise) or less, or 75 Pa·s (750 poise).

[0188]

[0187] The viscosity of the polyolefin-containing by-product stream 216a, b (or 316) is at least 50 Pa·s (500 poise), at least 75 Pa·s (750 poise), at least 90 Pa·s (900 poise), or at least 95 Pa·s (950 poise), and / or no more than 2,500 Pa·s (25,000 poise), no more than 2,000 Pa·s (20,000 poise), no more than 1,700 Pa·s (17,000 poise), no more than 1,500 Pa·s (1,500 poise), as measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / sec and a temperature of 250°C. s (15,000 poise) or less, 1,200 Pa·s (12,000 poise) or less, 1,100 Pa·s (11,000 poise) or less, 1,000 Pa·s (10,000 poise) or less, 500 Pa·s (5000 poise) or less, 250 Pa·s (2500 poise) or less, 125 Pa·s (1250 poise) or less, 100 Pa·s (1000 poise) The viscosity of the polyolefin-containing by-product stream 216a, b (or 316) can be in the range of 50-2,500 Pa·s (500-25,000 poise), 100-1,500 Pa·s (1000-15,000 poise), or 500-1,250 Pa·s (5000-12,500 poise).

[0189] The polyolefin-containing by-product stream 216a, b (or 316) may be a non-Newtonian fluid and / or a shear-thinning fluid. As used herein, the term "non-Newtonian" describes a fluid whose viscosity depends on shear rate, time, or deformation history. As used herein, the term "shear-thinning" refers to a non-Newtonian fluid whose viscosity decreases with shear rate. For example, a shear-thinning fluid has a viscosity at 1000 rad / sec that is lower than the viscosity at 1 rad / sec for temperatures of at least 260°C, at least 270°C, or at least 280°C.

[0190]

[0189] In one embodiment or in combination with any of the described embodiments, at least a portion, or all, of the polyolefin-containing by-product stream 216a, b (or 316) may be pelletized or micropelletized before being routed to one or more downstream facilities, as discussed in detail below.

[0191] If pelletized, the feedstream is introduced into a melt extruder where it is heated and melted to form a molten polymer at a temperature of at least 240° C., at least 245° C., at least 250° C., at least 255° C., at least 260° C., and / or no more than 310° C., no more than 305° C., no more than 300° C., no more than 290° C., no more than 280° C., no more than 275° C., no more than 270° C., no more than 265° C., or no more than 260° C., or at a temperature in the range of 240-280° C., 245-275° C., or 255-265° C. The molten polymer then passes through a die plate having a plurality of holes, optionally under water, and the resulting polymer strands are cut to form pellets. The resulting pellets can have an average particle size, measured along their longest dimension, of at least 0.5 mm, at least 0.75 mm, at least 0.90 mm, at least 1 mm, at least 1.1 mm, at least 1.25 mm, and / or no more than 2.25 mm, no more than 2.1 mm, no more than 2 mm, no more than 1.75 mm, or no more than 1.6 mm, or an average particle size in the range of 0.5 to 2.25 mm, 0.9 to 2.1 mm, or 1 to 2 mm.

[0192] In one embodiment or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a,b (or 316) has a polyolefin content of at least 0.75 g / cm 3 measured at a temperature of 25° C. 3 , at least 0.80 g / cm 3 , at least 0.85g / cm 3 , at least 0.90 g / cm 3 , at least 0.95 g / cm 3 , at least 0.99 g / cm 3 , and / or 1.5 g / cm 3 Below 1.4g / cm 3 Below 1.3g / cm 3 Below, 1.2g / cm 3 Below, 1.1g / cm 3 Below 1.05g / cm 3 or less, or 1.01g / cm 3 The density can be as follows: 0.80 to 1.4 g / cm 3, 0.90~1.2g / cm 3 , or 0.95 to 1.1 g / cm 3 It can be.

[0193]

[0192] When removed from the non-PET separation zone 220, the polyolefin-containing by-product stream 216a,b (or 316) may have a temperature of at least 200°C, at least 205°C, at least 210°C, at least 215°C, at least 220°C, at least 225°C, The temperature can be 230°C, or at least 235°C, and / or no greater than 350°C, no greater than 340°C, no greater than 335°C, no greater than 330°C, no greater than 325°C, no greater than 320°C, no greater than 315°C, no greater than 310°C, no greater than 305°C, or no greater than 300°C, or it can range from 200 to 350°C, 215 to 330°C, 220 to 340°C, or 235 to 300°C.

[0194]

[0193] In one embodiment or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b (or 316) can contain at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of components boiling higher than the primary terephthalyl, or, if the facility is a methanolysis facility 330, higher than DMT.

[0195]

[0194] In one embodiment or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b from the solvolysis facility 230 (or stream 316 from the methanolysis facility 330) can contain at least 90 weight percent, at least 92 weight percent, at least 95 weight percent, at least 97 weight percent, at least 99 weight percent, or at least 99.5 weight percent polyolefin, and / or 1 weight percent or less, 0.75 weight percent or less, 0.50 weight percent or less, 0.25 weight percent or less, or 0.10 weight percent or less PET, based on the total weight of the polyolefin-containing by-product stream. The flow may also have a viscosity of at least 10 Pa·s (100 poise), at least 15 Pa·s (150 poise), at least 20 Pa·s (200 poise), at least 25 Pa·s (250 poise), at least 30 Pa·s (300 poise), at least 35 Pa·s (350 poise), at least 40 Pa·s (400 poise), at least 45 Pa·s (450 poise), or at least 50 Pa·s (500 poise), as measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / sec and a temperature of 250°C.

[0196] In one embodiment, or in combination with any of the described embodiments, all or a portion of the polyolefin-containing by-product stream from solvolysis facility 230 (or methanolysis facility 330) may be introduced to one or more other facilities within the chemical recycling facility. Referring again to FIG. 1, this is generally represented by by-product stream 110. By-product stream 110 shown in FIG. 1 can include one or more of any of the by-product streams discussed herein, either separately or in combination with one or more other by-product streams.

[0197] As shown in FIG. 1 , all or a portion of the by-product stream 110 from the solvolysis facility 30 can be passed through one or more other processing facilities of the chemical recycling facility 10. Such facilities can include, for example, (i) a solidification facility 40, (ii) a partial oxidation (POX) gasification facility 50, (iii) a pyrolysis facility 60, (iv) a cracker facility 70, and (v) an energy generation / production facility 80. In one embodiment, or in combination with any of the described embodiments, at least 10 weight percent, at least 20 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent, at least 80 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent of the polyolefin-containing by-product stream is passed through at least one, at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least ninety percent, at least ninety percent, at least ninety-five, or at least ninety-nine weight percent of the polyolefin-containing by-product stream. At least three, or all, may be introduced as or with the feed stream.

[0198] In one embodiment or in combination with any of the described embodiments, at least one other by-product stream from the solvolysis facility 30 may also be introduced simultaneously with the polyolefin-containing by-product stream to one of: (i) a solidification facility 40, (ii) a partial oxidation (POX) gasification facility 50, (iii) a pyrolysis facility 60, (iv) a cracker facility 70, and (v) an energy generation / production facility 80. As used herein, the term "downstream facility" collectively refers to one or more of the above facilities.

[0199] If introduced simultaneously, the polyolefin-containing by-product stream may be introduced separately from the other by-product streams, or the two streams may be pre-combined and the combined stream introduced to a downstream facility. In one embodiment, or in combination with any of the described embodiments, the polyolefin-containing by-product stream may be introduced to the same downstream facility as the other by-product streams, while in one or more other embodiments, the polyolefin-containing by-product stream may be introduced to a different downstream facility than the other by-product streams. When three or more by-product streams from the solvolysis facility 30 are introduced to downstream processing facilities (e.g., pyrolysis facility 60, cracker facility 70, solidification facility 40, energy generation / production facility 80, and / or POX gasification facility 50), at least one of the other by-product streams may be introduced to the same facility as the polyolefin-containing by-product stream, and / or at least one of the other by-product streams may be introduced to a different downstream facility than the polyolefin-containing by-product stream.

[0200] 2 and 3, the PET-containing stream (comprising dissolved PET and its degradation products and solvent) exiting non-PET separation zone 220 in stream 214 may then be transferred to solvolysis reaction zone 240 (or methanolysis reaction zone 340), where degradation of at least 50 percent of the PET introduced therein may occur. In one embodiment, or in combination with any of the described embodiments, the reaction medium within reaction zone 240 (or 340) may be agitated or stirred, and one or more temperature control devices (e.g., heat exchangers) may be utilized to maintain a target reaction temperature.

[0201] In one embodiment, or in combination with any of the described embodiments, the average reaction temperature in the solvolysis reactor can be at least 50°C, at least 55°C, at least 60°C, at least 65°C, at least 70°C, at least 75°C, at least 80°C, or at least 85°C, and / or no more than 350°C, no more than 345°C, no more than 340°C, no more than 335°C, no more than 330°C, no more than 325°C, no more than 320°C, no more than 315°C, no more than 310°C, no more than 300°C, or no more than 295°C, or can range from 50 to 350°C, 60 to 325°C, or 85 to 295°C.

[0202] The pressure in the solvolysis reactor may be within 34.4738 kilopascals (kPa) (5 pounds per square inch gauge (psig)), at least within 68.9476 kPa (10 psig), at least within 103.421 kPa (15 psig), at least within 137.895 kPa (20 psig), at least within 172.369 kPa (25 psig), at least within 206.843 kPa (30 psig), at least within 241.317 kPa (35 psig), at least within 275.79 kPa (40 psig), at least within 250.0 ... The pressure can be within at least 45 psig (310.264 kPa), or within at least 50 psig (344.738 kPa), or can be within 55 psig (379.212 kPa), at least 75 psig (517.107 kPa), at least 90 psig (620.528 kPa), at least 100 psig (689.476 kPa), at least 125 psig (861.845 kPa), or at least 150 psig (1,034.21 kPa). The pressure is at least 35 kilopascals (kPa) (0.35 bar gauge (barg)), at least 70 kPa (0.70 barg), at least 100 kPa (1 barg), at least 140 kPa (1.4 barg), at least 175 kPa (1.75 barg), at least 200 kPa (2 barg), at least 250 kPa (2.5 barg), at least 275 kPa (2.75 barg), The pressure may be at least 300 kPa (3 barg), at least 350 kPa (3.5 barg), at least 375 kPa (3.75 barg), at least 500 kPa (5 barg), or at least 625 kPa (6.25 barg), and / or no more than 1,035 kPa (10.35 barg), no more than 860 kPa (8.6 barg), or no more than 690 kPa (6.9 barg).

[0203]

[0202] In one embodiment, or in combination with any of the described embodiments, the average residence time of the reaction medium within reaction zone 240 (or 340) can be at least 1 hour, at least 2 hours, at least 5 hours, at least 10 hours, or at least 15 minutes, and / or 12 hours or less, 11 hours or less, 10 hours or less, 9 hours or less, 8 hours or less, 7 hours or less, 6 hours or less, 5 hours or less, 4 hours or less, 3 hours or less, 2 hours or less, or 1 hour or less, or can range from 1 minute to 12 hours, 5 minutes to 7 hours, or 15 minutes to 1 hour.

[0204]

[0203] In one embodiment or in combination with any of the described embodiments, at least 50 percent, at least 55 percent, at least 60 percent, at least 65 percent, at least 70 percent, at least 75 percent, at least 80 percent, at least 85 percent, at least 90 percent, at least 95 percent, or at least 99 percent of the total weight of PET introduced into the solvolysis facility 230 (or methanolysis facility 330) is decomposed upon leaving the reaction zone 240 (or 340) in the reactor effluent stream.

[0205] In one embodiment or in combination with any of the described embodiments, a reactor effluent purge stream may be removed from reaction zone 240 (or 340), at least a portion of which may be passed through one or more downstream facilities within chemical recycling facility 10, shown in FIG. 1 as a reactor purge by-product stream, shown in FIG. 2 as line 218 in the solvolysis facility, and shown in FIG. 3 as line 318 in the methanolysis facility. Reactor purge by-product stream 218 (or 318) may have a moderate boiling point, higher than that of the primary terephthalyl (or DMT, in the case of methanolysis) produced from solvolysis facility 230 (or methanolysis facility 330).

[0206]

[0205] In one embodiment or in combination with any of the described embodiments, the reactor purge by-product stream 218 (or 318) shown in Figure 2 (or 3) can contain at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of components having a boiling point higher than the boiling point of the primary terephthalyl (or DMT). In addition, or in alternative embodiments, the by-product stream may be at least 0.10 weight percent, at least 0.25 weight percent, at least 0.50 weight percent, at least 0.75 weight percent, at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 8 weight percent, at least 10 weight percent, at least 12 weight percent, at least 15 weight percent, or at least 17 weight percent, and / or no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 12 weight percent, no more than 10 weight percent , 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 3 weight percent or less, or 2 weight percent or less of compounds having a higher boiling point than the primary terephthalyl (or DMT), or these may be present in an amount ranging from 0.10 to 30 weight percent, 0.50 to 20 weight percent, or 1 to 15 weight percent, based on the total weight of the stream.

