Process for recycling a solid automotive waste material w comprising a polyolefin-based solid mixture and / or a rubber-based solid mixture
The described process efficiently separates fillers from polyolefin and rubber-based mixtures in automotive waste, producing high-value pyrolysis oils and extrudates with reduced halogen content, addressing the limitations of existing ASR recycling methods.
Patent Information
- Application Number
- PCT/EP2025/058928
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-04-03
- Filing Date
- 2025-04-02
- Publication Date
- 2025-10-09
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Abstract
Description
Process for recycling a solid automotive waste material W comprising a polyolefin-based solid mixture and / or a rubber-based solid mixtureThe present invention relates to a process for recycling a solid automotive waste material W comprising a polyolefin- based solid mixture and / or a rubber-based solid mixture, a recycling unit for carrying out said process, and an automotive material comprising the product(s) obtained by said process.The recycling of end-of-life vehicles is known for years now. In particular, researches have been developed for recycling tires, windows, motors, etc. However, only very few processes for recycling automotive shredder residue (ASR) have been developed. As known in the art, ELVs (end-of-life vehicles) are processed according to a treatment scheme comprising three main phases: depollution, dismantling and shredding. The ferrous fraction represents about 70-75 weight-% of the weight of shredded material, while nonferrous metals represent about 5 weight-% of the total weight of shredded material. The remaining 20-25 weight-% is referred to as automotive shredder residue (ASR), such proportions in the ELV have increased over the past years and will most likely continue as may be taken from R. Cossu, et al., “Automotive shredder residue (ASR) management: An overview, Waste Management, Volume 45, November 2015, Pages 143-151. Such that processes for recycling ASR have to be developed. For example, EP0692356 suggests to recycle automotive shredder residue by preparing a composite material comprising ASR and a virgin polymer; Vijayan, S.K.; Kibria, M.A.; Uddin, M.H.; Bhattacharya, S. “Pretreatment of Automotive Shredder Residues, Their Chemical Characterisation, and Pyrolysis Kinetics." Sustainability 2021, 13, 10549 suggests to recycle automotive shredder residue by pyrolysis; and Juliana Argente Caetano, Valdir Schalch, Javier Mazariegos Pablos “Characterization and recycling of the fine fraction of automotive shredder residue (ASR) for concrete paving blocks production" Clean Technologies and Environmental Policy (2020) 22:835-847 suggest to recycle ASR by solidification with cement, gravel and sand for paving blocks production. As may be taken from the prior art, there is no technique which would permit to obtain high valued pyrolysis oils or extrudates from ASR, in particular for producing highly-valuable products with virgin-like properties. Therefore, there is still a need to provide improved process for recycling solid automotive waste material.Cardamone Giovanni Francesco et al., "Can plastics from end-of-life vehicles be managed in a sustainable way?”, Sustainable Production And Consumption, vol. 29, 1 January 2022, pages 115 to 127, relates to an analysis of novel treatments of sorting, dissolution / precipitation, extrusion, catalytic pyrolysis, and plastic upgrading, which could contribute to define a sustainable plastic from end-of-life vehicles management scheme.EP 0 894818 B1 relates to a processing method for recovery of soluble polymers or polymer mixtures from plasticcontaining materials.CN 117 136 212 A provides a process for extracting polymers, preferably polyolefins, from polymer-containing waste materials. By dissolving under specific conditions, the polymer can be extracted from the waste sample. Through a specific sequence of steps, different classes of polymers of high purity grade can be extracted.Ina Vollmer et al., “Beyond Mechanical Recycling: Giving New Life to Plastic Waste", Angewandte Chemie International Edition, Verlag Chemie, Hoboken, USA, vol. 59, no. 36, 25 June 2020, pages 15402 to 15423, is a review wherein a summary of the various chemical recycling routes and assessment via life-cycle analysis is complemented by an extensive list of processes developed by companies active in chemical recycling.US 2023 / 174736 A1 discloses a method to recover constituent polymers in a multilayer plastic film or mixed plastic waste.Marvin Kusenberg et al., “Towards high-quality petrochemical feedstocks from mixed plastic packaging waste via advanced recycling: The past, present and future”, Fuel Processing Technology, Elsevier BV, NL, vol. 238, 6 September 2022, is an overview relating to recycling methods for plastic waste via pyrolysis.Therefore, it was an object of the present invention to provide an improved process for recycling solid automotive waste material W, in particular automotive shredder residue (ASR), which permits to obtain high valued pyrolysis oils or extrudates, those being able to produce highly-valuable products with virgin-like properties. Indeed, it was an object to develop a process for improving sustainability of the recycling processes in the automotive industry.Therefore, the present invention relates to a process for recycling a solid automotive waste material W comprising a polyolefin-based solid mixture M(o) and / or a rubber-based solid mixture M(r), the process comprising(i) providing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o) and / or the rubber-based solid mixture M(r), wherein M(o) comprises, in addition to polyolefin, one or more fillers F, wherein M(r) comprises, in addition to rubber, one or more fillers F, wherein F is inert to the dissolution treatment according to (ii.1 ), and wherein the polyolefin and / or the rubber is not inert to the dissolution treatment;(ii) separating F from the polyolefin and / or the rubber comprised in W provided according to (i), comprising(11.1) subjecting W to a dissolution treatment in presence of a solvent SD, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD;(11.2) passing M1 obtained according to (ii.2) in a solid-liquid separation unit SU, obtaining a mixture M(A) comprising the one or more fillers F and a mixture M2 depleted in F compared to M1 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD;(iii) subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation conditions, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber;(iv) subjecting the solid mixture M3 obtained according to (iii) to a mechanical and / or thermal treatment, the mechanical and / or thermal treatment being selected from the group consisting of pyrolysis, extrusion and melt extrusion, obtaining a recycled material r-M.Step (I)Preferably the solid automotive waste material W is obtained from end-of-life vehicles, more preferably the solid waste material W is an automotive shredder residue ASR.The automotive shredder residue may be obtainable, preferably is obtained, by shredding vehicles. Preferably, the automotive shredder residue is obtainable by depollution of the vehicles, dismantling the vehicles, shredding the vehicles, and separating metal particles from the shredded vehicles.The vehicles are typically end-of-life vehicles (also called “ELV”), which are typically at least 15 years old. The vehicles can be passenger cars, light-duty or heavy-duty trucks, motorbikes, a utility vehicle, an agricultural vehicle, or recreational vehicles. The vehicle can be an electric vehicle, such as a fully electric vehicle or a hybrid electric vehicle.In depollution of vehicles hazardous liquids such as fuel, lubricating oil, coolants, brake fluids and batteries can be removed from the vehicles prior to shredding.The dismantling of vehicles may comprise selective removal of parts, such as engines, gearboxes, tires, glass, and plastics, for being reused as spare parts for the second-hand market. The dismantling may also comprise the removal of larger plastic components, such as bumpers, dashboard, fluid containers for recycling the plastics separately.The ASR may comprise further waste from other sources. For examples, garbage from the last owners may remain in the trunk or interior of the vehicles. The advantage of the present process is that it can handle broadly varying compositions of the ASR.The shredding can be made with a vehicle shredder machine. Vehicle shredder machines are manufactured in different sizes. Typically, a vehicle shredder machine comprises a heavy fast-turning rotor, which may revolve in a vertical or a horizontal plane and is often equipped with swinging hammers. The vehicle shredder machine tears and shreds the car hulk until its parts are reduced to fragments with a desired fragment size, such as up to 30 cm, preferably 1 mm to 15 cm. Then the fragments may pass through grids and leave the rotor housing.After shredding, the metal fragments such as ferrous and non-ferrous metal fragments can be separated from the shredded vehicles. The ferrous metal fragments can be removed by magnetic separators. The non-ferrous metalfragments can be separated from the shredded vehicles by eddy current separators, by heavy media sink / float units which separate on the basis of density, or by manual sorting. Typically, 60 - 90 wt.-% of the vehicle weight is metal, which can be separated from the shredded vehicle.The automotive shredder residue may represent about 10 - 40 wt.-%, preferably from 15 - 35, and in particular from 20 - 30 wt.-% of the original vehicle weight.The automotive shredder residue may comprise fragments of various polymeric vehicle parts, such as fragments of bumpers, interior panels, dashboard, cable insulation, fuel tank, electrical insulation, flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, car body parts, pillar coverings, spoilers polymer parts coated with automotive paint, wheel covers, gears, bushes, cams, bearings, weatherproof coatings, interior and exterior trims, fuel systems, gear housings, headlamp retainer, engine cover, connector housings, door handles, carburetor components, exterior mirror components, windscreen wiper components, windscreen wiper protective housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna cladding covers, front and rear lights, radiator grill and body exterior parts, engine covers, cylinder head covers, intake pipes, cylinder head covers, engine covers, housings for charge air coolers, charge air cooler valves.The automotive shredder residue may comprise fragments of various polymeric vehicle parts, such as fragments of- bumpers, interior panels, dashboard, cable insulation, where these fragments are often made of polypropylene;- fuel tank, electrical insulation, where these fragments are often made of polyethylene;- flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, hard plastic parts, transmission mounts, motor mounts, seals, impact foam parts, where these fragments are often made of polyurethane;- body parts, dashboards, wheel covers, where these fragments are often made of aery lonitri le-butadiene-styrene;- gears, bushes, cams, bearings, charge air coolers, cylinder head covers, oil pans, engine cooling systems, thermostat and heater housings, exhaust systems including mufflers and housings for catalytic converters, air intake manifolds, timing chain belt front covers, where these fragments are often made of nylon 6 or nylon 6.6.;- interior and exterior trims, fuel systems, small gears, where these fragments are often made of polyoxymethylene;- wiper arm and gear housings, headlamp retainer, connector housings, where these fragments are often made of polyethylene terephthalate; and- door handles, bumpers, carburetor components, where these fragments are often made of polybutylene terephthalate.The automotive shredder residue may comprise at least 30 wt.