[0207] In one embodiment or in combination with any of the described embodiments, reactor purge by-product stream 218 (or 318) can contain 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of components having a boiling point lower than the boiling point of the primary terephthalyl (or DMT). In addition, or in another embodiment, reactor purge by-product stream 218 (or 318) can have a melting temperature that is at least 5° C., at least 10° C., at least 15° C., at least 20° C., or at least 25° C. higher than the reactor temperature, and / or 50° C. or lower, 45° C. or lower, 40° C. or lower, 35° C. or lower, 30° C. or lower, 25° C. or lower, 20° C. or lower, or 15° C. or lower, or the melting temperature can range from 5 to 50° C. higher, or from 10 to 40° C. higher, or from 15 to 30° C. higher.

[0208]

[0207] In one embodiment or in combination with any of the described embodiments, reactor purge by-product stream 218 contains at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent primary terephthalyl, based on the total weight of the composition. When the solvolysis facility is a methanolysis facility such as that shown in FIG. 3, reactor purge by-product stream 318 can comprise at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent DMT, based on the total weight of the stream.

[0209] Additionally, reactor purge by-product stream 218 (or 318) may contain at least 100 ppm and up to 25 weight percent of one or more non-terephthalyl solids, based on the total weight of the stream. In one embodiment or combination with any of the described embodiments, the total amount of non-terephthalyl solids in reactor purge by-product stream 218 (or 318) is at least 150 ppm, at least 200 ppm, at least 250 ppm, at least 300 ppm, at least 350 ppm, at least 400 ppm, at least 500 ppm, at least 600 ppm, at least 700 ppm, at least 800 ppm, at least 900 ppm, at least 1000 ppm, at least 1500 ppm, at least 2000 ppm, at least 2500 ppm, at least 3000 ppm, at least 3500 ppm, at least 4000 ppm, at least 4500 ppm, at least 5000 ppm, at least 5500 ppm, at least 6000 ppm, at least 7000 ppm, at least 8000 ppm, at least 9000 ppm, at least 10,000 ppm, or at least 1 It can be 2,500 ppm, and / or 25 weight percent or less, 22 weight percent or less, 20 weight percent or less, 18 weight percent or less, 15 weight percent or less, 12 weight percent or less, 10 weight percent or less, 8 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less, or can range from 150 ppm to 22 weight percent, 500 ppm to 15 weight percent, or 1500 ppm to 5 weight percent, based on the total weight of the stream.

[0210] In one embodiment or combination with any of the described embodiments, reactor purge by-product stream 218 (or 318) has a total weight of at least 100 ppm, at least 250 ppm, at least 500 ppm, at least 750 ppm, at least 1000 ppm, at least 1500 ppm, at least 2000 ppm, at least 2500 ppm, at least 3000 ppm, at least 3500 ppm, at least 4000 ppm, at least 4500 ppm, at least 5000 ppm, at least 5500 ppm, at least 6000 ppm, at least 6500 ppm, at least 7000 ppm, at least 7500 ppm, at least 8000 ppm, at least 8500 ppm, at least 9000 ppm, at least 9500 ppm, or or at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 8 weight percent, at least 10 weight percent, or at least 12 weight percent, and / or a total solids content of 25 weight percent or less, 22 weight percent or less, 20 weight percent or less, 17 weight percent or less, 15 weight percent or less, 12 weight percent or less, 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, or 1 weight percent or less, or 7500 weight ppm or less, 5000 weight ppm or less, or 2500 weight ppm or less, or the total solids content may range from 100 ppm to 25 weight percent, 500 ppm to 15 weight percent, or 1000 ppm to 10 weight percent, based on the total weight of the stream. Examples of solids may include, but are not limited to, non-volatile catalyst compounds.

[0211] In one embodiment or in combination with any of the described embodiments, the reactor purge by-product stream 218 (or 318) has a CI concentration of at least 100 ppm, at least 250 ppm, at least 500 ppm, at least 750 ppm, at least 1000 ppm, at least 1500 ppm, at least 2000 ppm, at least 2500 ppm, at least 3000 ppm, at least 3500 ppm, at least 4000 ppm, at least 4500 ppm, at least 5000 ppm, at least 7500 ppm, at least 10, ...1500 ppm, at least 2000 ppm, at least 2500 ppm, at least 3000 ppm, at least 3500 ppm, at least 4000 ppm, at least 4500 ppm, at least 5000 ppm, at least 10,000 ppm, at least 1500 ppm, at least 1500 ppm, at least 1500 ppm, at least 1500 ppm, at least 1500 ppm, at least 1500 ppm, at least 1500 ppm, at The stream may contain 0 ppm, or at least 12,500 ppm, and / or no more than 60,000 ppm, 50,000 ppm, 40,000 ppm, 35,000 ppm, 30,000 ppm, 25,000 ppm, 20,000 ppm, 15,000 ppm, or 10,000 ppm of non-volatile catalyst compounds, or such compounds may be present in amounts ranging from 100 to 60,000 ppm, 500 to 30,000 ppm, or 1000 to 10,000 ppm, based on the total weight of the stream. Examples of suitable non-volatile catalyst compounds include, but are not limited to, titanium, zinc, methoxide, alkali metals, alkaline earth metals, tin, residual esterification catalyst, residual polycondensation catalyst, aluminum, and combinations thereof.

[0212] In one embodiment or in combination with any of the described embodiments, the reactor purge by-product stream 218 (or 318) has a shear rate of 10 rad / sec and a temperature of 250 at least 0.1 Pascal seconds (1 poise) (Pa·s (P)), at least 0.2 Pa·s (2P), at least 0.5 Pa·s (5P), at least 1 Pa·s (10P), at least 2 Pa·s (20P), at least 3 Pa·s (30P), at least 4 Pa·s (40P), at least 5 Pa·s (50P), at least 6 Pa·s (60P), at least 7 Pa·s (70P), at least 8 Pa·s (80P), at least 9 Pa·s (90P), at least 10 Pa·s (100P), at least 12 Pa·s (140P), at least 16 Pa·s (180P), at least 18 Pa·s (190P), at least 19 Pa·s (200P), at least 20 Pa·s (210P), at least 21 Pa·s (220P), at least 22 Pa·s (230P), at least 23 Pa·s (240P), at least 24 Pa·s (250P), at least 25 Pa·s (260P), at least 26 Pa·s (270P), at least 27 Pa·s (280P), at least 28 Pa·s (290P), at least 30 Pa·s (310P), at least 31 Pa·s (320P), at least 32 Pa·s (330P), at least 33 Pa·s (340P), at least 34 Pa·s (350P), at least 35 Pa·s (360P), at least 36 Pa·s (370P), at least 37 Pa·s (380P), at least 38 Pa·s (390P), at least 39 Pa·s (400P), at least 40 Pa·s (410P), at least 00P), at least 20Pa·s (200P), at least 30Pa·s (300P), at least 40Pa·s (400P), at least 50Pa·s (500P), at least 60Pa·s (600P), at least 70Pa·s (700P), at least 80Pa·s (800P), at least 90Pa·s (900P), at least 100Pa·s (1000P), at least 150Pa·s (1500P), at least 200Pa·s (2000P), at least 250Pa·s (2500P), at least 300Pa·s s (3000P), at least 350 Pa·s (3500P), at least 400 Pa·s (4000P), at least 450 Pa·s (4500P), at least 500 Pa·s (5000P), at least 550 Pa·s (5500P), at least 600 Pa·s (6000P), at least 650 Pa·s (6500P), at least 700 Pa·s (7000P), at least 750 Pa·s (7500P), at least 800 Pa·s (8000P), at least 850 Pa·s (8500P), at least 900 Pa·s s (9000P), at least 1,000 Pa·s (10,000P), at least 1,100 Pa·s (11,000P), at least 1,200 Pa·s (12,000P), at least 1,300 Pa·s (13,000P), at least 1,400 Pa·s (14,000P), or at least 1,500 Pa·s (15,000P), and / or not more than 2,500 Pa·s (25,000P), not more than 2,000 Pa·s (20,000P), not more than 1,500 Pa·s (15,000P), not more than 1,200 Pa·s (12,It has a viscosity of 1,000 Pa·s (10,000 P) or less, 800 Pa·s (8000 P) or less, 600 Pa·s (6000 P) or less, 500 Pa·s (5000 P) or less, 300 Pa·s (3000 P) or less, 200 Pa·s (2000 P) or less, 150 Pa·s (1500 P) or less, 100 Pa·s (1000 P) or less, 75 Pa·s (750 P) or less, 50 Pa·s (500 P) or less, 10 Pa·s (100 P) or less, 7.5 Pa·s (75 P) or less, 5 Pa·s (50 P) or less, or 2.5 Pa·s (25 P) or less.

[0213] Reactor purge by-product stream 218 (or 318) has a viscosity of at least 10 Pascal seconds (100 poise) (Pa·s (P)), at least 50 Pa·s (500 P), at least 100 Pa·s (1000 P), at least 250 Pa·s (2500 P), at least 500 Pa·s (5000 P), at least 1,000 Pa·s (10,000 P), or at least 1,500 Pa·s (15,000 P), and / or 2,500 Pa·s (25,000 P), or less, as measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / s and a temperature of 250° C. The viscosity may be 00 Pa·s (20,000 P) or less, 1,500 Pa·s (15,000 P) or less, 1,200 Pa·s (12,000 P) or less, 1,000 Pa·s (10,000 P) or less, or 800 Pa·s (8000 P) or less, or the viscosity may be in the range of 10-2,500 Pa·s (100-25,000 P), 50-1,500 Pa·s (500-15,000 P), or 100-1,000 Pa·s (1000-10,000 P).

[0214]

[0213] The temperature of reactor purge by-product stream 218 (or 318) withdrawn from reaction zone 240 (or 340) and / or upon introduction to one or more downstream facilities is at least 130°C, at least 135°C, at least 140°C, at least The temperature can be at least 145°C, at least 150°C, at least 155°C, at least 160°C, at least 165°C, at least 170°C, at least 175°C, at least 180°C, at least 185°C, at least 190°C, at least 195°C, at least 200°C, at least 205°C, at least 210°C, at least 215°C, at least 220°C, at least 225°C, at least 230°C, at least 245°C, at least 250°C, at least 255°C, at least 260°C, at least 265°C, at least 270°C, at least 275°C, at least 280°C, at least 285°C, at least 290°C, at least 295°C, or at least 300°C.

[0215] Additionally or in alternative embodiments, the temperature of reactor purge by-product stream 218 (or 318) withdrawn from reaction zone 240 (or 340) and / or upon introduction to one or more downstream facilities can be 350°C or less, 345°C or less, 340°C or less, 335°C or less, 330°C or less, 325°C or less, 320°C or less, 315°C or less, 310°C or less, 305°C or less, 300°C or less, 295°C or less, 290°C or less, 285°C or less, 280°C or less, 275°C or less, 270°C or less, 265°C or less, 260°C or less, 255°C or less, or 250°C or less.

[0216]

[0215] The temperature of the reactor purge stream withdrawn from reaction zone 240 (or 340) can be at least 150°C, at least 175°C, at least 200°C, at least 225°C, or at least 250°C and / or no more than 350°C, no more than 330°C, no more than 325°C, no more than 310°C, or no more than 300°C, or the temperature can range from 150 to 350°C, 200 to 330°C, or 250 to 330°C.

[0217]

[0216] When the reactor is purged, the purge may be conducted continuously or intermittently, and the resulting reactor purge by-product stream may be introduced into one of the downstream facilities in a continuous or intermittent manner. In one embodiment, or in combination with any of the described embodiments, the reactor purge stream may be withdrawn in a continuous manner from the solvolysis (or methanolysis) reactor when the feed stream to the solvolysis or methanolysis facility (or reactor) has a high content of inert components, such as components produced from recycling mixed plastic waste containing textiles. In one embodiment, or in combination with any of the described embodiments, the reactor purge may be conducted continuously when the amount of inert components in the feed stream to the reactor is at least 0.25 weight percent, at least 0.35 weight percent, at least 0.40 weight percent, at least 0.45 weight percent, at least 0.50 weight percent, or at least 0.55 weight percent, based on the total weight of the reactor feed stream.

[0218] In one embodiment, or in combination with any of the described embodiments, the reactor purge stream may be withdrawn in an intermittent manner from the solvolysis (or methanolysis) reactor when the feed stream to the solvolysis or methanolysis facility (or reactor) has a lower content of inert components. In one embodiment, or in combination with any of the described embodiments, the reactor purge may be conducted intermittently (or in a batch mode) when the amount of inert components in the feed stream to the reactor is less than 0.40, 0.35 or less, 0.30 or less, 0.25 or less, 0.20 or less, 0.15 or less, or 0.10 or less, based on the total weight of the reactor feed. In one embodiment or in combination with any of the described embodiments, at least a portion of the reactor purge stream may be pelletized, tableted, or flaked to form solids, and at least a portion of the solids may be transferred to one or more downstream facilities as described herein. Pelletizing may be performed with a reactor purge stream having a higher degree of cross-linking (e.g., a chain length of at least 6, at least 7, at least 8, or at least 10), while tableting and flaking may be performed with a lower degree of cross-linking (e.g., less than 6). , 5 or less, 4 or less, or 3 or less).

[0219] If pelletized, the molten feed stream can optionally be passed through a filter, and the resulting filtrate can be fed to a pelletizer. In the pelletizer, the molten feed passes through a die plate with multiple holes, and the resulting polymer strands are cut, optionally under water, to form pellets. The resulting pellets can have an average particle size, measured along their longest dimension, of at least 0.5 mm, at least 0.75 mm, at least 0.90 mm, at least 1 mm, at least 1.1 mm, at least 1.25 mm, and / or no more than 2.25 mm, no more than 2.1 mm, no more than 2 mm, no more than 1.75 mm, or no more than 1.6 mm, or in the ranges of 0.5 to 2.25 mm, 0.9 to 2.1 mm, or 1 to 2 mm.

[0220]

[0220] If tableting, the molten feed stream can optionally be passed through a filter, and the resulting filtrate can be fed to a pastillator. In the pastillator, the molten feed is introduced into a cylindrical rotoform, which rotates and deposits droplets of the molten stream onto a moving belt. The temperature of the feed to the rotoform can be at least 230°C, at least 235°C, at least 240°C, at least 245°C, at least 250°C, or at least 255°C, and / or up to 270°C, up to 265°C, up to 260°C, up to 255°C, or up to 250°C, or in the range of 230-270°C, 240-265°C, or 250-260°C.

[0221] Water or other suitable fluid medium having a temperature of at least 27°C, at least 30°C, at least 32°C, at least 35°C, and / or no more than 50°C, no more than 45°C, no more than 40°C, no more than 35°C, or no more than 32°C, or in the ranges of 27-50°C, 30-45°C, or 30-40°C, may be applied to the belt to cool and solidify the molten droplets. The solid pastels may then be collected and, if desired, transported to one or more locations within chemical recycling facility 10 as discussed herein. The produced pastels may have an average particle size measured along the longest particle dimension of at least 0.5 mm, at least 1 mm, at least 1.5 mm, at least 2 mm, at least 2.5 mm, at least 3 mm, at least 3.5 mm, or at least 4 mm, and / or no more than 8 mm, no more than 7.5 mm, no more than 7 mm, no more than 6.5 mm, no more than 6 mm, or in the ranges of 1-8 mm, 1.5-7.5 mm, 2-7 mm, or 4-6 mm.

[0222] In one embodiment, or in combination with any of the described embodiments, a belt flaker or drum flaker can be used to form flakes of polymeric material. When flaking with a belt flaker, the molten feed stream can be passed through a filter, and the resulting filtrate can be pumped into a cylindrical rotoform in a manner similar to that described for tableting. However, in flaking, the rotational speed of the rotoform can be slowed or stopped so that the molten feed stream can be deposited directly onto the belt. The speed of the rotoform and belt, as well as the temperature of the rotoform and melt, can be controlled to achieve the desired thickness of material on the belt. Generally, the temperature of the feed to the rotoform can be at least 230°C, at least 235°C, at least 240°C, at least 245°C, at least 250°C, or at least 255°C, and / or up to 270°C, up to 265°C, up to 260°C, up to 255°C, or up to 250°C, or in the range of 230-270°C, 240-265°C, or 250-260°C.

[0223] Once placed on the belt as a sheet or layer of molten polymer, it can be heated to a temperature of at least 27°C, at least 30°C, at least 32°C, at least 35°C, and / or at least 50°C. Water or other suitable fluid medium having a temperature of 45°C or less, 40°C or less, 35°C or less, or 32°C or less, or in the range of 27-50°C, 30-45°C, or 30-40°C, is applied to the belt, thereby allowing the molten material to cool and solidify. Solid pieces or flakes are formed, collected, and optionally transported to one or more locations within chemical recycling facility 10 as discussed herein. The average thickness of the resulting flakes, measured along the thickest portion of the flakes, can be at least 0.5 mm, at least 1 mm, at least 1.5 mm, at least 2 mm, at least 2.5 mm, and / or 4 mm or less, 3.5 mm or less, 3 mm or less, 2.5 mm or less, 2 mm or less, 1.5 mm or less, 1 mm, or 0.75 mm or less, or in the range of 0.5-4 mm, or 1-3 mm, or 1-2 mm.

[0224] When flaking in a drum flaker, the feed stream can be passed through a filter, and the resulting molten filtrate can be deposited onto the surface of a rotating, internally cooled drum. As the material contacts the surface of the cooled drum, it solidifies, and a scraper or fixed knife can be used to remove the material in flakes. The average thickness of the resulting flakes, measured along the thickest part of the flakes, can be at least 0.5 mm, at least 1 mm, at least 1.5 mm, at least 2 mm, at least 2.5 mm, and / or no more than 4 mm, no more than 3.5 mm, no more than 3 mm, no more than 2.5 mm, no more than 2 mm, no more than 1.5 mm, no more than 1 mm, no more than 1 mm, or no more than 0.75 mm, or in the range of 0.5 to 4 mm, or 1 to 3 mm, or 1 to 2 mm.

[0225] In one embodiment, or in combination with any of the described embodiments, as generally shown with respect to solvolysis facility 230 in Figure 2, the effluent stream from the reaction zone within solvolysis facility 30 may optionally be routed through a non-PET separation zone 220 located downstream of the reactor, as previously discussed in detail. This post-reactor non-PET separation zone 220 may also be used in addition to, or instead of, the non-PET separation zone 220 upstream of the reactor as shown in Figure 2.

[0226] 2 and 3, the effluent stream 222 produced from reaction zone 240 (or 340 in methanolysis facility 330), or, if present, non-PET separation zone 220, can be passed through product separation zone 250 (or 350), where at least 50 weight percent of the major solvent (or methanol) in the feed stream introduced into product separation zone 250 (or 350) is separated. In one embodiment, or in combination with any of the described embodiments, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, or at least 90 weight percent of the total amount of major solvent (or methanol, if the solvolysis facility is a methanolysis facility) can be separated from the feed stream in product separation zone 250 (or 350).

[0227] 2 and 3, a stream 222 comprising primarily main solvent 222 (or, in the case of a methanolysis facility, a stream comprising primarily methanol 322) can be removed from product separation zone 250 (or 350). In one embodiment, or in combination with any of the described embodiments, this main solvent stream 222 (or methanol stream 322) can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent main solvent (or methanol), based on the total weight of the stream.

[0228] In one embodiment or in combination with any of the described embodiments, at least a portion, or all, of this main solvent stream 222 (or methanol stream 322) may be recycled to the inlet of solvolysis facility 230 (or methanolysis facility 330) and reintroduced along with a new stream of PET-containing or PET-rich waste plastic. Additionally or in an alternative embodiment, at least a portion, or all, of solvent stream 222 (or methanol stream 322) may be sent to one or more of other facilities within or external to chemical recycling facility 10.

[0229] Additionally, as shown in Figures 2 and 3, product separation zone 250 (or 350) may be configured to provide a stream rich in major glycol 224 and a stream rich in major terephthalyl 226, or, if the facility is a methanolysis facility as shown in Figure 3, to provide a stream rich in EG 324 and a stream rich in DMT 326.

[0230] In one embodiment, or in combination with any of the described embodiments, major glycol stream 224 (or EG stream 324) can comprise at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, or at least 85 weight percent major glycol (or EG), based on the total weight of the stream. This can correspond to at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the total weight of major glycol (or EG) introduced into product separation zone 250 (or 350).

[0231] Similarly, the major terephthalyl stream 226 (or DMT stream 326) can contain at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, or at least 85 weight percent major terephthalyl (or DMT), based on the total weight of the stream. This can correspond to at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the total weight of major terephthalyl (or DMT) introduced into product separation zone 250 (or 350).

[0232] Any suitable separation device or method can be used in product separation zone 250 (or 350) to obtain a major solvent-rich stream (or methanol), a major glycol (or EG), and a major terephthalyl (or DMT). Examples of suitable separation methods include, but are not limited to, distillation, extraction, decanting, and combinations thereof. Equipment associated with such methods can include columns, vessels, decanters, membranes, and combinations thereof. In one embodiment, or in combination with any of the described embodiments, at least one separation step may be performed to separate the solvent from the major glycol (or, in the case of methanolysis, methanol from EG), and at least one other separation step may be performed to separate the major glycol (or DMT) from the major terephthalyl. Alternatively, it may be performed to separate EG from DMT.

[0233] 2 and 3, the major glycol stream 224 (324) withdrawn from product separation zone 250 (350) can be passed through glycol separation zone 260, where at least 50 weight percent of the major glycols in stream 224 introduced therein can be separated. When the solvolysis facility is a methanolysis facility, as shown in FIG. 3, the glycol separation zone is EG separation zone 360, which is used to separate at least 50 weight percent EG from stream 324 introduced therein. Glycol separation zone 260 (or EG separation zone 360) can include any suitable device or utilize any suitable method needed to effect the separation, including, but not limited to, distillation (including azeotropic distillation), extraction, filtering, and combinations thereof.

[0234] 2 and 3, glycol separation zone 260 (or EG separation zone 360) may be configured to separate at least a portion of the remaining solvent (or methanol) from glycol stream 224 (or EG stream 324) withdrawn from product separation zone 250 (or 350). In one embodiment, or in combination with any of the described embodiments, this solvent (or methanol) stream withdrawn from glycol (or EG) separation zone 204 (or 304) can contain at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent solvent (or methanol), based on the total weight of the stream.

[0235] 2 and 3, a stream of recycled component glycol 206 (or recycled component EG 306) and a stream of glycol sludge 228 (or a stream of EG sludge 328) may also be removed from glycol separation zone 260 (or 360). In one embodiment, or in combination with any of the described embodiments, r-glycol stream 206 and glycol sludge stream 228 (or r-EG stream 306 and EG sludge stream 328) can contain 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of solvent (or methanol), based on the total weight of each respective stream.

[0236] In one embodiment, or in combination with any of the described embodiments, glycol separation zone 260 (or EG separation zone 360) may be configured to provide a stream rich in major glycols 206. In one embodiment, or in combination with any of the described embodiments, glycol rich stream 206 can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 97 weight percent major glycols, based on the total weight of the stream.

[0237] In one embodiment or in combination with any of the described embodiments, the glycol stream 206 withdrawn from the glycol separation zone 260 has a glycol content of at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, based on the total weight of the stream. The recycled component glycols may comprise at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent of the total r-glycols produced in the solvolysis facility 230. This may correspond to at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, at least 97 weight percent, or at least 99 weight percent of the total r-glycols produced in the solvolysis facility 230.

[0238]

[0238] When the solvolysis facility is a methanolysis facility 330 as shown in Figure 3, the EG separation zone 360 ​​is configured to provide a stream enriched in EG 306. In one embodiment, or in combination with any of the described embodiments, the EG stream 306 withdrawn from the EG separation zone 360 ​​can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 97 weight percent EG, based on the total weight of the stream.

[0239]

[0239] In one embodiment or in combination with any of the described embodiments, the EG stream 306 withdrawn from the EG separation zone 360 ​​can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent recycled component EG, based on the total weight of the stream. This may correspond to at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, at least 97 weight percent, or at least 99 weight percent of the total amount of EG produced within the methanolysis facility, which can be routed for further processing, storage, and / or use.

[0240] As shown in FIGS. 2 and 3, glycol separation zone 260 (or, in the case of methanolysis, EG separation zone 360) may also be configured to provide glycol column bottoms by-product stream 228 (or EG bottoms by-product stream). The terms "glycol bottoms" or "glycol column bottoms" or "glycol sludge" refer to components other than the major glycol having a boiling point (or azeotrope) higher than the boiling point of the major glycol but lower than the boiling point of the major terephthalyl. Similarly, the terms "EG bottoms" or "EG column bottoms" or "EG sludge" refer to components other than the major glycol having a boiling point (or azeotrope) higher than the boiling point of the major glycol but lower than the boiling point of the major terephthalyl.

[0241] In one embodiment or combination with any of the described embodiments, the glycol column bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, the EG bottoms or EG sludge stream 328) is at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent The primary glycol (or ethylene glycol) may comprise at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of a component having a boiling point higher than the boiling point of the primary glycol (or ethylene glycol).

[0242] In one embodiment, or in combination with any of the described embodiments, glycol column bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, EG bottoms or EG sludge stream 328) can contain no more than 60 weight percent, no more than 55 weight percent, no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent of components having a boiling point lower than the boiling point of the major glycol (or ethylene glycol). Glycol column bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, EG bottoms or EG sludge stream 328) can have a moderate boiling point higher than the boiling point of the major glycol (or ethylene glycol).

[0243] In one embodiment or in combination with any of the described embodiments, the bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, the EG bottoms or EG sludge stream 328) is fed to a Brookfield EG column having a V80-40 vane spindle operating at a shear rate of 10 rad / sec and a temperature of 250° C. at least 0.001 Pascal seconds (0.01 poise) (Pa·s (P)), at least 0.005 Pa·s (0.05P), at least 0.010 Pa·s (0.10P), at least 0.025 Pa·s (0.25P), at least 0.050 Pa·s (0.50P), at least 0.1 Pa·s (1P), at least 0.2 Pa·s (2P), at least 0.3 Pa·s (3P), at least 0.5 Pa·s (5P), at least 0.8 Pa·s (8P), and / or 1.5 Pa·s (10P), as measured using an R / S rheometer It may have a viscosity of 15 Pa·s or less, 1.2 Pa·s (12 P) or less, 1 Pa·s (10 P) or less, 0.8 Pa·s (8 P) or less, 0.6 Pa·s (6 P) or less, 0.5 Pa·s (5 P) or less, 0.3 Pa·s (3 P) or less, 0.2 Pa·s (2 P) or less, 0.1 Pa·s (1 P) or less, or 0.05 Pa·s (0.5 P) or less, or in the range of 0.001 to 1.5 Pa·s (0.01 to 15 P), 0.005 to 1 Pa·s (0.05 to 10 P), or 0.010 to 0.5 Pa·s (0.10 to 5 P).