-%, preferably at least 40 wt-%, and in particular at least 50 wt.-% of the fragments of the polymeric vehicle parts.The automotive shredder residue may comprise at least 20 wt.-%, preferably at least 30 wt-%, and in particular at least 40 wt,-% of the fragments of the polymeric vehicle parts, which are black polymeric vehicle parts. The black polymeric vehicle parts usually comprise carbon black pigments.The automotive shredder residue may comprise up to 15 wt.-%, preferably up to 10 wt.-%, and in particular up to 5 wt.-% of metal fragments, such as ferrous and non-ferrous metal particles.The automotive shredder residue may comprise up to 15 wt.-%, preferably up to 10 wt-%, and in particular up to 5 wt.-% of wood and cardboard.The automotive shredder residue may comprise up to 15 wt.-%, preferably up to 10 wt-%, and in particular up to 5 wt.-% of glass fragments, e.g. broken window glass fragments.The automotive shredder residue can be separated into a shredder light fraction (also called SLF) and a shredder heavy fraction (also called SHF). The separation of the SLF and the SHF can be achieved by air classification. Another air classification can be made by the rotary movement of the vehicle shredder machine may create a fanning action that can blow out the shredder light fraction, and the shredder heavy fraction may leave the vehicle shredder machine through a grid.The SLF can be present in an amount of 55 - 90 wt.-%, preferably 65 - 85 wt.-%, and in particular at 70 - 80 wt.-% of the automotive shredder residue The SHF may represent the remaining amount to 100 wt -%.The SHF can be present in an amount of 10 - 45 wt.-%, preferably 15 - 35 wt.-%, and in particular at 20 - 30 wt.-% of the automotive shredder residue The SLF may represent the remaining amount to 100 wt.-%.The SLF usually contains a lower weight percentage of rubber particles than the SHF.The SLF usually contains a lower weight percentage of glass particles than the SHF.The SLF usually contains a lower weight percentage of metal particles than the SHF.The SLF usually contains a higher weight percentage of polyurethane foam particles than the SHF.The SLF usually contains a lower weight percentage of solid and sand than the SHF.Preferably at least 20 weight-%, more preferably at least 30 weight-%, more preferably at least 40 weight-%, more preferably at least 50 weight-%, of the polyolefin-based solid mixture consist of polyolefin.Preferably at least 5 weight-%, more preferably at least 10 weight-%, more preferably at least 30 weight-%, more preferably at least 40 weight-%, of the rubber-based solid mixture consist of rubber.Preferably the solid automotive waste material W, more preferably the ASR, has an halogen content of at most 6 weight-%, more preferably at most 3 weight-%, more preferably in the range of from 0.05 to 3 weight-%, based on the weight of W, the content being determined as described in Analytics 2.Preferably the polyolefin-based solid mixture has an halogen content of at most 3 weight-%, more preferably in the range of from 0.05 to 3 weight-%, based on the weight of the polyolefin-based solid mixture, the content being determined as described in Analytics 2.Preferably the rubber-based solid mixture has an halogen content of at most 3 weight-%, more preferably in the range of from 0.05 to 3 weight-%, based on the weight of the rubber-based solid mixture, the content being determined as described in Analytics 2.Preferably (i) comprises(i.1 ) providing a solid automotive waste material W0 comprising a polyolefin-based solid mixture and / or a rubberbased solid mixture, W0 further comprising a solid mixture M0(a) having a chemical composition different to M0(o), if present, and / or different to M0(r), if present, wherein the polyolefin-based solid mixture M0(o) comprises, in addition to polyolefin, one or more fillers F and wherein the rubber-based solid mixture M0(r) comprises, in addition to rubber, one or more fillers F;(i.2) sorting W0, obtaining a stream S1 comprising M0(a) and a stream S2, depleted in M0(a) compared to W0, comprising the solid automotive waste material W.Preferably sorting W0 according to (i.2) is an optical sorting, a density sorting, a ballistic sorting, or a sink-float sorting, more preferably an optical sorting. The optical sorting more preferably is laser induced fluorescence (LIF) sorting or infrared sorting.Preferably, prior to (ii), the process further comprises passing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o) and / or the rubberbased solid mixture M(r) provided according to (i) in a sorting device, obtaining a fillers-rich fraction f11 comprising F and further comprising the polyolefin and / or the rubber, and a fillers-poor fraction f12, being depleted in fillers F compared to W, comprising the polyolefin and / or the rubber.Preferably the sorting device being a media separating device, a magnetic density sorting device, a gas-solid fluidized device (sink-float technology) or a froth flotation device.In the context of the present invention, it is noted that such density sorting method permits to reduce the amount of solvent SD needed in (iii).Preferably the polyolefin comprised in W is selected from the group consisting of polyethylene (PE), polypropylene (PP), polymethylpentene (PMP), polybutene-1 (PB-1 ), ethylene-octene copolymers, stereo-block PP, olefin block copolymers, propylene-butane copolymers, polyisobutylene (PIB), and a mixture of two or more thereof, more preferably selected from the group consisting of polyethylene, polypropylene, and a mixture of polyethylene and polypropylene.In the context of the present invention, the polyolefin can preferably be a mixture of the same polyolefin, namely a mixture of PE or PP, or a mixture of two or more different polyolefins, such as a mixture of PE and PP.Preferably, providing the solid automotive waste material W comprising the polyolefin-based solid mixture and / or the rubber-based solid mixture according to (i) comprises shredding and / or cutting W in a shredding unit US1.Preferably the length of each sides of the shredded and / or cut material W is in the range of from 0.5 to 10 cm, more preferably in the range of from 1 to 5 cm.In the context of the present invention, the term “fillers", as also known in the art, refers to inorganic materials (inert materials) having a structural function which are typically added to a substance (e.g. a polymer) to improve certain characteristics such as physical and / or mechanical properties. For example, fillers are incorporated into polymer- based materials to improve strength, stiffness, thermal conductivity, reduce shrinkage, and so on. Examples of fillers include glass fibers, carbon particles such as carbon black or talc Fillers are not additives which are rather active (non-inert) substances.Preferably the one or more fillers F comprises one or more of magnesium silicate hydrate, glass fibers, aluminum hydroxide (inorganic flame retardant), ammonium polyphosphate (inorganic flame retardant), barium sulfate, calcium carbonate, wollastonite, carbon black, and titanium dioxide.Preferably the one or more fillers F are present in the polyolefin-based solid mixture in an amount in the range of from 0.1 to 75 weight-%, more preferably in the range of from 5 to 70 weight-%, based on the weight of the polyolefin-based solid mixture.Preferably the one or more fillers F are present in the rubber-based solid mixture in an amount in the range of from 0.1 to 75 weight-%, more preferably in the range of from 5 to 70 weight-%, based on the weight of the rubber-based solid mixture.Preferably the one or more fillers F are present in W in an amount in the range of from 0.05 to 75 weight-%, based on the weight of W.Preferably the solvent SD is selected from the group consisting of xylene, toluene, benzene, n-hexane, n-heptane, pentyl acetate, n-amyl acetate, isobutyl acetate, 2,2-dimethylbutane, n-propyl propanoate, n-butyl propanoate, hep- tan-2-one, cyclopentane, methylcyclopentane, methylcyclohexane, cyclohexane, and mixtures of two or more thereof.In the context of the present invention, the term “xylene" refers to all isomers and mixtures thereof of xylene, preferably refers to a mixture of ortho-xylene, meta-xylene and para-xylene isomers.Preferably, when W comprises the polyolefin-based solid mixture, SD is selected from the group consisting of xylene, toluene, n-heptane, pentyl acetate, n-amyl acetate, isobutyl acetate, n-propyl propanoate, n-butyl propanoate, hep- tan-2-one, methyl-cyclohexane, cyclohexane, and a mixture of two or more thereof, more preferably is selected from the group consisting of xylene, toluene, pentyl acetate, cyclohexane, and mixtures of two or more thereof, more preferably is xylene.Preferably, when W comprises the rubber-based solid mixture, SD is selected from the group consisting of n-hexane, n-heptane, 2,2-dimethylbutane, toluene, benzene, cyclohexane, methylcyclohexane, cyclopentane, methylcyclopentane, and mixtures of two or more thereof, more preferably is selected from the group consisting of n-hexane, n-hep- tane, 2,2-dimethylbutane, methylcyclohexane and methylcyclopentane.Preferably the present invention relates to a process for recycling a solid automotive waste material W comprising a polyolefin-based solid mixture, the process comprising(I) providing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o), wherein the polyolefin-based solid mixture comprises, in addition to polyolefin, one or more fillers F, wherein F is inert to the dissolution treatment according to (II.1) and wherein the polyolefin is not inert to the dissolution treatment;(ii) separating F from the polyolefin comprised in W provided according to (i), comprising(ii.1 ) subjecting W to a dissolution treatment in presence of a solvent SD, preferably a non-polar solvent, more preferably selected from the group consisting of xylene, toluene, n-heptane, pentyl acetate, n-amyl acetate, isobutyl acetate, n-propyl propanoate, n-butyl propanoate, heptan-2-one, methyl-cyclohexane, cyclohexane, and a mixture of two or more thereof, more preferably is selected from the group consisting of xylene, toluene, pentyl acetate, cyclohexane, and a mixture of two or more thereof, more preferably being xylene, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD;(ii.2) passing M1 obtained according to (ii.2) in a solid-liquid separation unit SU, obtaining a mixture M(A) comprising the one or more fillers F and a mixture M2 depleted in F compared to M1 comprising the polyolefin dissolved in SD;(iii) subjecting M2 comprising the polyolefin dissolved in SD obtained according to (ii.2) to precipitation conditions, obtaining a solid mixture M3 comprising the precipitated polyolefin;(iv) subjecting the solid mixture M3 obtained according to (iii) to a mechanical and / or thermal treatment, the mechanical and / or thermal treatment being selected from the group consisting of pyrolysis, extrusion and melt extrusion, obtaining a recycled material r-M.Preferably W is substantially free of rubber. Preferably at most 3 weight-%, more preferably at most 2 weight-%, more preferably at most 1 weight-%, more preferably at most 0.5 weight-%, of W consist of rubber.In the context of the present invention, the dissolution treatment is performed at a temperature below the ebullition temperature of SD.Preferably the dissolution treatment is performed in a dissolution treatment unit, being a vessel, or a tube.Preferably, SD has a Hansen solubility parameter 6H in the range of from 0 to 10 MPa1 / 2, more preferably in the range of from 0 to 8 MPa1 / 2, more preferably in the range of from 0 to 7 MPa1 / 2.In the context of the present invention, the Hansen solubility parameter 6H is a known parameter which characterizes the solubility of a compound. 