[0244]

[0244] The total solids content of the glycol column bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, the EG bottoms or EG sludge stream 328) can be 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.5 weight percent or less, based on the total weight of the stream.

[0245] In one embodiment or in combination with any of the described embodiments, the glycol can comprise an oligomer comprising at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 92 weight percent, at least 95 weight percent, at least 97 weight percent, at least 98 weight percent, at least 99 weight percent, or at least 99.5 weight percent polyester moieties, based on the total weight of the stream. As used herein, the term "polyester moieties" refers to portions or residues of polyesters, or reaction products of polyester portions or residues.

[0246] The oligomer can have a chain length of at least 2 monomer units, at least 3 monomer units, at least 4 monomer units, at least 5 monomer units, at least 6 monomer units, at least 7 monomer units, or at least 8 monomer units, and / or a chain length of no more than 30 monomer units, no more than 27 monomer units, no more than 25 monomer units, no more than 22 monomer units, no more than 20 monomer units, no more than 17 monomer units, no more than 15 monomer units, no more than 12 monomer units, or no more than 10 monomer units, or a chain length in the range of 2 to 30 monomer units, 3 to 25 monomer units, or 5 to 20 monomer units. The oligomer can include portions of treated polyesters, including, for example, PET.

[0247] In one embodiment, or in combination with any of the described embodiments, the bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, the EG bottoms or EG sludge stream 328) comprises at least 0.01 weight percent, at least 0.05 weight percent, at least 0.10 weight percent, at least 0.50 weight percent, at least 1 weight percent, or at least 1.5 weight percent, and / or no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, or no more than 2 weight percent of non-oligomeric components, based on the total weight of the stream, or these components may be present in an amount ranging from 0.01 to 40 weight percent, from 0.10 to 30 weight percent, or from 1 to 20 weight percent, based on the total weight of the stream.

[0248]

[0248] In one embodiment or in combination with any of the described embodiments, the oligomer further comprises at least one ester other than dimethyl terephthalate, at least one carboxylic acid other than terephthalic acid, and / or at least one glycol other than ethylene glycol moiety. For example, oligomers include diethylene glycol, triethylene glycol, 1,4-cyclohexane-dimethanol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentane-diol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropane-diol-(1,3), hexanediol-(1,3), 1,4-di-(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane , 2,2,4,4-tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone, BDS-(2,2-(sulfonylbis)4,1-phenyleneoxy))bis(ethanol), phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, diphenyl-3,4'-dicarboxylic acid, 2,2-dimethyl-1,3-propanediol, dicarboxylic acids, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and combinations thereof.

[0249] Bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, EG bottoms or EG sludge stream 328) may also contain primary glycol (or, in the case of methanolysis, ethylene glycol) in an amount of at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 3 weight percent, at least 5 weight percent, or at least 8 weight percent, and / or no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 12 weight percent, or no more than 10 weight percent, based on the total weight of the stream, or from 0.5 to 30 weight percent, based on the total weight of the stream. The polyolefin polymer may contain a major glycol (or ethylene glycol) in an amount ranging from 1 to 25 weight percent, or from 5 to 20 weight percent. The major glycol (or ethylene glycol) may be present by itself (in a free state) or as part of another compound. Other examples of possible major glycols (depending on the specific type of PET or other polymer being treated) include, but are not limited to, diethylene glycol, neopentyl glycol, 1,4-cyclohexanedimethanol, and 2,2,4,4-tetramethyl-1,3-cyclobutanediol.

[0250] In one embodiment or in combination with any of the described embodiments, the glycol column bottoms (or glycol sludge) by-product stream 228 can further comprise at least one glycol other than the primary glycol. In the case of methanolysis, the EG bottoms or EG sludge stream 328 can comprise at least one glycol other than EG. Some examples of other glycols include, but are not limited to, diethylene glycol, triethylene glycol, 1,4-cyclohexane-dimethanol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentane-diol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropane-diol-(1,3), hexanediol, ... Examples of suitable glycols include 1,3-, 1,4-di-(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, 2,2,4,4-tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone, BDS-(2,2-(sulfonylbis)4,1-phenyleneoxy))bis(ethanol), and combinations thereof. The other glycols may not be ethylene glycol or may not contain ethylene glycol.

[0251] In one embodiment or combination with any of the described embodiments, glycols other than the primary glycol (or ethylene glycol, in the case of methanolysis) are added to the glycol column bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, EG bottoms or EG sludge stream 328) in an amount of at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, based on the total weight of glycols in the stream. percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, or at least 75 weight percent, and / or up to 99 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, up to 75 weight percent, up to 70 weight percent, up to 65 weight percent, up to 60 weight percent, up to 55 weight percent, up to 50 weight percent, up to 45 weight percent, up to 40 weight percent, or up to 35 weight percent, or in an amount ranging from 5 to 75 weight percent, 10 to 60 weight percent, or 15 to 45 weight percent, based on the total weight of the stream.

[0252] In one embodiment or in combination with any of the described embodiments, the weight ratio of the at least one glycol other than the major glycol (or ethylene glycol) to the major glycol (or ethylene glycol) is at least 0.5:1, at least 0.55:1, at least 0.65:1, at least 0.70:1, at least 0.75:1, at least 0.80:1, at least 0.85:1, at least 0.86:1, at least 0.87:1, at least 0.88:1, at least 0.89:1, at least 0.90:1, at least 0.91:1, at least 0.92:1, at least 0.93:1, at least 0.94:1, at least 0.95:1, at least 0.96:1, at least 0.97:1, at least 0.98:1, at least 0.9 ... 1, at least 0.80:1, at least 0.85:1, at least 0.90:1, at least 0.95:1, at least 0.97:1, at least 0.99:1, at least 1:1, at least 1.05:1, at least 1.1:1, at least 1.15:1, at least 1.2:1, or at least 1.25:1. In addition or alternative embodiments, the weight ratio of the at least one glycol other than the major glycol (or ethylene glycol) to the major glycol (or ethylene glycol) is 5:1 or less, 4.5:1 or less, 4:1 or less, 3.5:1 or less, 3:1 or less, 2.5:1 or less, 2:1 or less, 1.5:1 or less, 1.25:1 or less, or 1:1 or less, or can range from 0.5:1 to 5:1, or from 0.75:1 to 3.5:1, or from 0.95:1 to 1.25:1.

[0253] In one embodiment, or in combination with any of the described embodiments, the bottoms (or glycol sludge) by-product stream 228 (or, in the case of methanolysis, the EG bottoms or EG sludge stream 328) withdrawn from the solvolysis facility 230 (or methanolysis facility 330) and / or introduced into one or more downstream facilities shown in FIG. 1 is heated to a temperature of at least 150° C., at least 100° C., ... The stream 228 (or 328) can have a temperature of at least 155°C, at least 160°C, at least 165°C, at least 170°C, at least 175°C, at least 180°C, at least 185°C, at least 190°C, or at least 195°C, and / or no greater than 260°C, no greater than 255°C, no greater than 250°C, no greater than 245°C, no greater than 240°C, no greater than 235°C, no greater than 230°C, or no greater than 225°C, or the temperature can range from 150 to 260°C, 175 to 250°C, or 190 to 240°C. Stream 228 (or 328) can be in the form of a liquid, a melt, a slurry, or a plurality of solid particles.

[0254]

[0254] Referring again to Figure 2, stream 226 containing primarily terephthalyl can be passed from product separation zone 250 to terephthalyl separation zone 270, where at least 50 weight percent of the primary terephthalyl in the stream introduced into the terephthalyl separation zone is separated. If the facility is a methanolysis facility as shown in Figure 3, stream 326 containing primarily DMT can be passed from product separation zone 350 to DMT separation zone 370. Terephthalyl separation zone 270 of solvolysis facility 230 (or DMT separation zone 370 of methanolysis facility 330) can include any suitable device or utilize any suitable method required for separation, including, but not limited to, distillation (including azeotropic distillation), extraction, filtering, crystallization, washing, drying, and combinations thereof.

[0255] 2 and 3, the terephthalyl separation zone 270 (or DMT separation zone 370) may be configured to provide a primary terephthalyl 208-rich stream (or DMT-rich stream 308). In one embodiment, or in combination with any of the described embodiments, the terephthalyl stream 208 (or DMT stream 308) can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 97 weight percent terephthalyl (or DMT), based on the total weight of the stream. This may correspond to at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, at least 97 weight percent, or at least 99 weight percent of the total amount of terephthalyl (or DMT) produced in the solvolysis facility 230 (or methanolysis facility 330). In combination with any of the described embodiments, the terephthalyl stream 208 (or DMT stream 308) withdrawn from the terephthalyl separation zone can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent recycled component terephthalyl, based on the total weight of the stream. The terephthalyl stream 208 (or DMT stream 308) can also be routed for further processing, storage, and / or use.

[0256]

[0256] When the solvolysis facility is a methanolysis facility 330 as shown in Figure 3, the DMT separation zone 370 is configured to produce a recycle component DMT (r-DMT)-enriched stream 308. In one embodiment, or in combination with any of the described embodiments, the r-DMT stream 308 can contain at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 97 weight percent r-DMT, based on the total weight of the stream. This can correspond to at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, at least 97 weight percent, or at least 99 weight percent of the total amount of r-DMT produced in the methanolysis facility 330.

[0257] In one embodiment or in combination with any of the described embodiments, the DMT stream 308 withdrawn from the DMT separation zone 370 can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent recycled component DMT, based on the total weight of the stream. The r-DMT stream 308 can also be routed for further processing, storage, and / or use.

[0258] As shown in Figure 2, terephthalyl separation zone 270 may be configured to provide a terephthalyl bottoms (or terephthalyl sludge) by-product stream 232. The terms "terephthalyl bottoms" or "terephthalyl column bottoms" or "terephthalyl sludge" refer to components (or azeotropes) other than the primary terephthalyl that have a boiling point higher than that of the primary terephthalyl. Similarly, DMT separation zone 370 shown in methanolysis facility 330 in Figure 3 may also be configured to provide a DMT bottoms (or DMT sludge) by-product stream 332. The terms "terephthalyl bottoms" or "terephthalyl column bottoms" or "terephthalyl sludge" refer to components (or azeotropes) other than the primary terephthalyl that have a boiling point higher than that of the primary terephthalyl.

[0259]

[0259] In one embodiment or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can contain at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of components having a boiling point higher than the boiling point of the primary terephthalyl (or DMT). In one embodiment, or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can contain 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less of components having a boiling point lower than that of DMT. The terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can have a medium boiling point higher than that of the primary terephthalyl (or DMT).

[0260] In one embodiment or combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) is fed to a Brookfield sludge refinery having a V80-40 vane spindle operating at a shear rate of 10 rad / sec and a temperature of 250° C. a viscosity of at least 0.001 Pascal seconds (0.01 poise) (Pa·s (P)), at least 0.005 Pa·s (0.05P), at least 0.010 Pa·s (0.10P), at least 0.025 Pa·s (0.25P), at least 0.050 Pa·s (0.50P), at least 0.1 Pa·s (1P), at least 0.2 Pa·s (2P), at least 0.3 Pa·s (3P), at least 0.5 Pa·s (5P), at least 0.6 Pa·s (6P), or at least 0.8 Pa·s (8P), and / or 1 Pa·s ( The viscosity may be 0.10 P or less, 0.8 Pa·s (8 P) or less, 0.6 Pa·s (6 P) or less, 0.5 Pa·s (5 P) or less, 0.3 Pa·s (3 P) or less, 0.2 Pa·s (2 P) or less, 0.1 Pa·s (1 P) or less, 0.05 Pa·s (0.5 P) or less, 0.01 Pa·s (0.1 P) or less, 0.005 Pa·s (0.05 P) or less, or 0.0025 Pa·s (0.025 P) or less, or may have a viscosity in the range of 0.001 to 1 Pa·s (0.01 to 10 P), 0.005 to 0.6 Pa·s (0.05 to 6 P), or 0.1 to 0.5 Pa·s (1 to 5 P).

[0261] The total solids content of the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can be 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.5 weight percent or less, based on the total weight of the stream. In one embodiment, or in combination with any of the described embodiments, the terephthalyl sludge by-product stream 232 (or DMT sludge by-product stream 332) can include particles of DMT formed by tableting, pelleting, or flaking. The particles, if present, may be transported as particles or may be combined with a liquid to form a slurry.

[0262] In one embodiment or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) comprises at least 60 weight percent, based on the total weight of the stream, at least The oligomer may comprise an oligomer comprising 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 92 weight percent, at least 95 weight percent, at least 97 weight percent, at least 98 weight percent, at least 99 weight percent, or at least 99.5 weight percent polyester moieties. The oligomer may have at least 2 monomer units, at least 3 monomer units, at least 4 monomer units, at least 5 monomer units, at least 6 monomer units, at least 7 monomer units, or at least 8 monomer units, and / or a chain length of 30 monomer units or less, 27 monomer units or less, 25 monomer units or less, 22 monomer units or less, 20 monomer units or less, 17 monomer units or less, 15 monomer units or less, 12 monomer units or less, or 10 monomer units or less, or the chain length may range from 2 to 30 monomer units, 4 to 25 monomer units, or 5 to 20 monomer units.

[0263] The oligomers can comprise a portion of the polyester being treated, e.g., PET. In one embodiment, or in combination with any of the described embodiments, the terephthalyl bottoms by-product stream comprises at least 0.01 weight percent, at least 0.05 weight percent, at least 0.10 weight percent, at least 0.50 weight percent, at least 1 weight percent, or at least 1.5 weight percent, and / or no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, or no more than 2 weight percent of non-oligomeric components, based on the total weight of the stream, or the non-oligomeric components can range from 0.01 to 40 weight percent, 0.10 to 30 weight percent, or 1 to 10 weight percent, based on the total weight of the stream.

[0264]

[0264] In one embodiment or in combination with any of the described embodiments, the oligomer further comprises at least one ester other than dimethyl terephthalate, at least one carboxylic acid other than terephthalic acid or DMT, and / or at least one glycol other than ethylene glycol. For example, oligomers include diethylene glycol, triethylene glycol, 1,4-cyclohexane-dimethanol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4), 2,2,4-trimethylpentane-diol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropane-diol-(1,3), hexanediol-(1,3), 1,4-di-(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, and the like. The aqueous dispersion medium may further comprise one or more moieties of methylpropane, 2,2,4,4 tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone, BDS-(2,2-(sulfonylbis)4,1-phenyleneoxy))bis(ethanol), phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, diphenyl-3,4'-dicarboxylic acid, 2,2-dimethyl-1,3-propanediol, dicarboxylic acids, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and combinations thereof.

[0265] Terephthalyl Bottoms or Sludge By-Product Stream 232 (or DMT Bottoms or Sludge By-Product Stream 332) also contains, based on the total weight of the by-product streams, the primary terephthalyl In the case of primary terephthalyl or methanolysis, DMT may be present in an amount of at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent and / or no more than 99 weight percent, no more than 95 weight percent, no more than 90 weight percent, no more than 85 weight percent, no more than 80 weight percent, no more than 75 weight percent, no more than 70 weight percent, no more than 65 weight percent, no more than 60 weight percent, no more than 55 weight percent, no more than 50 weight percent, no more than 45 weight percent, or no more than 40 weight percent, or in the case of primary terephthalyl or methanolysis, DMT may be present in an amount of 40-99 weight percent, 50-90 weight percent, or 55-90 weight percent, based on the total weight of the stream.

[0266] Additionally, the terephthalyl bottoms or sludge by-product stream 232 (or the DMT bottoms or sludge by-product stream 332) may contain trace amounts of major glycols (or ethylene glycol, in the case of methanolysis). Examples of possible major glycols (depending on the PET or other polymer being processed) may include, but are not limited to, diethylene glycol, neopentyl glycol, 1,4-cyclohexanedimethanol, and 2,2,4,4-tetramethyl-1,3-cyclobutanediol. In one embodiment, or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or the DMT bottoms or sludge by-product stream 332) may contain, based on the total weight of the stream, 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 4 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.5 weight percent or less of major glycols (or ethylene glycol).

[0267]

[0267] In one embodiment or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can contain 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, 5 weight percent or less, 4 weight percent or less, 2 weight percent or less, 1 weight percent or less, 0.5 weight percent or less of terephthalyl (or carboxyl) other than the primary terephthalyl (or DMT), based on the total weight of the stream.

[0268] In one embodiment or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) may further comprise at least one substituted terephthalyl component. As used herein, the term "substituted terephthalyl" refers to a terephthalyl component having at least one substituted atom or group. In one embodiment, or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) has a saturation rate of at least 1 part per billion by weight, at least 100 parts per billion by weight, at least 500 parts per billion by weight, or at least 1 part per million by weight, at least 50 parts per million by weight, at least 1000 parts per million by weight, at least 2500 parts per million by weight, at least 5000 parts per million by weight, at least 7500 parts per million by weight, or at least 10,000 parts per million by weight, or at least 1 percent by weight, at least 2 percent by weight, or at least 5 percent by weight, and / or 25 percent by weight or less, 20 percent by weight or less, 15 percent by weight or less, 10 percent by weight or less, 5 percent by weight or less, based on the total weight of the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332). percent or less, 2 percent or less, 1 percent or less, 0.5 percent or less, 0.1 percent or less, 0.05 percent or less, or 0.01 percent or less by weight of the substituted terephthalyl component, or the substituted terephthalyl component may be present in an amount ranging from 100 ppb to 20 percent by weight, from 100 ppm to 10 percent by weight, or from 2500 ppm to 5 percent by weight, based on the total weight of the stream.

[0269] In one embodiment or combination with any of the described embodiments, terephthalyl other than the primary terephthalyl (or DMT, in the case of methanolysis) is present in the Terephthalyl Bottoms or Sludge By-Product Stream 232 (or DMT Bottoms or Sludge By-Product Stream 332) in an amount of at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 ... It can be present in an amount of 5 weight percent, at least 70 weight percent, or at least 75 weight percent, and / or no more than 99 weight percent, no more than 95 weight percent, no more than 90 weight percent, no more than 85 weight percent, no more than 80 weight percent, no more than 75 weight percent, no more than 70 weight percent, no more than 65 weight percent, no more than 60 weight percent, no more than 55 weight percent, no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, or no more than 35 weight percent, or can be present in an amount of 15 to 75 weight percent, 20 to 65 weight percent, or 25 to 50 weight percent, based on the total weight of the stream.

[0270]

[0270] In one embodiment or in combination with any of the described embodiments, the weight ratio of the at least one terephthalyl other than the primary terephthalyl to the primary terephthalyl is at least 0.5:1, at least 0.55:1, at least 0.65:1, at least 0.70:1, at least 0.75:1, at least 0.80:1, at least 0.85:1, at least 0.90:1, at least 0.95:1, at least 0.97:1, at least 0.99:1, at least 1:1, at least 1.05:1, at least 1.1:1, at least 1.15:1, at least 1.2:1, or at least 1.25:1. In addition, or in alternative embodiments, the weight ratio of the at least one terephthalyl other than the primary terephthalyl to the primary terephthalyl is 5:1 or less, 4.5:1 or less, 4:1 or less, 3.5:1 or less, 3:1 or less, 2.5:1 or less, 2:1 or less, 1.5:1 or less, 1.25:1 or less, or 1:1 or less, or can range from 0.5:1 to 5:1, 0:75:1 to 3.5:1, or 1:1 to 2.5:1.

[0271] In one embodiment, or in combination with any of the described embodiments, the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) withdrawn from the solvolysis facility 230 (or methanolysis facility 330) and / or the terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) introduced to one or more of the downstream facilities shown in FIG. 1 can be extracted from the solvolysis facility 230 (or methanolysis facility 330) by a suitable process. Upon drawing, it can have a temperature of at least 150°C, at least 155°C, at least 160°C, at least 165°C, at least 170°C, at least 175°C, at least 180°C, at least 185°C, at least 190°C, or at least 195°C, and / or no more than 260°C, no more than 255°C, no more than 250°C, no more than 245°C, no more than 240°C, no more than 235°C, no more than 230°C, or no more than 225°C, or the temperature can range from 150 to 260°C, 175 to 250°C, or 195 to 225°C.

[0272] In one embodiment, or in combination with any of the described embodiments, terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can comprise at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of components having a boiling point higher than the boiling point of DMT. In one embodiment, or in combination with any of the described embodiments, terephthalyl bottoms or sludge by-product stream 232 (or DMT bottoms or sludge by-product stream 332) can comprise no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent of components having a boiling point lower than the boiling point of DMT.

[0273] In one embodiment or in combination with any of the described embodiments, one or more of the by-product streams withdrawn from the solvolysis facility 230 (or methanolysis facility 330), including the polyolefin-containing by-product stream 216a,b (or 316), the terephthalyl (or DMT) sludge stream 232 (or 332), and the reactor purge by-product stream 218 (or 318), can be or include solids. Examples of such streams can include solid particles, as well as melts and slurries, transportable by solid transport devices and systems.

[0274]

[0274] In one embodiment or in combination with any of the described embodiments, the polyolefin-containing by-product stream 216a, b (or 316) may be pelletized or micropelletized and sent to a gasifier or sold as a product stream.

[0275] In one embodiment, or in combination with any of the described embodiments, the terephthalyl sludge 232 (or DMT sludge 332) may be formed into tablets or flakes (e.g., by a drum flaker) by any suitable method, and the tablets or flakes may be transported to the POX gasification facility 50 and / or transported for further transportation, storage, use, and / or disposal. In one embodiment, or in combination with any of the described embodiments, the terephthalyl sludge 232 (or DMT sludge 332) may be transported as a liquid-phase stream (e.g., as a melt or a slurry) to the POX gasification facility 50 and / or energy generation / production facility 80.

[0276] In one embodiment, or in combination with any of the described embodiments, reactor purge by-product stream 218 (or 318) may be formed into tablets or flakes (e.g., by a drum flaker) by any suitable method, and the tablets or flakes may be transported to POX gasification facility 50 and / or transported for further transportation, storage, use, and / or disposal. In one embodiment, or in combination with any of the described embodiments, reactor purge by-product stream 218 (or 318) may be transported as a liquid-phase stream (e.g., as a melt or slurry) to POX gasification facility 50 and / or energy generation / production facility 80. When the purge from the reactor is continuous, one or more of the above may occur. This can occur, for example, when the total content of inert components in the feed to the solvolysis (or methanolysis) facility 30 or chemical recycling facility 10 is less than 0.40 weight percent, 0.35 weight percent or less, 0.30 weight percent or less, 0.25 weight percent or less, 0.20 weight percent or less, 0.15 weight percent or less, or 0.10 weight percent or less, based on the total content of the feed stream, as shown in FIG.

[0277] In one embodiment or in combination with any of the described embodiments, reactor purge by-product stream 218 (or 318) may be formed into pellets or micropellets by any suitable method, and the pellets may be transported to POX gasification facility 50 and / or transported for further transportation, storage, use, and / or disposal. One or more of the above may occur when the reactor purge is batch. This may occur, for example, when the total content of inert components in the feed to solvolysis (or methanolysis) facility 30 or chemical recycling facility 10 is at least 0.40 weight percent, at least 0.45 weight percent, at least 0.50 weight percent, at least 0.55 weight percent, or at least 0.60 weight percent, based on the total content of the feed stream, as shown in FIG. 1 .

[0278] In one embodiment or in combination with any of the described embodiments, the glycol sludge 228 (or EG sludge 328) may be transported as a liquid phase stream to the POX gasification facility 50 and / or the energy generation / production facility 80. One or more of the above may occur when the purge from the reactor is continuous.

[0279] In one embodiment, or in combination with any of the described embodiments, all or a portion of one or more of the solvolysis by-product streams may be withdrawn from the solvolysis facility 30 and routed for further processing, storage, sale, and / or disposal. This may include one or more of the polyolefin-containing by-product stream, the reactor purge by-product stream, the glycol column bottoms by-product stream, and the terephthalyl column bottoms stream, as discussed above.

[0280] Solidification Facility

[0280] Referring again to Figure 1, the chemical recycling facility 10 may also include a solidification facility 40. As used herein, the term "solidification" refers to the transformation of non-solid materials into solids through physical means (e.g., cooling) and / or chemical means (e.g., precipitation). A "solidification facility" is a facility that includes all the equipment, lines, and controls necessary to effect the solidification of waste plastic-derived feedstock.

[0281]

[0281] Referring now to Figure 4, a schematic diagram of a solidification facility 40 suitable for use in a chemical recycling facility 10 such as that generally shown in Figure 1 is provided. As shown in Figure 4, the feed stream 112 introduced into the solidification facility 40 can originate from one or more locations within the chemical recycling facility. In one embodiment, or in combination with any of the described embodiments, the feed stream to the solidification facility 40 can include at least one of: (i) one or more solvolysis (or methanolysis) by-product streams 110, as previously described; (ii) a pyrolysis oil (pyoil) stream 120; and (iii) a pyrolysis residue stream 122. Definitions for pyrolysis oil and pyrolysis residue are provided in subsequent sections of this specification, and definitions for solvolysis (or methanolysis) by-products are provided in previous sections.

[0282] In one embodiment, or in combination with any of the described embodiments, one or more of these streams 110, 120, 122 may be introduced continuously into the solidification facility 40, and / or one or more of these streams 110, 120, 122 may be introduced intermittently. When multiple types of feed streams are present, each may be introduced separately, or all or a portion of the streams may be combined so that a combined stream can be introduced into the solidification facility 40. Combining, when implemented, may be done in a continuous or batch (intermittent) manner.