6H relates to the energy from hydrogen bonds between molecules. For numerous compounds, such as xylene, toluene and cyclohexane, the Hansen parameter OH can be found in standard chemical books The Hansen solubility parameters <5H mentioned in the present invention refers to values tabulated in: Hansen, C.M., Hansen Solubility Parameters - A user's handbook, 2. Edition, CRC Press, Boca Raton, USA, 2007.It is preferred that according to (ii.1), no solvent other than SD is involved in the dissolution treatment.Preferably from 5 to 99 weight-%, more preferably from 20 to 98.5 weight-%, more preferably from 30 to 98 weight- %, more preferably from 40 to 98 weight-%, of W consist of the polyolefin-based mixture and / or the rubber-based mixture.Preferably the dissolution treatment according to (ii.1) is performed at a temperature in the range of from 55 to 200 °C, more preferably in the range of from 60 to 160 °C.Preferably, for the polyolefin-based mixture, the dissolution treatment according to (ii.1 ) is performed at a temperature in the range of from 55 to 150 °C, more preferably in the range of from 60 to 140 °C.Preferably, for the rubber-based mixture, the dissolution treatment according to (ii .1 ) is performed at a temperature in the range of from 55 to 200 °C, more preferably in the range of from 100 to 140 °C.In the context of the present invention, preferably the dissolution treatment according to (ii.1 ) is performed at a pressure in the range of from 800 to 200 000 hPa, more preferably in the range of from 800 to 10000 hPa.The present inventive process has an improved polymer extraction and isolation method by using a solvent SD at elevated temperatures, i.e. preferably from 55 to 200 °C, to extract the desired polymers which are then obtained by precipitating (for example by cooling) the desired polyolefin / rubber from supersaturated solutions of the single nonpolar solvent. This approach simplifies the overall process including the recycling of solvents as well as the equipment needed for carrying out the process on large continuous scale while reducing the energy expenditure compared to the process known in the art.Preferably the dissolution treatment according to (ii.1 ) is performed in a reactor unit RD.Preferably, the solid waste material W is fed into the reactor unit RD via gravity or pneumatic transport.Preferably the dissolution treatment according to (ii.1 ) comprises bringing in contact W with the solvent SD at a weight ratio of the solid material W relative to the solvent SD being in the range of from 1 :1 to 1 :20, more preferably in the range of from 1 :3 to 1 : 15, more preferably in the range of from 1 :4 to 1 : 12, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD.Preferably, the temperature of M1 obtained according to (ii.1) is essentially maintained, more preferably maintained, via one or more heated tubes used for transferring M1 into SU.Preferably the solid-liquid separation unit SU used in (ii .2) is a filtration unit or a centrifugation unit, more preferably a filtration unit, the filtration unit more preferably having a mesh size in the range of from 1 to 100 micrometers, more preferably in the range of from 10 to 50 micrometers.Optionally M(A) further comprises, in addition to F, one or more of a polymer other than polyolefin and / or rubber, polyethylene terephthalate (PET), polyvinyl chloride (PVC), polyurethane (PU), polybutylene terephthalate (PBT), and polyamide (PA).Preferably the filtration unit comprises a filter for blocking the mixture M(A) comprising the one or more fillers F and a receiving vessel for the mixture M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD. Preferably the filtration unit is operated under a pressure pF, with pp 1 bar(abs), more preferably pp is in the range of from 1 to 30 bar(abs), more preferably in the range of from 1 to 10 bar(abs), more preferably in the range of from 1 to 6 bar(abs).It is more preferred that, when SD is xylene, pp is in the range of from 2 to 4 bar(abs), more preferably 2.5 to 3.5 bar(abs) and that TSP is in the range of from 110 to 130 °C.Preferably the process further comprises recycling at least a portion of the solvent SD comprised in M2 obtained according to (ii) to the dissolution treatment according to (ii.1); wherein recycling more preferably comprises passing the at least a portion of the solvent SD comprised in M2 obtained according to (ii) in a distillation unit D, obtaining a purified solvent; using the purified solvent to the dissolution treatment according to (ii.1 ).Preferably, the distillation unit D is heated by a heating source, more preferably steam. Such heating source preferably is generated from the recycled gas stream obtained after pyrolysis according to (iv).Step (iii)Preferably, the precipitated polyolefin and / or the precipitated rubber are in the form of powder, the particles having an average size in the range of from 1 micrometer to 1 millimeter, more preferably in the range of from 10 micrometers to 100 micrometers, the particles average size being determined as defined in Analytics 1.Preferably the halogen content in M3 obtained according to (iii) is inferior to the halogen content in W provided in (i).Preferably M3 obtained according to (iii) has a halogen content of at most 1 weight-%, based on the weight of M3, the content being determined as described in Analytics 2.Preferably the precipitated polyolefin obtained according to (iii) has a halogen content of at most 1 weight-%, based on the weight of the precipitated polyolefin, the content being determined as described in Analytics 2.Preferably the precipitated rubber obtained according to (iii) has a halogen content of at most 1 weight-%, based on the weight of the precipitated rubber, the content being determined as described in Analytics 2.Preferably M3 obtained according to (iii) has a Cl content of at most 5000 ppmw, more preferably at most 2000 ppmw, based on the weight of M3, the content being determined as described in Analytics 2.Preferably the precipitated polyolefin obtained according to (iii) has a Cl content of at most 5000 ppmw, more preferably at most 2000 ppmw, based on the weight of the precipitated polyolefin, the content being determined as described in Analytics 2.Preferably the precipitated rubber obtained according to (iii) has a Cl content of at most 5000 ppmw, more preferably at most 2000 ppmw, based on the weight of the precipitated rubber, the content being determined as described in Analytics 2.- Temperature reductionPreferably (iii) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation at a temperature Tp and a pressure pP, with Tp < TD, being the temperature of dissolution according to (ii.1 ), and Tp < 100 °C, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.Preferably (iii) comprises cooling M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) for precipitation at a temperature Tp and a pressure pP, with Tp < TD, being the temperature of dissolution according to (ii.1), and Tp < 100 °C, obtaining a mixture comprising the precipitated polyolefin and / or the precipitated rubber and SD; passing said mixture in a solid-liquid separation unit, more preferably a filtration unit or a centrifugation unit, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber. Preferably M3 is further dried.Preferably, TP< TD - 5 °C, more preferably TP< TD - 10 °C, more preferably TP< TD - 30 °C, more preferably TP< TD - 30 °CPreferably, cooling according to (iii) comprises(iii. a) passing a cooling medium into a cooling jacket of a precipitation unit containing M2; or (iii.b) letting M2 stand into a precipitation unit.Preferably, the cooling rate is in the range of from 2 to 200 K / h, more preferably in the range of from 3 to 150 K / h, more preferably 20 to 120 K / h, more preferably 10 to 60 K / h.- Anti-solvent additionPreferably (iii) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation by contacting M2 with a polar solvent (acting as “anti-solvent”), obtaining an intermediate mixture IM comprising the polar solvent and the precipitated polyolefin and / or the precipitated rubber;passing IM in a solid-liquid separation unit, obtaining the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.Optionally (ill) further comprises. washing M3, more preferably the solid mixture M3 is washed with one or more of methanol, ethanol, propanol, isopropanol, acetonitrile, ethyl acetate, acetone and water; and optionally drying the washed solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.Preferably, contacting M2 with the polar solvent is performed at a temperature in the range of from 10 to 120 °C, more preferably in the range of from 20 to 60 °C.Preferably, contacting M2 with the polar solvent is performed at a pressure in the range of from 0 to 10 bar(abs), more preferably in the range of from 0.5 to 2 bar(abs).Preferably, the polar solvent is selected from the group consisting of water, ethanol, methanol, propanol, butanol, acetone, dimethylsulfoxide, acetonitrile, dimethylformamide, ethylacetate, sulfolane, dichloromethane, tetrahydrofu- rane, and a mixture of two or more thereof, more preferably selected from the group consisting of water, acetone, ethanol, methanol and a mixture of two or more thereof.Preferably, the polar solvent has an Hansen solubility parameter 5H of more than 5 MPa1 / 2, preferably in the range of from 6 to 50 MPa1 / 2, more preferably in the range of from 10 to 30 MPa1 / 2.Optionally the process further comprises recycling both the solvent SD and the polar solvent by fractional distillation.- Flash evaporationPreferably (ill) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation by passing M2 in a flash evaporator, obtaining a gaseous stream G3 comprising the evaporated solvent, and further obtaining the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.Step (iv)Preferably, the solid mixture M3 obtained according to (iii) comprises the precipitated olefin and / or the precipitated rubber in an amount in the range of from 90 to 100 weight- %, more preferably in the range of from 95 to 100 weight- %, more preferably in the range of from 98 to 100 weight- %, based on the weight of the solid mixture.