[0283] In one embodiment or in combination with any of the described embodiments, a solidification facility The feed stream 112 to solidification facility 40 can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the one or more solvolysis by-product streams 110, based on the total weight of the feed stream introduced to solidification facility 40. In addition, or in alternative embodiments, the feed stream to solidification facility 40 can comprise 99 weight percent or less, 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of one or more solvolysis by-product streams 110, based on the total weight of the feed stream introduced to solidification facility 40, or can comprise one or more solvolysis streams in an amount ranging from 1 to 99 weight percent, 10 to 90 weight percent, or 20 to 80 weight percent, based on the total weight of the stream.

[0284]

[0284] The solvolysis by-product stream 110 introduced into the solidification facility 40 can have a total recycled component content of at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent, based on the total weight of the solvolysis by-product stream(s) introduced into the solidification facility 40.

[0285]

[0285] In one embodiment or in combination with any of the described embodiments, the feed stream 112 to the solidification facility 40 can contain at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent pyrolysis oil, based on the total weight of the feed stream introduced to the solidification facility 40.

[0286] In addition, or in alternative embodiments, the feed stream 112 to the solidification facility 40 may contain less than 99 weight percent, less than 95 weight percent, less than 90 weight percent, less than 85 weight percent, less than 80 weight percent, less than 75 weight percent, less than 70 weight percent, less than 65 weight percent, less than 60 weight percent, less than 55 weight percent, less than 50 weight percent, less than 45 weight percent, less than 40 weight percent, less than 35 weight percent, less than 30 weight percent, based on the total weight of the feed stream 112 introduced to the solidification facility 40. The pyrolysis oil 120 introduced into the solidification facility 40 may contain less than 1 cent, less than 25 percent by weight, less than 20 percent by weight, less than 15 percent by weight, less than 10 percent by weight, less than 5 percent by weight, less than 2 percent by weight, or less than 1 percent by weight of pyrolysis oil. The pyrolysis oil 120 introduced into the solidification facility 40 may have a total recycled content of at least 1 percent by weight, at least 5 percent by weight, at least 10 percent by weight, at least 15 percent by weight, at least 20 percent by weight, at least 25 percent by weight, at least 30 percent by weight, at least 35 percent by weight, at least 40 percent by weight, at least 45 percent by weight, at least 50 percent by weight, at least 55 percent by weight, at least 60 percent by weight, at least 65 percent by weight, at least 70 percent by weight, at least 75 percent by weight, at least 80 percent by weight, at least 85 percent by weight, at least 90 percent by weight, or at least 95 percent by weight.

[0287]

[0287] In one embodiment or in combination with any of the described embodiments, the feed stream 112 to the solidification facility 40 can contain at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent pyrolysis residue 122, based on the total weight of the feed stream 112 introduced to the solidification facility 40.

[0288]

[0288] In addition, or in alternative embodiments, the feed stream 112 to the solidification facility 40 may contain less than 99 weight percent, less than 95 weight percent, less than 90 weight percent, less than 85 weight percent, less than 80 weight percent, less than 75 weight percent, less than 70 weight percent, less than 65 weight percent, less than 60 weight percent, less than 55 weight percent, less than 50 weight percent, less than 45 weight percent, less than 40 weight percent, less than 35 weight percent, less than 30 weight percent, less than 25 weight percent, less than 20 weight percent, less than 15 weight percent, less than 10 weight percent, less than 5 weight percent, less than 2 weight percent, or less than 1 weight percent pyrolysis residue 122, based on the total weight of the feed stream introduced to the solidification facility 40. The pyrolysis residue 122 introduced into the solidification facility 40 can have a total recycled content of at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent, based on the total weight of the pyrolysis residue 122 introduced into the solidification facility 40.

[0289] In one embodiment, or in combination with any of the described embodiments, the weight ratio of any one stream to another stream in the combined feed stream 112 is at least 1:10, at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:4, at least 1:3, at least 1:2, at least 1:1.5, or at least 1:1, and / or 10:1 or less, 9:1 or less, It can be 8:1 or less, 7:1 or less, 6:1 or less, 5:1 or less, 4:1 or less, 3:1 or less, 2:1 or less, 1.5:1 or less, or 1:1 or less, or can be in the range of 1:10 to 10:1, 1:5 to 5:1, or 1:3 to 3:1.

[0290] Solidification facility 40, shown generally in FIG. 4, includes a cooling zone 442 for cooling and at least partially solidifying feed stream 112, followed by an optional size reduction zone 444. Upon leaving cooling zone 442, all or a portion of the stream may be solidified material. In some cases, the solidified material may be in the form of sheets, blocks, or chunks, or the solidified material may be in the form of particles, pellets, micropellets, or powder. In one or more embodiments, when the feed stream is only partially solidified, the stream withdrawn from the cooling zone may include both solid and liquid phases. In one embodiment, or in combination with any of the described embodiments, at least a portion of the solid phase may be removed, and all or a portion of the liquid phase may be withdrawn from solidification facility 40 and introduced to another facility, optionally within a chemical recycling facility (e.g., solvolysis facility 30). In some embodiments (not shown), solidification facility 40 may also include a precipitation zone in addition to or instead of cooling zone 442 for chemically precipitating (solidifying) certain components from the liquid stream.

[0291] 4, solidification facility 40 may also include a size reduction zone 444 for reducing the size of solids withdrawn from cooling zone 442 (and / or settling zone, not shown) and forming a plurality of particles. In one embodiment, or in combination with any of the described embodiments, the size reduction step performed in size reduction zone 444 may include chopping, crushing, breaking, or grinding larger pieces or chunks of the solidified material to form particles. In other embodiments, at least a portion of the feed stream to solidification facility 40 may be at least partially cooled before being pelletized via a conventional pelletizing device utilized in size reduction zone 444.

[0292] Regardless of how the particles are formed, the resulting solids withdrawn from solidification facility 40 will be at least 50 microns, at least 75 microns, at least 100 microns, at least 150 microns, at least 250 microns, at least 350 microns, at least 450 microns, at least 500 microns, at least 750 microns, or at least 0.5 mm, at least 1 mm, at least 2 mm, at least 5 mm, or at least 10 mm, and / or at most 50 mm, at most 45 mm, or less. The particles may have an average particle size of 40 mm or less, 30 mm or less, 35 mm or less, 30 mm or less, 25 mm or less, 20 mm or less, 15 mm or less, 10 mm or less, 5 mm or less, 2 mm or less, 1 mm or less, or 750 microns or less, 500 microns or less, 250 microns or less, or 200 microns or less, or the average particle size may be in the range of 50 to 750 microns, or 100 to 500 microns, or 150 to 250 microns, or 0.5 to 50 mm, or 1 to 35 mm, or 5 to 25 mm.

[0293] In one embodiment, or in combination with any of the described embodiments, the solid can comprise a powder. In one embodiment, or in combination with any of the described embodiments, the solid can comprise pellets of any shape. The solid can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 ...15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, It can have a recycled content of at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent.

[0294] 4, solids withdrawn from solidification facility 40 can be routed to at least one of (i) pyrolysis facility 60, (ii) energy generation / production facility 80, (iii) POX gasification facility 50, and (iv) reuse or recycling facility 90. In one embodiment, or in combination with any of the described embodiments, the solids can be routed to only one of facilities (i) through (iv), while in other embodiments, the solids can be routed to two or more, or three or more, of facilities (i) through (iii).

[0295]

[0295] If routed to one or more downstream facilities, the solids in line 114 may be transported or introduced to the facility as solids (e.g., powder or pellets) or may be combined with a liquid stream (not shown) to form a slurry. Examples of suitable liquids may include, but are not limited to, water, alcohol, and combinations thereof. In one embodiment, or in combination with any of the described embodiments, at least a portion of the solids may be heated to at least partially melt the solids, and the resulting melt may be introduced to one or more of the facilities described above. Optionally, at least a portion of the solids may be sent to an industrial landfill (not shown).

[0296] Pyrolysis Facility As shown in FIG. 1 , in one embodiment or in combination with any of the described embodiments, the chemical recycling facility 10 can include a pyrolysis facility 60. As used herein, the term “pyrolysis” refers to the thermal decomposition of one or more organic materials at high temperatures in an inert (i.e., substantially oxygen-free) atmosphere. A “pyrolysis facility” is a facility that includes all the equipment, lines, and controls necessary to carry out the pyrolysis of waste plastics and feedstocks derived therefrom.

[0297]

[0297] Referring now to Figure 5, a schematic diagram of a pyrolysis facility 60 suitable for use in a chemical recycling facility in accordance with one or more embodiments of the present technology is provided. As shown in Figure 5, a feed stream 116 may be introduced to an inlet of the pyrolysis facility 60, where the feed stream 116 may be thermally decomposed at high temperatures in an inert environment. In one embodiment, or in combination with any of the described embodiments, the feed stream 116 to the pyrolysis facility 60 may include at least one of: (i) at least one solvolysis by-product stream 110 as previously described; (ii) a waste plastic PO-rich stream 104; and (iii) particles and / or melt from the solidification facility 40.

[0298]

[0298] One or more of these streams may be introduced continuously into the pyrolysis facility 60, or one or more of these streams may be introduced intermittently. When multiple types of feed streams are present, each may be introduced separately, or all or a portion of the streams may be combined so that a combined stream can be introduced into the pyrolysis facility 60. Combining, when carried out, can be done continuously or batchwise.

[0299] In one embodiment or in combination with any of the described embodiments, the feed stream to the pyrolysis facility 60 comprises at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, based on the total weight of the feed stream 116 introduced into the pyrolysis facility 60. at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent of the at least one solvolysis by-product stream 110. In addition, or in alternative embodiments, the feed stream 116 to the pyrolysis facility 60 can comprise 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, 25 weight percent or less, 20 weight percent or less, 15 weight percent or less, 10 weight percent or less, 5 weight percent or less, 2 weight percent or less, or 1 weight percent or less of at least one solvolysis by-product stream 110, based on the total weight of the feed stream 116 introduced to the pyrolysis facility 60, or the at least one solvolysis by-product stream 110 can be in the range of 1 to 99 weight percent, 10 to 90 weight percent, 20 to 80 weight percent, or 25 to 75 weight percent, based on the total weight of the stream.

[0300]

[0300] The at least one solvolysis by-product stream 110 introduced into the pyrolysis facility 60 can have a total recycled component content of at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent, based on the total weight of the solvolysis by-product stream(s) introduced into the pyrolysis facility 60 and / or based on the total weight of the feed stream 116.

[0301]

[0301] In one embodiment or in combination with any of the described embodiments, the feed stream 116 to the pyrolysis facility 60 can contain at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent PO-rich waste plastics, based on the total weight of the feed stream 116 introduced to the pyrolysis facility 60. In addition, or in alternative embodiments, the feed stream 116 to the pyrolysis facility 60 may contain less than or equal to 95 weight percent, less than or equal to 90 weight percent, less than or equal to 85 weight percent, less than or equal to 80 weight percent, less than or equal to 75 weight percent, less than or equal to 70 weight percent, less than or equal to 65 weight percent, less than or equal to 60 weight percent, less than or equal to 55 weight percent, less than or equal to 50 weight percent, less than or equal to 45 weight percent, less than or equal to 40 weight percent, less than or equal to 35 weight percent, less than or equal to 30 weight percent, less than or equal to 25 weight percent, less than or equal to 20 weight percent, less than or equal to 15 weight percent, less than or equal to 10 weight percent, less than or equal to 5 weight percent, less than or equal to 2 weight percent, or less than or equal to 1 weight percent, based on the total weight of the feed stream 116 introduced to the pyrolysis facility 60. The PO-rich waste plastics may comprise up to 100 percent or less of PO, or may comprise amounts ranging from 1 to 95 weight percent, 5 to 85 weight percent, or 10 to 75 weight percent, based on the total weight of the feed stream.

[0302] The PO-rich waste plastic introduced into the pyrolysis facility 60 can have a total recycled content of at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent, based on the total weight of the PO-rich waste plastic 104 introduced into the pyrolysis facility 60. As shown in FIG. 1 , the PO-rich plastic stream 104 can originate from the pre-treatment facility 20 and / or from another source of PO-rich waste plastic (not shown). The stream can be in the form of a plastic melt or in the form of particulates, or the stream can comprise a slurry.

[0303]

[0303] In one embodiment or in combination with any of the described embodiments, the feed stream 116 to the pyrolysis facility 60 may comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent solids-containing stream 114 (e.g., particles, slurry, and / or melt) from the solidification facility 40, based on the total weight of the feed stream 116 introduced to the pyrolysis facility 60.

[0304]

[0304] In addition, or in alternative embodiments, the feed stream 116 to the pyrolysis facility 60 may contain less than 95 weight percent, less than 90 weight percent, less than 85 weight percent, less than 80 weight percent, less than 75 weight percent, less than 70 weight percent, less than 65 weight percent, less than 60 weight percent, less than 55 weight percent, less than 50 weight percent, less than 45 weight percent, less than 40 weight percent, less than 35 weight percent, less than 30 weight percent, less than 25 weight percent, less than 20 weight percent, less than 15 weight percent, less than 10 weight percent, less than 5 weight percent, less than 2 weight percent, or less than 1 weight percent of the solids-containing stream 114 from the solidification facility 40, based on the total weight of the feed stream 116 introduced to the pyrolysis facility 60.

[0305] The PO-rich waste plastic stream 104 introduced into the pyrolysis facility 60 may contain at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, or less, based on the total weight of the solids-containing stream 114 (e.g., particles, slurry, and / or melt) from the solidification facility 40 introduced into the pyrolysis facility 60. The solids-containing stream may be in the form of particles, a slurry, or a melt and may originate from a solidification facility 40 as shown in Figure 1 and / or from another source (not shown). In one embodiment, or in combination with any of the described embodiments, the particles may be present in a liquid such that the feedstock is in the form of a slurry.

[0306] 5 , in one embodiment or in combination with any of the described embodiments, the PO-rich waste plastic stream 104 can be combined with one or more other streams including, for example, a by-product stream 110 from the solvolysis facility 30, a solids-containing stream 114 from the solidification facility 40, to form a combined pyrolysis feed stream 116. The combined stream 116 can have a PO content of at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, and / or at least 99 weight percent, based on the total weight of the combined stream 116. The PO or PO-rich stream 104 can comprise up to 90 weight percent, up to 95 weight percent, up to 90 weight percent, up to 85 weight percent, up to 80 weight percent, up to 75 weight percent, up to 70 weight percent, up to 65 weight percent, up to 60 weight percent, up to 55 weight percent, up to 50 weight percent, up to 45 weight percent, or up to 40 weight percent, or can comprise an amount ranging from 5 to 95 weight percent, 10 to 90 weight percent, 20 to 80 weight percent, or 25 to 75 weight percent, based on the total weight of the stream.

[0307]

[0307] In addition, or in alternative embodiments, the combined stream of PO-rich waste plastics and at least one other process stream from a portion of chemical recycling facility 10 may contain at least 1 weight percent, at least 2 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, and / or no more than 50 weight percent, no more than 45 weight percent, no more than 40 weight percent, no more than 35 weight percent, no more than 30 weight percent, no more than 25 weight percent, no more than 20 weight percent, no more than 15 weight percent, no more than 10 weight percent, no more than 5 weight percent, no more than 2 weight percent, no more than 1 weight percent of components other than polyolefins, based on the total weight of feed stream 116.

[0308]

[0308] In one embodiment, or in combination with any of the described embodiments, the weight ratio of any one of streams 104, 110, 114 to another stream in the combined stream can be at least 1:10, at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:4, at least 1:3, at least 1:2, at least 1:1.5, or at least 1:1, and / or 10:1 or less, 9:1 or less, 8:1 or less, 7:1 or less, 6:1 or less, 5:1 or less, 4:1 or less, 3:1 or less, 2:1 or less, 1.5:1, or 1:1 or less, or can be an amount in the range of 1:10 to 10:1, 1:5 to 5:1, or 1:3 to 3:1.

[0309]

[0309] As generally shown in Figure 5, the pyrolysis facility 60 includes a pyrolysis reactor 542 and a separation zone 544 for separating the product stream from the reactor effluent stream 117. In the pyrolysis reactor, at least a portion of the feedstock can be subjected to a pyrolysis reaction, thereby producing a pyrolysis effluent 117 comprising pyrolysis oil, pyrolysis gas, and pyrolysis residue. As used herein, the term "pyrolysis gas" refers to a composition resulting from pyrolysis that is gaseous at 25°C. As used herein, the term "pyrolysis oil" or "pyoil" refers to a composition resulting from pyrolysis that is liquid at 25°C and 101,325 Pa (1 atm). As used herein, the term "pyrolysis residue" refers to a composition resulting from pyrolysis that is not pyrolysis gas or pyrolysis oil and that contains primarily pyrolysis charcoal and pyrolysis heavy waxes. As used herein, the term "pyrolysis charcoal" refers to a carbon-containing composition resulting from pyrolysis that is solid at 200°C and 101,325 Pa (1 atm). As used herein, the term "pyrolysis heavy waxes" refers to a carbon-containing composition resulting from pyrolysis that is not pyrolysis charcoal, pyrolysis gas, or pyrolysis oil. 20+ Refers to hydrocarbons.

[0310]

[0310] Generally, pyrolysis is a process that involves the chemical and thermal decomposition of an introduced feedstock. While all pyrolysis processes can generally be characterized by a substantially oxygen-free reaction environment, pyrolysis processes can be further defined by, for example, the pyrolysis reaction temperature within the reactor, the residence time within the pyrolysis reactor, the type of reactor, the pressure within the pyrolysis reactor, and the presence or absence of a pyrolysis catalyst.

[0311] In one embodiment or in combination with any of the described embodiments, pyrolysis reactor 542 can be, for example, a screw extruder, a tubular reactor, a tank, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, a vacuum reactor, a microwave reactor, or an autoclave. Pyrolysis reactor 542 can include a single reaction vessel or two or more reaction vessels of the same or different types arranged in series or parallel.

[0312] In one embodiment or in combination with any of the described embodiments, the pyrolysis reaction can include heating and converting the feedstock in an atmosphere that is substantially oxygen-free or that contains less oxygen than ambient air. For example, the atmosphere in the pyrolysis reactor 542 can include no more than 5 volume percent, no more than 4 volume percent, no more than 3 volume percent, no more than 2 volume percent, no more than 1 volume percent, or no more than 0.5 volume percent oxygen gas, based on the internal volume of the reactor.

[0313] In one embodiment or in combination with any of the described embodiments, the feed stream 116 introduced into the pyrolysis reactor 542 can include a lift gas stream and / or feed gas stream 115, which can be used to introduce the feedstock or feed stream 116 into the pyrolysis reactor 542 and / or to promote various reactions within the pyrolysis reactor 542. For example, the lift gas and / or feed gas 115 can comprise, consist essentially of, or consist of nitrogen, carbon dioxide, and / or water vapor. The lift gas and / or feed gas can be added to the waste plastic or combined with the feed stream 116 prior to introduction into the pyrolysis reactor 542 and / or added directly to the pyrolysis reactor 542.

[0314] In one embodiment or combination with any of the described embodiments, the pyrolysis may be carried out in the presence of a lift gas and / or feed gas that comprises, consists essentially of, or consists of water vapor. For example, the pyrolysis may be carried out in the presence of at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, based on the total weight of the lift gas. percent, at least 60 percent, at least 65 percent, at least 70 percent, at least 75 percent, at least 80 percent, at least 85 percent, at least 90 percent, at least 95 percent, or at least 99 percent by weight of water vapor.

[0315] Additionally or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis is conducted in the presence of a feed gas and / or lift gas that includes 99 weight percent or less, 90 weight percent or less, 80 weight percent or less, 70 weight percent or less, 60 weight percent or less, 50 weight percent or less, 40 weight percent or less, 30 weight percent or less, or 20 weight percent or less of water vapor, based on the total weight of the lift gas. Without wishing to be bound by theory, it is believed that the presence of water vapor in the pyrolysis reactor 542 can promote a water-gas shift reaction, which can promote the removal of any halogen compounds that may be produced during the pyrolysis reaction. The water vapor may be added to the waste plastic or waste plastic-derived feed stream 116 prior to introduction into the pyrolysis reactor 542 and / or may be added directly to the pyrolysis reactor 542.

[0316] Additionally or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis can be carried out in the presence of a reducing gas, e.g., a lift gas and / or feed gas comprising, consisting essentially of, or consisting of hydrogen, carbon monoxide, or a combination thereof. The reducing gas can function as a feed gas and / or lift gas and can facilitate the introduction of the feedstock into the pyrolysis reactor. The reducing gas can be added to the waste plastic or waste plastic-derived feed stream 116 prior to introduction into the pyrolysis reactor 542 and / or can be added directly to the pyrolysis reactor 542.

[0317] In one embodiment or in combination with any of the described embodiments, the pyrolysis may be carried out in the presence of a feed gas and / or a lift gas comprising at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent of at least one reducing gas. Additionally or alternatively, in one embodiment or combination with any of the described embodiments, the pyrolysis is conducted in the presence of a feed gas and / or lift gas comprising at most 99 weight percent, at most 90 weight percent, at most 80 weight percent, at most 70 weight percent, at most 60 weight percent, at most 50 weight percent, at most 40 weight percent, at most 30 weight percent, or at most 20 weight percent of at least one reducing gas, or the reducing gas can be present in an amount ranging from 5 to 99 weight percent, from 15 to 90 weight percent, or from 20 to 75 weight percent, based on the total weight of the stream.

[0318] In one embodiment or combination with any of the described embodiments, the pyrolysis is at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent The pyrolysis may be carried out in the presence of a feed gas and / or lift gas 115 comprising at least 100 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent hydrogen. Additionally, or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis is carried out in the presence of a feed gas and / or lift gas comprising no more than 99 weight percent, no more than 90 weight percent, no more than 80 weight percent, no more than 70 weight percent, no more than 60 weight percent, no more than 50 weight percent, no more than 40 weight percent, no more than 30 weight percent, or no more than 20 weight percent hydrogen, based on the total weight of the stream, or the hydrogen can be present in an amount ranging from 5 to 70 weight percent, 10 to 60 weight percent, or 15 to 50 weight percent.

[0319] In one embodiment or in combination with any of the described embodiments, the pyrolysis may be carried out in the presence of a feed gas and / or a lift gas comprising at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, at least 95 weight percent, or at least 99 weight percent carbon monoxide. Additionally or alternatively, in one embodiment or combination with any of the described embodiments, the pyrolysis is conducted in the presence of a feed gas and / or lift gas comprising 99 weight percent or less, 90 weight percent or less, 80 weight percent or less, 70 weight percent or less, 60 weight percent or less, 50 weight percent or less, 40 weight percent or less, 30 weight percent or less, or 20 weight percent or less of carbon monoxide, based on the total weight of the stream, or the carbon monoxide can be present in an amount ranging from 5 to 70 weight percent, 10 to 60 weight percent, or 15 to 50 weight percent.

[0320] Additionally, the temperature within the pyrolysis reactor can be adjusted to promote the production of certain end products. In one embodiment, or in combination with any of the described embodiments, the pyrolysis temperature within the pyrolysis reactor can be at least 325°C, at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, at least 650°C, at least 675°C, at least 700°C, at least 725°C, at least 750°C, at least 775°C, or at least 800°C.

[0321] Additionally or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis temperature in the pyrolysis reactor can be 1,100°C or less, 1,050°C or less, 1,000°C or less, 950°C or less, 900°C or less, 850°C or less, 800°C or less, 750°C or less, 700°C or less, 650°C or less, 600°C or less, 550°C or less, 525°C or less, 500°C or less, 475°C or less, 450°C or less, 425°C or less, or 400°C or less.

[0322] More specifically, in one embodiment or in combination with any of the described embodiments, the pyrolysis temperature in the pyrolysis reactor may be 325-1,100°C, 350-900°C, 350-700°C, 350-550°C, 350-475°C, 425-1,100°C, 425-550°C, 425-600°C, 425-700°C, 425-800°C, 425-900°C, 425-1,1 ... The temperature can be in the range of 500 to 800°C, 500 to 1,100°C, 500 to 800°C, 600 to 1,100°C, 600 to 800°C, 650 to 1,000°C, or 650 to 800°C.

[0323] In one embodiment, or in combination with any of the described embodiments, the residence time of the feedstock in the pyrolysis reactor can be at least 0.1 seconds, at least 0.2 seconds, at least 0.3 seconds, at least 0.5 seconds, at least 1 second, at least 1.2 seconds, at least 1.3 seconds, at least 2 seconds, at least 3 seconds, or at least 4 seconds. Alternatively, in one embodiment, or in combination with any of the described embodiments, the residence time of the feedstock in the pyrolysis reactor can be at least 1 minute, at least 2 minutes, at least 3 minutes, at least 4 minutes, at least 5 minutes, at least 6 minutes, at least 7 minutes, at least 8 minutes, at least 9 minutes, at least 10 minutes, at least 20 minutes, at least 30 minutes, at least 45 minutes, at least 60 minutes, at least 75 minutes, or at least 90 minutes. Additionally, or alternatively, in one embodiment or in combination with any of the described embodiments, the residence time of the feedstock in the pyrolysis reactor can be 6 hours or less, 5 hours or less, 4 hours or less, 3 hours or less, 2 hours or less, 90 minutes or less, 60 minutes or less, 45 minutes or less, or 30 minutes or less, 15 minutes or less, or 45 seconds or less, 30 seconds or less, 25 seconds or less, or 20 seconds or less, or the residence time can range from about 0.1 to 45 seconds, 0.5 to 30 seconds, or 1 to 20 seconds, or 1 to 90 minutes, 5 to 45 minutes, or 7 to 15 minutes.

[0324] Additionally, in one embodiment, or in combination with any of the described embodiments, the residence time of the feedstock in the pyrolysis reactor can be 100 seconds or less, 90 seconds or less, 80 seconds or less, 70 seconds or less, 60 seconds or less, 50 seconds or less, 40 seconds or less, 30 seconds or less, 20 seconds or less, 10 seconds or less, 9 seconds or less, 8 seconds or less, 7 seconds or less, 6 seconds or less, 5 seconds or less, 4 seconds or less, 3 seconds or less, 2 seconds or less, or 1 second or less. More specifically, in one embodiment, or in combination with any of the described embodiments, the residence time of the feedstock in the pyrolysis reactor can be in the range of 0.1 to 10 seconds, 0.5 to 10 seconds, 30 minutes to 4 hours, 30 minutes to 3 hours, 1 hour to 3 hours, or 1 hour to 2 hours.