- PyrolysisPreferably (iv) comprises subjecting the solid mixture M3 obtained according to (ill) to a thermal treatment, the thermal treatment being pyrolysis, obtaining a recycled material r-M being a pyrolysis oil.Preferably (iv) preferably comprises(iv.1 ) feeding M3 obtained according to (ill) into a pyrolysis reactor Rp;(iv.2) heating the polyolefin precipitated and / or the precipitated rubber into the pyrolysis reactor Rp to a temperature in the range of from 350 to 900 °C, more preferably in the range of from 400 to 550 °C, and a pressure in the range of from 0.5 to 2 bar(abs), more preferably in the range of from 0.9 to 1 .5 bar(abs);(iv.3) removing a gas stream GS from the top of Rp and subjecting GS to condensation conditions in a gas-liquid separation unit LGU, obtaining a recycled material r-M being a pyrolysis oil.Preferably feeding according to (iv.1 ) is performed via a dosing unit, the dosing unit being more preferably one or more of a screw, an extruder and a rotary valve.It is also conceivable that feeding according to (iv.1) is performed via pneumatic conveyor or liquid injector into the pyrolysis reactor Rp.Preferably, the pyrolysis reactor Rp is selected from the group consisting of a fluidized bed, a moving bed, an entrained flow, an auger, a screw reactor, an extruder, a stirred tank reactor, a moving bed rotor-stator type reactor, and a rotary kiln, more preferably a fluidized bed. Preferably the fluidized bed is bubbling, turbulent, fast or circulating.Preferably, the pyrolysis is performed in the pyrolysis reactor Rp under an atmosphere exempt of oxygen.Preferably, the pyrolysis is performed by thermal cracking (absence of catalyst) or catalytic cracking, more preferably thermal cracking.It is noted that such catalyst are used to influence the properties of the pyrolysis products as known by the skilled person.Preferably the pyrolysis according to (iv) is not a hydrothermal treatment.Optionally, according to (iv) the pyrolysis reactor Rp contains trace amounts of water, wherein preferably trace amounts of water is less than 2 wt.% water calculated on the basis of the total weight of the precipitated polyolefin PP, more preferably less than 1 wt.% water, more preferably less than 0.1 wt.% water.Preferably the pyrolysis reactor Rp is free of water.It is conceivable that prior to the pyrolysis according to (iv), the solid mixture M3 may be subjected to a pre-pyrolysis at a temperature in the range of from 220 to 360 °C. Such pyrolysis at low temperature permits to pyrolysed PVC if present in the solid mixture. However, in the context of the present invention, such step can be avoided in view of the particular process steps (i) to (iii) prior to (iv) of the process according to the present invention.The precipitated polyolefin obtained according to (iii) of the present process are advantageously pyrolyzed under thermal conditions in absence of water at pressures close to atmospheric pressure. The present inventive process does not require either water or hydrothermal reactors which greatly reduces the equipment cost and complexity since hydrothermal conditions are well known to be corrosive. Further, non-desirable side products such as coke that builds up in the hydrothermal reactors is also reduced with the process of the present invention.Optionally, in the pyrolysis reactor Rp, the solid mixture comprising the precipitated polyolefin is mixed with one or more of CaO, Ca(OH)2 and CaCOa. Such additives permit to react with formed HOI and thus remove impurities such as chlorine from PVC.In addition or as an alternative, it is conceivable that the gas stream GS exiting the pyrolysis reactor is passed through a catalyst bed or an adsorption bed, in order to reduce the concentration of impurities and atoms other than C and H.Preferably, in (iv.3) after removing GS from Rp and prior to subjecting GS to condensation conditions in LGU, the gas stream GS is passed through a filtration unit, more preferably a filter, or a cyclone. Such filtration unit or cyclone permits to remove dust particles from the gas stream GS before condensation In addition to such removal of dust, a catalyst bed or an adsorption bed can be used upstream thereof or downstream thereof to reduce the concentration of impurities and atoms other than C and H.Preferably, according to (iv.3) GS is subjected to a condensation step in LGU at a temperature in the range of from 0 to 80 °C; wherein more preferably LGU is a condenser, a scrubber or a quench.Preferably, the gas stream GS in (iv.3) is subjected to a first condensation step at a temperature in the range of from 50 to 150 °C and to a second condensation step at a temperature in the range of from 35 to 0°C, obtaining the pyrolysis oil; each of the first and second condensation steps more preferably being performed in a separate condenser or quench. Alternatively, the gas stream GS in (iv.3) is preferably subjected to only one condensation step at a temperature in the range of from 0 to 80 °C.The non-condensable “permanent” gases G exiting LGU can be used to generate process heat / electricity by burning in a gas burner, gas motor or combined heat and power plant. The flue gases of this combustion might need to be cleaned according to emission laws to remove dust, ashes and other components.Preferably the process further comprises, after (iv), passing the recycled material r-M obtained according to (iv), more preferably the pyrolysis oil obtained according to (iv), as a stream So, into a purification unit PU, obtaining a purified recycled material r-M.Preferably, the purification unit PU comprises one or more of a filter, a centrifuge, a decanter, and a decanter centrifuge, more preferably one or more of a filter, a centrifuge and a decanter.The pyrolysis oil obtained according to (iv), more preferably (iv.3), can be filtered including the possible use of a filter agent to remove solids. Alternatively, said pyrolysis oil can be centrifuged to remove solids.Further, in the purification unit PU, water residue can be removed from the pyrolysis oil by decanting or centrifugation. Furthermore, the pH can be adjusted to a pH value of at most 3 or, alternatively, a pH value of at least 8, preferably at least 9. Preferably, the adjustement is performed by the addition of an acid or a base such as an alkali metal hydroxide, for example sodium hydroxide (NaOH), potassium hydroxide (KOH), alkaline earth metal hydroxide, for example calcium hydroxide (Ca(OH)2, N Ha, or mixtures thereof sulfuric acid (H2SO4), nitric acid (HNO3) or phosphoric acid (H3PO4).- Extrusion or melt extrusionPreferably extrusion or melt extrusion is performed, when W comprises, more preferably consist of M(o) in (i).Preferably (iv) comprises subjecting the solid mixture M3 obtained according to (iii), more preferably the precipitated polyolefin, to a thermal and mechanical treatment, the treatment being extrusion or melt extrusion, obtaining a recycled material r-M being an extrudate.Preferably (iv) comprises feeding M3 obtained according to (iii) into an extruder for extruding at a temperature in the range of from 200 to 280 °C, obtaining a recycled material r-M being an extrudate.Preferably the process further comprises pelletizing (or granulating) the obtained extrudate, for example by underwater granulation or strand granulation.Preferably the process of the present invention is a continuous process or a semi-continuous process, more preferably the process is a continuous process.Steps (v), (vi) and (vii)When r-M is a pyrolysis oil, the process preferably further comprises (v).Preferably the process further comprises(v) subjecting at least a portion of the recycled material r-M obtained from the pyrolysis according to (iv) to (v.1 ) cracking, obtaining a stream P1 comprising cracked hydrocarbons; and / or(v.2) partial oxidation, obtaining a syngas stream P2 comprising CO and H2.Optionally the at least a portion of the pyrolysis oil obtained according to (iv) is mixed / blended with one or more of a pyrolysis oil other than the one obtained according to (iv), bio-oil, hydrotreated bio-oil, naphtha, and feedstocks other than the oils listed in the foregoing suited for such (steam) cracking, prior to cracking according to (v.1).Optionally the at least a portion of the pyrolysis oil obtained according to (iv) is mixed / blended with one or more of a pyrolysis oil other than the one obtained according to (iv), bio-oil, hydrotreated bio-oil, and fossil co-feedstocks suited for partial oxidation, such as heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, waste oils, tar oils, prior to partial oxidation according to (v.2).Preferably cracking according to (v.1) is performed in a cracker, more preferably a steam cracker.Preferably the cracker is supplied by gas or electrically, more preferably electrically, more preferably from renewable sources.In the context of the present invention, the stream P1 is a gaseous stream.Preferably cracking according to (v.1) is performed at a temperature in the range of from 400 to 1000 °C, more preferably in the range of from 500 to 900 °C.The cracking is preferably performed according to processes know in the art such as those cited in Ullmann’s Encyclopedia of Industrial Chemistry, Ethylene, Ch. 5.1, pages 469-475.Preferably partial oxidation according to (v.2) is performed in a gasifier, such an entrained flow reactor and / or a fluidized bed reactor. The partial oxidation is preferably performed according to processes known in the art.Preferably the process further comprises(vi) preparing a polymer PA, comprisingusing one or more of the recycled material r-M obtained according to (iv), the cracked hydrocarbons comprised in the stream P1 comprising obtained according to (v) as described herein, and the CO and / or H2 comprised in the syngas stream P2 obtained according to (v) as described herein.Preferably the polymer PA is a polyolefin or rubber.Any process known in the art can be used for preparing the polymer PA being a polyolefin such as PE or PP such as the processes as disclosed in Ullmann’s Encyclopedia of Industrial Chemistry, Polyolefins, 2005 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim, DOI 10.1002 / 14356007.a21 487.Any process known in the art can be used for preparing the polymer PA being rubber such asthe processes as disclosed in Ullmann’s Encyclopedia of Industrial Chemistry, Rubber, 3. Synthetic Rubbers, Introduction and Overview, p 602-604(2011), DOI 10.1002 / 14356007 a23_239.pub5.Preferably the process further comprises(vii) preparing an automotive material, comprising using one or more of the recycled material r-M obtained according to (iv), the cracked hydrocarbons comprised in the stream P1 comprising obtained according to (v) as described herein, the CO and / or H2 comprised in the syngas stream P2 obtained according to (v) as described herein, and the polymer PA obtained according to (vi) as described herein.The present invention further relates to a recycling unit for carrying out the process according to the present invention, the recycling unit comprising a dissolution treatment unit for dissolving M(o) and / or M(r) comprised in W; an inlet means for introducing W in the means for the dissolution treatment; an outlet means for M1 from the means for the dissolution treatment; a solid-liquid separation unit SU; an inlet means for introducing M1 into SU; an outlet means for removing M2 from SU; a precipitation unit for precipitating the polyolefin and / or the rubber; an outlet means for removing M3 comprising the precipitated polyolefin and / or the precipitated rubber from the precipitation unit; a mechanical and / or thermal treatment unit MTU; an inlet means for introducing M3 into MTU; an outlet means for removing the recycled material r-M from MTU.Preferably the dissolution treatment unit is a vessel, or a tube.Preferably the solid-liquid separation unit SU is a filtration unit or a centrifugation unit, more preferably a filtration unit, the filtration unit more preferably having a mesh size in the range of from 1 to 100 micrometers, more preferably in the range of from 10 to 50 micrometers.Preferably the precipitation unit is a vessel or a flash evaporator.Preferably the mechanical and / or thermal treatment unit MTU is a pyrolysis reactor or an extruder, wherein the extruder more preferably is a die or a mold.The present invention further relates to an automotive material, preferably an automotive vehicle, comprising a recycled material r-M RM obtained according to the present invention, and / or a polymer PA obtained according to the present invention.The present invention further relates to a process as described above, preferably the process comprising (i) to (iv), or (i) to (v), as described above, wherein said process (further) comprises the step of converting the recycled material r- M obtainable or obtained according to (iv) as described herein, or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v), or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described herein, or a chemical material obtainable or obtained by the process described herein, to obtain a product Q. Said product O is preferably selected from building block or monomer; or polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or aqueous polymer dispersion, preferably polyurethane or polyurethane - poly(meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.Further regarding said product Q, it is preferred thatthe content of the recycled material r-M obtainable or obtained according to (iv), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v) as described herein, or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described herein, in the product 0 is 1 weight-% or more, more preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and / or the content of the recycled material r-M obtainable or obtained according to (iv), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v) as described herein, or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described herein, in the product 0 is 100 weight-% or less, more preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less; and wherein the content is preferably determined based on identity preservation and / or segregation and / or mass balance and / or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.The publication Prior Art Disclosure; Issue 684; paragraphs
[1000] to
[8005] ; ISSN: 2198-4786; published: February 12, 2024 will be regarded as Reference RF1 , which is incorporated herein by reference in its entirety. Preferably, the product 0 referred to in the preceding paragraph is a product as described in Reference RF1 ; paragraphs
[1000] to
[8005] , Preferably, the process described herein is further a process for the production of a product referred to in the preceding paragraph.The converting step to obtain the product 0 preferably comprises one or more step(s) as described below and can be performed by conventional methods well known to a person skilled in the art. The converting step preferably comprises one or more step(s) selected from: recycling, preferably depolymerizing, gasifying, pyrolyzing, and / or steam cracking; and / or purifying, preferably crystallizing, (solvent) extracting, distilling, evaporating, hydrotreating, absorbing, adsorbing and / or subjecting to ion exchanger; and / or assembling, preferably foaming, synthesizing, chemical conversion, chemically transforming, polymerizing and / or compounding; and / or forming, preferably foaming, extruding and / or molding; and / or finishing, preferably coating and / or smoothing.In addition, the one or more step(s) are described in detail in Reference RF1; paragraphs
[1000] to
[8005] ,The term “building block”, as used in the context of the product 0 herein, comprises compounds, which are in a gaseous or liquid state under standard conditions of 0°C and 0.1 MPa. Building blocks are typically used in chemical industry to form secondary products, which provide a higher structural complexity and / or higher molecular weight than the building block on which the secondary product is based. The building block is preferably selected from the groupconsisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycols, syngas comprising a mixture of hydrogen and carbon monoxide, alkanes, alkenes, alkynes and aromatic compounds. The alkanes, alkenes, alkynes and aromatic compounds comprise in particular 1 to 12 carbon atoms, respectively.The term “monomer”, as used in the context of the product 0 herein, comprises molecules, which can react with each other to form polymer chains by polymerization. The monomer is preferably selected from the group consisting of (meth)acrylic acid, salts of (meth)acrylic acid; in particular sodium, potassium and zinc salts; (meth)acrolein and (meth)acrylates. (Meth)acrylates comprising 1 to 22 carbon atoms are preferred, in particular comprising 1 to 8 carbon atoms. The terms (meth)acrylic acid, (meth)acrolein or (meth)acrylate relate to acrylic acid, acrolein or acrylate and also to methacrylic acid, methacrolein or methacrylate, where applicable. Further, the monomer can be selected from hexamethylenediamine (HMD) and adipic acid.The building block can further be an intermediate compound. The term “intermediate compound”, as used in the context of the product 0 herein, comprises organic reagents, which are applied for formation of compounds with higher molecular complexity. The intermediate compound can be selected for example from the group consisting of phosgene, polyisocyanates and propylene oxide. The polyisocyanates are in particular aromatic di- and polyisocyanates, preferably toluene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI).The building block and the monomer and typical converting step(s) to obtain the building block or monomer are described in more detail in paragraphs
[1000] to
[1012] of Reference RF1.The term “polymer A”, as used in the context of the product 0 herein, comprises thermoplastic, e.g., polyamide or thermoplastic polyurethane, thermoset, e g., polyurethane, elastomer, e.g , polybutadiene, or a copolymer or a mixture thereof and is defined in more detail in paragraphs
[2001] to
[2007] of Reference RF1 .The term “polymer composition A”, as used in the context of the product 0 herein, comprises all compositions comprising a polymer as described above and one or more additive(s), e.g. reinforcement, colorant, modifier and / or flame retardant, and is defined in more detail in paragraph
[2008] of Reference RF1.The term “polymer product A", as used in the context of the product 0 herein, comprises any product comprising the polymer A and / or polymer composition A as described above and is defined in more detail in paragraphs
[2009] and
[2010] of Reference RF1.The step(s) to obtain the polymer, preferably polymer A, polymer composition, preferably polymer composition A or polymer product, preferably polymer product A is / are described in more detail in paragraph
[2011] of Reference RF1.The term “industrial use polymer”, as used in the context of the product 0 herein, comprises rheology, polycarboxylate, alkoxylated polyalkylenamine, alkoxylated polyalkylenimine, polyether-based, dye inhibition and soil release cleaning polymers defined in more detail in paragraphs
[3035] to
[3044] of Reference RF1. The term “industrial use surfactant”, as used in the context of the product 0 herein, comprises non-ionic, anionic and amphoteric industrialuse surfactants defined in more detail in paragraphs
[3008] to
[3034] of Reference RF1. The term "industrial use descaling compound”, as used in the context of the product 0 herein, comprises non-phosphate based builders (NPB) and phosphonates (CoP) described in more detail in paragraphs
[3001] to
[3005] of Reference RF1. The term "industrial use biocide”, as used herein, refers to a chemical compound that kills microorganisms or inhibits their growth or reproduction defined in more detail in paragraphs
[3006] to
[3007] of Reference RF1 . The term “industrial use solvent”, as used in the context of the product O herein, comprises alkyl amides, alkyl lactamides, alkyl esters, lactate esters, alkyl diester, cyclic alkyl diester, cyclic carbonates, aromatic aldehydes and aromatic esters defined in more detail in paragraphs
[3045] to
[3055] of Reference RF1. The term "industrial use dispersant”, as used in the context of the product O herein, comprises anionic and non-ionic industrial use dispersants defined in more detail in paragraphs
[3056] to
[3058] of Reference RF1. The term “composition and / or formulation thereof” with reference to the industrial use polymers, industrial use surfactants, descaling compounds and / or industrial use biocides refers to industrial use compositions and / or institutional use products and / or fabric and home care products and / or personal care products defined in more detail in paragraph
[3059] of Reference RF1. The converting step(s) to obtain the industrial use polymer, industrial use surfactant, descaling compound and / or industrial use biocide are defined in more detail in paragraph
[3060] of Reference RF1 . The converting steps to obtain the industrial use composition or formulation of the industrial use polymer, industrial use surfactant, descaling compound and / or industrial use biocide are defined in more detail in paragraph
[3061] of Reference RF1.The term “agrochemical composition”, as used in the context of the product Q herein, typically relates to a composition comprising an agrochemically active ingredient and at least one agrochemical formulation auxiliary. Examples of agrochemical compositions, active ingredients and auxiliaries are described in more detail in Reference RF1 , paragraph
[4001] ,The agrochemical composition may take the form of any customary formulation. The agrochemical compositions are prepared in a known manner, e g. described by Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. The converting step(s) to obtain the agrochemically active ingredients and auxiliaries may be conducted in analogy to the production step(s) of their analogues that are based on petrochemicals or other precursors that are not gained by recycling processes. In addition, conversion to compounds mentioned in sections “Polymer” and “Cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or compositions or formulations thereof' may be performed as described in these sections as well as the respective paragraphs in Reference RF1.The term active pharmaceutical ingredients and / or intermediates thereof, as used in the context of the product Q herein, comprises substances that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or to affect the structure or any function of the body. Intermediates thereof are isolated products that are generated during a multi-step route of synthesis of an active pharmaceuticalingredient. The term pharmaceutical excipients, as used in the context of the product Q herein, comprises compounds or compound mixtures used in compositions for various pharmaceutical applications, which are not substantially pharmaceutically active on itself. Active pharmaceutical ingredients and / or intermediates thereof and pharmaceutical excipients are defined in more detail in paragraph