[0325] In one embodiment, or in combination with any of the described embodiments, the pressure in the pyrolysis reactor may be maintained at a pressure of at least 10 kilopascals (0.1 bar), at least 20 kilopascals (0.2 bar), at least or 30 kilopascals (0.3 bar) and / or no more than 6,000 kilopascals (60 bar), no more than 5,000 kilopascals (50 bar), no more than 4,000 kilopascals (40 bar), no more than 3,000 kilopascals (30 bar), no more than 2,000 kilopascals (20 bar), no more than 1,000 kilopascals (10 bar), no more than 800 kilopascals (8 bar), no more than 500 kilopascals (5 bar), no more than 200 kilopascals (2 bar), no more than 150 kilopascals (1.5 bar), or no more than 110 kilopascals (1.1 bar). As used herein, the term "bar" refers to gauge pressure unless otherwise specified. In one embodiment, or in combination with any of the described embodiments, the pressure in the pyrolysis reactor is at least about 1,000 kilopascals (10 bar), at least 2,000 kilopascals (20 bar), at least 3,000 kilopascals (30 bar), at least 4,000 kilopascals (40 bar), at least 5,000 kilopascals (50 bar), at least 6,000 kilopascals (60 bar), or at least 7,000 kilopascals (70 bar) and / or 10,000 kilopascals (100 bar), 9,500 kilopascals (95 bar), 9,000 kilopascals (90 bar), 8,500 kilopascals (85 bar), 8,000 kilopascals (80 bar), 7,500 kilopascals (75 bar), 7,000 kilopascals (70 bar), 6,500 kilopascals (65 bar), if The pressure can be up to 6,000 kilopascals (60 bar), or the pressure can range from 1,000 to 10,000 kilopascals (10 to 100 bar), 2,000 to 8,000 kilopascals (20 to 80 bar), or 3,000 to 7,500 kilopascals (30 to 75 bar).

[0326] In one embodiment or in combination with any of the described embodiments, the pressure in the pyrolysis reactor can be maintained at atmospheric pressure, or within the range of 10 to 10,000 kilopascals (0.1 to 100 bar), or 10 to 6,000 kilopascals (0.1 to 60 bar), or 10 to 3,000 kilopascals (0.1 to 30 bar), or 10 to 1,000 kilopascals (0.1 to 10 bar), or 150 kilopascals (1.5 bar), 20 to 150 kilopascals (0.2 to 1.5 bar), or 30 to 110 kilopascals (0.3 to 1.1 bar).

[0327]

[0327] In one embodiment or in combination with any of the described embodiments, the pyrolysis catalyst may be introduced into the feedstock prior to introduction into the pyrolysis reactor 542 and / or may be introduced directly into the pyrolysis reactor 542. Further, in one embodiment or in combination with any of the described embodiments, the catalyst can include: (i) a solid acid, such as a zeolite (e.g., ZSM-5, mordenite, beta, Ferrierite, and / or zeolite-Y); (ii) a superacid, such as a sulfonated, phosphorylated, or fluorinated form of zirconia, titania, alumina, silica-alumina, and / or clay; (iii) a solid base, such as a metal oxide, mixed metal oxide, metal hydroxide, and / or metal carbonate, particularly of alkali metals, alkaline earth metals, transition metals, and / or rare earth metals; (iv) hydrotalcites and other clays; (v) a metal hydride, particularly of alkali metals, alkaline earth metals, transition metals, and / or rare earth metals; (vi) alumina and / or silica-alumina; (vii) a homogeneous catalyst, such as a Lewis acid, metal tetrachloroaluminate, or organic ionic liquid; (viii) activated carbon; or (ix) a combination thereof.

[0328]

[0328] In one embodiment or in combination with any of the described embodiments, the pyrolysis catalyst can comprise a homogeneous catalyst or a heterogeneous catalyst.

[0329] In one embodiment or in combination with any of the described embodiments, the pyrolysis catalyst can include a mesostructured catalyst, for example, MCM-41, FSM-16, Al-SBA-15, or a combination thereof.

[0329]

[0330] In one embodiment or in combination with any of the described embodiments, the pyrolysis catalyst can comprise silica-alumina, alumina, mordenite, zeolite, a microporous catalyst, a macroporous catalyst, or combinations thereof.

[0330]

[0331] In one embodiment, or in combination with any of the described embodiments, the pyrolysis reaction in the pyrolysis reactor occurs substantially in the absence of a catalyst. In such an embodiment, a non-catalytic, heat-retaining, inert additive, such as sand, may still be introduced into the pyrolysis reactor to facilitate heat transfer within the reactor. Such a catalyst-free pyrolysis process may be referred to as "thermal pyrolysis."

[0331]

[0332] In one embodiment or in combination with any of the described embodiments, the pyrolysis reaction in pyrolysis reactor 542 can occur in the substantial absence of a pyrolysis catalyst, at a temperature in the range of 350 to 550°C, a pressure in the range of 10 to 10,000 kilopascals (0.1 to 100 bar), and a residence time of 0.2 seconds to 4 hours, or 0.5 hours to 3 hours.

[0332]

[0333] In one embodiment or in combination with any of the described embodiments, reactor 5 The pyrolysis effluent 117 withdrawn from reactor 42 can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, or at least 75 weight percent pyrolysis oil, which may be in the form of vapor in the pyrolysis effluent 117 as it exits the heated reactor 542. Such vapor may subsequently condense to form pyrolysis oil.

[0333]

[0334] Additionally or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis effluent 117 can comprise 99 weight percent or less, 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, 40 weight percent or less, 35 weight percent or less, 30 weight percent or less, or 25 weight percent or less of pyrolysis oil, which may be in the form of vapor in the pyrolysis effluent upon exiting the heated reactor. In one embodiment or in combination with any of the described embodiments, the pyrolysis effluent can comprise pyrolysis oil in the range of 20 to 99 weight percent, 25 to 80 weight percent, 30 to 85 weight percent, 30 to 80 weight percent, 30 to 75 weight percent, 30 to 70 weight percent, or 30 to 65 weight percent.

[0334]

[0335] In one embodiment, or in combination with any of the described embodiments, the pyrolysis effluent 117 can comprise at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, or at least 80 weight percent pyrolysis gases. Additionally or alternatively, in one embodiment, or in combination with any of the described embodiments, the pyrolysis effluent 117 can comprise no more than 99 weight percent, no more than 95 weight percent, no more than 90 weight percent, no more than 85 weight percent, no more than 80 weight percent, no more than 75 weight percent, no more than 70 weight percent, no more than 65 weight percent, no more than 60 weight percent, no more than 55 weight percent, no more than 50 weight percent, or no more than 45 weight percent pyrolysis gases.

[0335]

[0336] In one embodiment or in combination with any of the described embodiments, the pyrolysis effluent 117 can include 1 to 90 weight percent, 10 to 85 weight percent, 15 to 85 weight percent, 20 to 80 weight percent, 25 to 80 weight percent, 30 to 75 weight percent, or 35 to 75 weight percent pyrolysis gases.

[0336]

[0337] In one embodiment, or in combination with any of the described embodiments, the pyrolysis effluent 117 can comprise at least 0.5 weight percent, at least 1 weight percent, at least 2 weight percent, at least 3 weight percent, at least 4 weight percent, at least 5 weight percent, at least 6 weight percent, at least 7 weight percent, at least 8 weight percent, at least 9 weight percent, or at least 10 weight percent pyrolysis residue. Additionally or alternatively, in one embodiment, or in combination with any of the described embodiments, the pyrolysis effluent 117 can comprise at least 60 weight percent pyrolysis residue. % or less, 50% or less, 40% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight of pyrolysis residue. In one embodiment or in combination with any of the described embodiments, the pyrolysis effluent 117 can comprise pyrolysis residue in the range of 0.1 to 25 weight percent, 1 to 15 weight percent, 1 to 8 weight percent, or 1 to 5 weight percent.

[0337]

[0338] In one embodiment or in combination with any of the described embodiments, the pyrolysis effluent 117 can contain 15 weight percent or less, 14 weight percent or less, 13 weight percent or less, 12 weight percent or less, 11 weight percent or less, 10 weight percent or less, 9 weight percent or less, 8 weight percent or less, 7 weight percent or less, 6 weight percent or less, 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, 2 weight percent or less, 1 weight percent or less, or 0.5 weight percent or less of free water. As used herein, "free water" refers to water previously added to pyrolysis unit 60 and water produced in pyrolysis unit 60.

[0338]

[0339] The pyrolysis facility 60 described herein may produce a pyrolysis oil stream 120, a pyrolysis gas stream 118, and a pyrolysis residue stream 122, which may be used directly in various downstream facilities and / or applications based on these combinations. Various characteristics and properties of the pyrolysis oil, pyrolysis gas, and pyrolysis residue are described below. It should be noted that although all of the following characteristics and properties may be listed separately, it is contemplated that each of the following characteristics and / or properties of the pyrolysis gas, pyrolysis oil, and / or pyrolysis residue are not mutually exclusive and may be combined and present in any combination.

[0339]

[0340] In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 is a hydrocarbon having 4 to 30 carbon atoms per molecule (e.g., C4 to C6). 30 As used herein, "C x " or "C x The term "hydrocarbon" refers to a hydrocarbon compound containing "x" total carbons per molecule and includes all olefins, paraffins, aromatics, heterocycles, and isomers having that number of carbon atoms. For example, straight-chain and isobutane, and butene and butadiene molecules, respectively, are classified under the general description "C4."

[0340]

[0341] In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 comprises at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent C4-C6 hydrocarbons, based on the total weight of the pyrolysis oil stream 120. 30 It may have a hydrocarbon content.

[0341]

[0342] In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 is a C5 to C6 25Hydrocarbons, C5-C 22 Hydrocarbons, or C5-C 20 For example, in one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 may comprise at least 55 weight percent, at least 60 weight percent, at least 65 weight percent, at least 70 weight percent, at least 75 weight percent, at least 80 weight percent, at least 85 weight percent, at least 90 weight percent, or at least 95 weight percent C5-C6 hydrocarbons, based on the total weight of the pyrolysis oil stream 120. 25 Hydrocarbons, C5-C 22 Hydrocarbons, or C5-C 20 It may contain hydrocarbons.

[0342]

[0343] In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 comprises at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, or at least 55 weight percent C5-C6 12 Additionally or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 may have a C5-C hydrocarbon content of 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, or 50 weight percent or less. 12 In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 may have a C5-C hydrocarbon content in the range of 10 to 95 weight percent, 20 to 80 weight percent, or 35 to 80 weight percent. 12 It may have a hydrocarbon content.

[0343]

[0344] In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 comprises at least 1 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, or at least 30 weight percent C, based on the total weight of the pyrolysis oil stream 120. 13 ~C 23 Additionally, or alternatively, in one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 may have a hydrocarbon content of 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, 55 weight percent or less, 50 weight percent or less, 45 weight percent or less, or 40 weight percent or less. 13 ~C 23 In one embodiment or in combination with any of the described embodiments, the pyrolysis oil stream 120 may have a hydrocarbon content in the range of 1 to 80 weight percent, 5 to 65 weight percent, or 10 to 60 weight percent. 13 ~C 23 It may have a hydroc...

Claims

1. A method for treating waste plastics, comprising: (a) separating mixed plastic waste (MPW) into a polyethylene terephthalate-rich (PET-rich) stream and a polyolefin-rich (PO-rich) stream; (b) subjecting at least a portion of the PET-rich stream to solvolysis in a solvolysis facility producing a stream comprising a solvolysis by-product stream; (c) subjecting at least a portion of the PO-rich stream and the solvolysis by-product stream to at least one of (i) partial oxidation (POX) in a gasification facility, (ii) pyrolysis in a pyrolysis facility, and (iii) chemical conversion in an energy production facility; Including, The method wherein the combined amount of PET and PO in the MPW is at least 5 weight percent and no more than 95 weight percent, based on the total weight of the MPW.

2. 10. The method of claim 1, wherein the PO-rich stream comprises no more than 40 weight percent polyethylene terephthalate, based on the total weight of the stream, and the PET-rich stream comprises no more than 40 weight percent polyolefin, based on the total weight of the stream.

3. 10. The method of claim 1, wherein the PET-rich stream comprises at least 0.1 weight percent and no more than 10 weight percent (dry basis) halogen, based on the total weight of the stream.

4. The method of claim 1 , wherein at least a portion of the PO-rich stream is introduced into the POX gasification facility.

5. 10. The method of claim 1, wherein step (c) comprises subjecting at least a portion of the PO-rich stream to two or more of (i)-(iii).

6. 2. The method of claim 1, wherein the MPW comprises PVC in an amount of at least 0.001 weight percent and / or no more than 5 weight percent, based on the total weight of the MPW; the MPW comprises at least 0.1 weight percent and / or no more than 25 weight percent non-plastic solids, based on the total weight of the MPW; the MPW comprises at least 5 weight percent PET, based on the total weight of the MPW, and at least 5 weight percent PO, based on the total weight of the MPW.

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