[5001] of Reference RF1.The converting step(s) to obtain the active pharmaceutical ingredients and / or intermediates thereof and pharmaceutical excipients may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.The terms animal feed additives, human food additives, dietary supplements, as used in the context of the product Q herein, comprises Vitamins, Pro-Vitamins and active metabolites thereof including intermediates and precursors, especially Vitamin A, B, E, D, K and esters thereof, like acetate, propionate, palmitate esters or alcohols thereof like retinol or salts thereof and any combinations thereof; Tetraterpenes, especially isoprenoids like carotenoids and xanthophylls including their intermediates and precursors as well as mixtures and derivates thereof, especially beta carotene, Canthaxanthin, Citranaxanthin, Astaxanthin, Zeaxanthin, Lutein, Lycopene, Apo-carotenoids, and any combinations thereof; organic acids, especially formic acid, propionic acid and salts thereof, such as sodium, calcium or ammonium salts, and any combinations thereof, such as but not limited to mixtures of formic acid and sodium formiate, propionic acid and ammonium propionate, formic acid and propionic acid, formic acid and sodium formiate and propionic acid, propionic acid and sodium propionate and formic acid and sodium formiate; glycerides of carboxylic acids and short and medium chain fatty acids, conjugated linoleic acids, such as omega-6 fatty acid (018:2) methyl ester and 1 ,2-propandiol and beverage stabilizers, such as polyvinyl pyrrol idone-polymer or polyvinylimidazole / polyvinylpyr- rolidone-copolymer Animal feed additives, human food additives and dietary supplements are defined in more detail in paragraph
[5002] of Reference RF1.The converting step(s) to obtain the animal feed additives, human food additives, dietary supplements may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.The terms aroma chemical and aroma composition as used in the context of the product Q herein, comprise a volatile organic substance with a molecular weight between 70-250 g / mol comprising a functional group with a carbon skeleton of C5-C16 carbon atoms comprising linear, branched, cyclic, for example with a ring size of C5-C18, bicyclic or tricyclic aliphatic chains and but not necessarily one or more unsaturated structural elements like double bonds, triple bonds, aromatics or heteroaromatics and preferably the one or more additional functional groups are selected from alcohol, ether, ester, ketone, aldehyde, acetal, carboxylic acid, nitrile, thiol, amine. In one aspect, the aroma chemical is a terpene-based aroma chemical, for example selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes or tetraterpenes. Aroma chemicals can be combined with further aroma chemicals to give an aroma composition. Aroma chemicals and aroma compositions are defined in more detail in paragraph
[5003] of Reference RF1.The converting step(s) to obtain the aroma chemical and aroma composition may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.The term “aqueous polymer dispersion", as used in the context of the product Q herein, comprises aqueous compositions) comprising dispersed polymer(s) and is defined in more detail in the section
[6001] entitled “aqueous polymer dispersion” of Reference RF1. The dispersed polymer(s) may be selected from acrylic emulsion polymer(s), styrene acrylic emulsion polymer(s), styrene butadiene dispersion(s), aqueous dispersion(s) comprising composite particles, acrylate alkyd hybrid dispersion(s), polyurethane(s) (including UV-curable polyurethanes) and polyurethane - poly(meth)acrylate hybrid polymer(s). The term “emulsion polymer", as used herein, comprises polymer(s) made by free-radical emulsion polymerization. Aqueous polyurethane dispersion(s) are defined in more detail in the section
[6002] entitled “Polyurethane dispersions” of Reference RF1 . UV-curable polyurethane(s) is / are defined in more detail in the section
[6017] of Reference RF1. Polyurethane - poly(meth)acrylate hybrid polymer(s) is / are defined in more detail in the section
[6016] of Reference RF1 .The term “polymeric dispersant”, as used in the context of the product Q herein, comprises preferably polymer(s) comprising polyether side chain, in particular polycarboxylate ether polymer(s) and polycondensation product(s) defined in more detail in paragraph
[6020] entitled “Polymeric dispersant" of Reference RF1 .The converting (polymerization) step(s) to obtain the aqueous polymer dispersion(s) comprising emulsion polymer(s) is / are defined in more detail in the section
[6003] entitled “Emulsion polymerization” of Reference RF1.The converting (polymerization) step(s) to obtain the aqueous polyurethane dispersion(s) is / are defined in more detail in the section
[6014] entitled “Process for the preparation of aqueous polyurethane dispersions” and section [6017)] entitled “Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” of Reference RF1.Composition(s) and uses of aqueous polymer dispersion(s) and of polymeric dispersant(s) are defined in more detail in the following sections of Reference RF1 : section
[6004] entitled “Uses of aqueous polymer dispersions”, section
[6005] entitled “Binders for architectural and construction coatings” section
[6006] entitled “Binders for paper coating” section
[6007] entitled “Binders for fiber bonding” section
[6008] entitled “Adhesive polymers and adhesive compositions” section
[6015] entitled “Aqueous polyurethane dispersions suitable for use in coating compositions” section
[6016] entitled “Aqueous polyurethane - poly(meth)acrylate hybride polymer dispersions suitable for use in coating compositions” section
[6017] entitled “Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them”section
[6018] entitled “Inorganic binder compositions comprising polymeric dispersants and their use”
[6019] 100% curable coating compositionsUV-crosslinkable poly(meth)acrylate(s) and its / their uses are defined in more detail in section
[6009] entitled “UV- crosslinkable poly(meth)acrylates for use in UV-curable solvent-free hot melt adhesives and their use for making pressure-sensitive self-adhesive articles” of Reference RF1.Polyisocyanate(s), composition(s) comprising them and their uses are defined in more detail in section
[6010] entitled “Polyisocyanates" of Reference RF1.Hyperbranched polyester polyol (s) and its / their uses are defined in more detail in section
[6011] entitled “Organic solvent based hyperbranched polyester polyols suitable for use in coating compositions” of Reference RF1. The converting step(s) to obtain the hyperbranched polyester polyols is / are defined in more detail in the section
[6012] entitled “Preparation of organic solvent based hyperbranched polyester polyols” of Reference RF1. Coating composi- tion(s) comprising hyperbranched polyester polyol(s), polyisocyanate(s) and additive(s) and substrate(s) coated therewith are defined in more detail in section
[6013] entitled “Organic solvent based two component coating compositions comprising hyperbranched polyester polyols and polyisocyanates” of Reference RF1.Unsaturated polyester polyol(s), solvent-based coating composition(s) comprising said unsaturated polyester pol- yol(s) and substrate(s) for coating with said coating composition(s) are defined in more detail in section
[6018] entitled “Organic solvent based coating composition comprising unsaturated polyester polyols” of Reference RF1. 100% curable coating composition(s) is / are defined in more detail in section
[6019] of Reference RF1Polymeric dispersant(s) for inorganic binder compositions is / are defined in more detail in section
[6020] of Reference RF1. The inorganic binder composition(s) comprising the polymeric dispersants and their use are defined in more detail in section
[6021] of Reference RF1 . The converting step(s) to obtain the polymeric dispersant(s) are defined in more detail in section
[6020] of Reference RF1. The term “inorganic binder composition” comprising the polymeric dispersant(s), as used herein, comprises preferably in particular hydraulically setting compositions and compositions comprising calcium sulfate and is defined in more detail in section
[6021] of Reference RF1 entitled “Inorganic binder compositions comprising the polymeric dispersant and their use". Specific building material formulation(s) comprising polymeric dispersant(s) or building product(s) produced by a building material formulation comprising a polymeric dispersant are disclosed in more detail in section
[6021] of Reference RF1.The term “cosmetic surfactant", as used in the context of the product Q herein, comprises non-ionic, anionic, cationic and amphoteric surfactants and is defined in more detail in paragraph
[7002] of Reference RF1 . The term “emollient”, as used in the context of the product Q herein, refers to a chemical compound used for protecting, moisturizing, and / or lubricating the skin and is defined in more detail in paragraph
[7003] of Reference RF1. The term “wax”, asused in the context of the product 0 herein, comprises pearlizers and opacifiers and is defined in more detail in paragraph
[7004] of Reference RF1 . The term “cosmetic polymer”, as used in the context of the product Q herein, comprises any polymer that can be used as an ingredient in a cosmetic formulation and is defined in more detail in paragraph
[7005] of Reference RF1 . The term “UV filter”, as used in the context of the product Q herein, refers to a chemical compound that blocks or absorbs ultraviolet light and is defined in more detail in paragraph
[7006] of Reference RF1. The term “further cosmetic ingredient”, as used in the context of the product Q herein, comprises any ingredient suitable for making a cosmetic formulation. Several sources disclose cosmetically acceptable ingredients. E. g. the database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC), discloses cosmetic ingredients. The term “composition and / or formulation thereof" with reference to the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter and / or further cosmetic ingredient refers to personal care and / or cosmetic compositions or formulations defined in more detail in paragraph
[7007] of Reference RF1 . The converting step(s) to obtain the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter or further cosmetic ingredient is / are defined in more detail in paragraph
[7008] of Reference RF1.The terms “polymer B”, “polymer composition B”, “coating composition”, “other functional composition”, “foil”, “molded body”, “coating” and “coated substrate” are well known to the person skilled in the art and are defined in more detail from paragraph
[8000] to
[8005] of Reference RF1.The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as "The process of any one of embodiments 1 to 3", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The process of any one of embodiments 1 , 2 and 3". Further, it is explicitly noted that the following set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and, thus, suitably supports, but does not represent the claims of the present invention.1 . A process for recycling a solid automotive waste material W comprising a polyolefin-based solid mixture M(o) and / or a rubber-based solid mixture M(r), the process comprising(i) providing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o) and / or the rubber-based solid mixture M(r), wherein M(o) comprises, in addition to polyolefin, one or more fillers F, wherein M(r) comprises, in addition to rubber, one or more fillers F, wherein F is inert to the dissolution treatment according to (ii .1) and wherein the polyolefin and / or the rubber is not inert to the dissolution treatment;(ii) separating F from the polyolefin and / or the rubber comprised in W provided according to (i), comprising (ii.1 ) subjecting W to a dissolution treatment in presence of a solvent SD, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD;(ii.2) passing M1 obtained according to (ii.2) in a solid-liquid separation unit SU, obtaining a mixture M(A) comprising the one or more fillers F and a mixture M2 depleted in F compared to M1 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD;(ill) subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation conditions, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber;(iv) subjecting the solid mixture M3 obtained according to (ill) to a mechanical and / or thermal treatment, the mechanical and / or thermal treatment being selected from the group consisting of pyrolysis, extrusion and melt extrusion, obtaining a recycled material r-M. The process of embodiment 1 , wherein the solid automotive waste material W is obtained from end-of-life vehicles, preferably the solid waste material W is an automotive shredder residue ASR. The process of embodiment 1 or 2, wherein (i) comprises(i.1 ) providing a solid automotive waste material WO comprising a polyolefin-based solid mixture and / or a rubber-based solid mixture, WO further comprising a solid mixture M0(a) having a chemical composition different to M0(o), if present, and / or different to MO(r), if present, wherein the polyolefin-based solid mixture M0(o) comprises, in addition to polyolefin, one or more fillers F and wherein the rubber-based solid mixture MO(r) comprises, in addition to rubber, one or more fillers F;(1.2) sorting WO, obtaining a stream S1 comprising M0(a) and a stream S2, depleted in M0(a) compared toWO, comprising the solid automotive waste material W The process of embodiment 3, wherein sorting WO according to (i.2) is an optical sorting, a density sorting, a ballistic sorting, or a sink-float sorting, preferably an optical sorting, wherein the optical sorting more preferably is laser induced fluorescence (LIF) sorting or infrared sorting The process of any one of embodiments 1 to 4, wherein, prior to (ii), the process further comprises passing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o) and / or the rubberbased solid mixture M(r) provided according to (i) in a sorting device, obtaining a fillers-rich fraction f11 comprising F and further comprising the polyolefin and / or the rubber, and a fillers-poor fraction f12, being depleted in fillers F compared to W, comprising the polyolefin and / or the rubber. The process of any one of embodiments 1 to 5, wherein the one or more fillers F comprises one or more of magnesium silicate hydrate, glass fibers, aluminum hydroxide, ammonium polyphosphate, barium sulfate, calcium carbonate, wollastonite, carbon black, and titanium dioxide.The process of any one of embodiments 1 to 6, wherein the solvent SD is selected from the group consisting of xylene, toluene, benzene, n-hexane, n-heptane, pentyl acetate, n-amyl acetate, isobutyl acetate, 2,2-dime- thylbutane, n-propyl propanoate, n-butyl propanoate, heptan-2-one, cyclopentane, methylcyclopentane, methylcyclohexane, cyclohexane, and mixtures of two or more thereof. The process of embodiment 7, wherein when W comprises the polyolefin-based solid mixture, SD is selected from the group consisting of xylene, toluene, n-heptane, pentyl acetate, n-amyl acetate, isobutyl acetate, n- propyl propanoate, n-butyl propanoate, heptan-2-one, methyl-cyclohexane, cyclohexane, and a mixture of two or more thereof, preferably is selected from the group consisting of xylene, toluene, pentyl acetate, cyclohexane, and mixtures of two or more thereof, more preferably is xylene. The process of embodiment 7, wherein when W comprises the rubber-based solid mixture, SD is selected from the group consisting of n-hexane, n-heptane, 2,2-dimethylbutane, toluene, benzene, cyclohexane, methylcyclohexane, cyclopentane, methylcyclopentane, and mixtures of two or more thereof, more preferably is selected from the group consisting of n-hexane, n-heptane, 2,2-dimethylbutane, methylcyclohexane and methylcyclopentane. The process of any one of embodiments 1 to 9, wherein from 5 to 99 weight-%, preferably from 20 to 98.5 weight-%, more preferably from 30 to 98 weight-%, more preferably from 40 to 98 weight-%, of W consist of the polyolefin-based mixture and / or the rubber-based mixture. The process of any one of embodiments 1 to 10, wherein the dissolution treatment according to (ii.1) is performed at a temperature in the range of from 55 to 200 °C, preferably in the range of from 60 to 160 °C. The process of any one of embodiments 1 to 11 , wherein the dissolution treatment according to (ii.1 ) comprises bringing in contact W with the solvent SD at a weight ratio of the solid material W relative to the solvent SD being in the range of from 1 :1 to 1 :20, preferably in the range of from 1 :3 to 1 : 15, more preferably in the range of from 1 :4 to 1 :12, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD. The process of any one of embodiments 1 to 12, wherein the solid-liquid separation unit SU used in (ii.2) is a filtration unit or a centrifugation unit, preferably a filtration unit, the filtration unit more preferably having a mesh size in the range of from 1 to 100 micrometers, more preferably in the range of from 10 to 50 micrometers. The process of embodiment 13, wherein the filtration unit comprises a filter for blocking the mixture M(A) comprising the one or more fillers F and a receiving vessel for the mixture M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD.15. The process of embodiment 13 or 14, wherein the filtration unit is operated under a pressure pP, with PF 1 bar(abs), preferably PF is in the range of from 1 to 30 bar(abs), more preferably in the range of from 1 to 10 bar(abs), more preferably in the range of from 1 to 6 bar(abs).16. The process of any one of embodiments 1 to 15, further comprising recycling at least a portion of the solvent SD comprised in M2 obtained according to (ii) to the dissolution treatment according to (ii.1); wherein recycling preferably comprises passing the at least a portion of the solvent SD comprised in M2 obtained according to (ii) in a distillation unit D, obtaining a purified solvent; using the purified solvent to the dissolution treatment according to (ii.1).17. The process of any one of embodiments 1 to 16, wherein (iii) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation at a temperature Tp and a pressure pP, with Tp < TD, being the temperature of dissolution according to (ii.1 ), and Tp < 100 °C, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.18. The process of embodiment 17, wherein (iii) comprises cooling M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) for precipitation at a temperature Tp and a pressure pP, with Tp < TD, being the temperature of dissolution according to (ii.1), and Tp < 100 °C, obtaining a mixture comprising the precipitated polyolefin and / or the precipitated rubber and SD; passing said mixture in a solid-liquid separation unit, more preferably a filtration unit or a centrifugation unit, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber19. The process of any one of embodiments 1 to 16, wherein (iii) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation by contacting M2 with a polar solvent, also commonly called "anti-solvent", obtaining an intermediate mixture IM comprising the polar solvent and the precipitated polyolefin and / or the precipitated rubber; passing IM in a solid-liquid separation unit, obtaining the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.20. The process of any one of embodiments 1 to 16, wherein (iii) comprisessubjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation by passing M2 in a flash evaporator, obtaining a gaseous stream G3 comprising the evaporated solvent and the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.21. The process of any one of embodiments 1 to 20, wherein (iv) comprises subjecting the solid mixture M3 obtained according to (ill) to a thermal treatment, the thermal treatment being pyrolysis, obtaining a recycled material r-M being a pyrolysis oil ; wherein (iv) preferably comprises (iv.1 ) feeding M3 obtained according to (ill) into a pyrolysis reactor Rp;(iv.2) heating the polyolefin precipitated and / or the precipitated rubber into the pyrolysis reactor Rp to a temperature in the range of from 350 to 900 °C, more preferably in the range of from 400 to 550 °C, and a pressure in the range of from 0.5 to 2 bar(abs), more preferably in the range of from 0.9 to 1.5 bar(abs);(iv.3) removing a gas stream GS from the top of Rp and subjecting GS to condensation conditions in a gasliquid separation unit LGU, obtaining a recycled material r-M being a pyrolysis oil.22. The process of any one of embodiments 1 to 21 , wherein the process further comprises, after (iv), passing the recycled material r-M obtained according to (iv), preferably the pyrolysis oil obtained according to (iv), as a stream So, into a purification unit PU, obtaining a purified recycled material r-M.23. The process of any one of embodiments 1 to 20, wherein (iv) comprises subjecting the solid mixture M3 obtained according to (iii) to a thermal and mechanical treatment, the treatment being extrusion or melt extrusion, obtaining a recycled material r-M being an extrudate ; wherein (iv) preferably comprises feeding M3 obtained according to (iii) into an extruder for extruding at a temperature in the range of from 200 to 280 °C, obtaining a recycled material r-M being an extrudate.24. The process of any one of embodiments 1 to 23, wherein the process further comprises(v) subjecting at least a portion of the recycled material r-M obtained from the pyrolysis according to (iv) to (v.1 ) cracking, obtaining a stream P1 comprising cracked hydrocarbons; and / or(v.2) partial oxidation, obtaining a syngas stream P2 comprising CO and H2.25. The process of embodiment 24, wherein cracking according to (v.1 ) is performed in a cracker, preferably a steam cracker.26. The process of any one of embodiments 1 to 25, further comprising(vi) preparing a polymer PA, comprising using one or more of the recycled material r-M obtained according to (iv), the cracked hydrocarbons comprised in the stream P1 comprising obtained according to (v) as described in embodiment 24 or25, and the CO and / or H2 comprised in the syngas stream P2 obtained according to (v) as described in embodiment 24.27. The process of any one of embodiments 1 to 26, further comprising(vii) preparing an automotive material, comprising using one or more of the recycled material r-M obtained according to (iv), the cracked hydrocarbons comprised in the stream P1 comprising obtained according to (v) as described in embodiment 24 or 25, the CO and / or H2 comprised in the syngas stream P2 obtained according to (v) as described in embodiment 24, and the polymer PA obtained according to (vi) as described in embodiment 26.28. A recycling unit for carrying out the process according to any one of embodiments 1 to 27, the production unit comprising a dissolution treatment unit for dissolving M(o) and / or M(r) comprised in W; an inlet means for introducing W in the means for the dissolution treatment; an outlet means for M1 from the means for the dissolution treatment; a solid-liquid separation unit SU; an inlet means for introducing M1 into SU; an outlet means for removing M2 from SU; a precipitation unit for precipitating the polyolefin and / or the rubber; an outlet means for removing M3 comprising the precipitated polyolefin and / or the precipitated rubber from the precipitation unit; a mechanical and / or thermal treatment unit MTU; an inlet means for introducing M3 into MTU; an outlet means for removing the recycled material r-M from MTU.29. An automotive material, preferably an automotive vehicle, comprising a recycled material r-M RM being an extrudate obtained according to any one of embodiments 1 to 25, and / or a polymer PA obtained according to embodiment 26.30. A process, preferably according to any one of embodiments 1 to 25, comprising the step of converting the recycled material r-M obtainable or obtained according to (iv), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v)as described in embodiment 24 or 25, or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described in embodiment 24, to obtain a product 0.31. The process of embodiment 30, wherein the product Q is selected from: building block or monomer; or polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; orcleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or aqueous polymer dispersion, preferably polyurethane or polyurethane - poly (meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.32. The process of embodiment 30 or 31 , wherein the content of the recycled material r-M obtainable or obtained according to (iv), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v) as described in embodiment 24 or 25, or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described in embodiment 24, in the product 0 is 1 weight-% or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and / or wherein the content of the recycled material r-M obtainable or obtained according to (iv), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v) as described in embodiment 24 or 25, or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described in embodiment 24, in the product Q is 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less; and preferably wherein the content is determined based on identity preservation and / or segregation and / or mass balance and / or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.It is explicitly noted that the above set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and, thus, suitably supports, but does not represent the claims of the present invention.In the context of the present invention, a term ‘‘X is one or more of A, B and C”, wherein X is a given feature and each of A, B and C stands for specific realization of said feature, is to be understood as disclosing that X is either A,or B, or C, or A and B, or A and C, or B and C, or A and B and C. In this regard, it is noted that the skilled person is capable of transfer to above abstract term to a concrete example, e.g. where X is a chemical element and A, B and C are concrete elements such as Li, Na, and K, or X is a temperature and A, B and C are concrete temperatures such as 10 °C, 20 °C, and 30 °C. In this regard, it is further noted that the skilled person is capable of extending the above term to less specific realizations of said feature, e.g. "X is one or more of A and B” disclosing that X is either A, or B, or A and B, or to more specific realizations of said feature, e.g. "X is one or more of A, B, C and D”, disclosing that X is either A, or B, or C, or D, or A and B, or A and C, or A and D, or B and C, or B and D, or C and D, or A and B and C, or A and B and D, or B and C and D, or A and B and C and D.The present invention is further illustrated by the following examples.Analytics1 . Average particle sizeThe average particle size was measured with a Mastersizer 3000 which uses laser diffraction to measure the particle size, and size distribution. This is described in Particle Size Measurements: Fundamentals, Practice, Quality (Particle Technology Series Book 17), Henk G. Merkus, 2009 Edition.2. Halogen content, Cl contentThese contents in the different materials were measured according to DIN EN 15408: 2011-05.Examples1 Preparation of starting ASR Samples (Solid automotive waste material W)To prepare the model ASR-1 to ASR-3 the single components are collected from a local End-of-Life Vehicles “ELV” collector company (an authorized treatment facility which depollutes ELV) from about 15 year-old passenger cars. For example, glass is the glass from front windshields and rear windows, dirt is collected as attached to the car exterior, PUR foam is collected from the seat foam, and plastic is collected from selected plastic parts of the cars, such as wheel covers, dashboard, wiper arm, door handle, gears, and bushes, where the type of polymer is known.The model ASR-1 to ASR-3 are prepared in 5 kg batches by weighing in the components and by shredding the components listed in Table 1 first by hand with a hammer and metal scissors, followed by shredding with a four-shaft shredder (like Model "JFS 8080” from Jogindra, India with main blade rotation diameter 245 mm, assistant rotation diameter 270 mm, 42 main blades, 20 assistant blades, 25 rpm main axle rotation speed, 120-200 kg / hr capacity). The maximum fragment size is 10 cm.Table 1 : Composition of model ASR (amounts in wt.-%)2. Preparation of SLF and SHF Samples from ASR (Solid automotive waste material W) To prepare the model shredder light fractions SLF-1 to SLF-3 and the shredder heavy fractions SHF-1 to SHF-3 the single components are collected from a local ELV collector company as described in Example 1.The samples are prepared in 5 kg batches by weighing in the components and by shredding the components listed in Tables 2 and 3 first by hand with a hammer and metal scissors, followed by shredding with a four-shaft shredder. The maximum fragment size is 10 cm.Table 2: Composition of SLF (amounts in wt.-%)Table 3: Composition of SHF (amounts in wt.-%)The process of the present invention is reproduced by using the materials in 1 . and in 2. as the material W in (i).Brief description of the figureFigure 1 shows a possible flow scheme with a suitable process sequence for obtaining the automotive shredder residue ASR. Starting from the vehicles, followed by optional depollution, followed by optional dismantling, followed by shredding the vehicles, followed by optional separating the metal fragments from the shredded vehicle, then the ASR is obtained, followed by optional separation of the ASR in shredder light fraction and shredder heavy fraction.Figure 2 is a schematic representation of a recycling unit used for the process according to embodiments of the present invention. The recycling unit comprises a dissolution treatment unit DU for dissolving a polyolefin-based solid mixture M(o) and / or a rubber-based solid mixture M(r) comprised in a solid automotive waste material W, wherein M(o) and M(r) comprise one or more fillers F; a solid-liquid separation unit SU, a precipitation unit PRU for precipitating a polyolefin and / or rubber and a mechanical and / or thermal treatment unit MTU. The solid material W is introduced in DU together with a solvent SD for the separation of F from the polyolefin and / or rubber comprised in W. Indeed, the polyolefin and / or rubber are dissolved in SD while F being inert to SD remains as solid. The mixture M1 comprising F and the polyolefin and / or rubber are dissolved in SD is passed in a solid-liquid separation unit, preferably a filtration unit, obtaining a solid mixture M(A) comprising F and a mixture M2 depleted in F compared to M1 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD. Further, the mixture M2 is subjected to precipitation conditions in PRU to obtain a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber. Finally, the mixture M3 is passed in MTU and subjected to a mechanical and / or thermal treatment, the mechanical and / or thermal treatment being selected from the group consisting of pyrolysis, extrusion and melt extrusion, obtaining a recycled material r-M (pyrolysis oil or extrudate).Cited Literature- R. Cossu, et al., “Automotive shredder residue (ASR) management: An overview", Waste Management, Volume 45, November 2015, Pages 143-151- EP0692356- Vijayan, S.K.; Kibria, M.A.; Uddin, M.H.; Bhattacharya, S. “Pretreatment of Automotive Shredder Residues, Their Chemical Characterisation, and Pyrolysis Kinetics." Sustainability 2021 , 13, 10549- Juliana Argente Caetano, Valdir Schalch, Javier Mazariegos Pablos “Characterization and recycling of the fine fraction of automotive shredder residue (ASR) for concrete paving blocks production" Clean Technologies and Environmental Policy (2020) 22:835-847- Hansen, C.M., Hansen Solubility Parameters - A user's handbook, 2. Edition, CRC Press, Boca Raton, USA, 2007- Ullmann’s Encyclopedia of Industrial Chemistry, Ethylene, Ch. 5.1, pages 469-475- Prior Art Disclosure; Issue 684; paragraphs
[1000] to
[8005] ; ISSN: 2198-4786; published: February 12, 2024- Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001- Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005- Database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC)- Cardamone Giovanni Francesco et al., “Can plastics from end-of-life vehicles be managed in a sustainable way?”, Sustainable Production And Consumption, vol. 29, 1 January 2022, pages 115 to 127- EP 0 894818 B1- CN 117 136 212 A- Ina Vollmer et al., “Beyond Mechanical Recycling: Giving New Life to Plastic Waste”, Angewandte Chemie International Edition, Verlag Chemie, Hoboken, USA, vol. 59, no. 36, 25 June 2020, pages 15402 to 15423,- US 2023 / 174736 A1- Marvin Kusenberg et al., “Towards high-quality petrochemical feedstocks from mixed plastic packaging waste via advanced recycling: The past, present and future”, Fuel Processing Technology, Elsevier BV, NL, vol. 238, 6 September 2022
Claims
Claims1 . A process for recycling a solid automotive waste material W comprising a polyolefin-based solid mixture M(o) and / or a rubber-based solid mixture M(r), the process comprising(i) providing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o) and / or the rubber-based solid mixture M(r), wherein M(o) comprises, in addition to polyolefin, one or more fillers F, wherein M(r) comprises, in addition to rubber, one or more fillers F, wherein F is inert to the dissolution treatment according to (ii .1 ), and wherein the polyolefin and / or the rubber is not inert to the dissolution treatment;(ii) separating F from the polyolefin and / or the rubber comprised in W provided according to (i), comprising (ii.1 ) subjecting W to a dissolution treatment in presence of a solvent SD, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD;(ii.2) passing M1 obtained according to (ii.2) in a solid-liquid separation unit SU, obtaining a mixture M(A) comprising the one or more fillers F and a mixture M2 depleted in F compared to M1 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD;(iii) subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation conditions, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber;(iv) subjecting the solid mixture M3 obtained according to (iii) to a mechanical and / or thermal treatment, the mechanical and / or thermal treatment being selected from the group consisting of pyrolysis, extrusion and melt extrusion, obtaining a recycled material r-M.2 The process of claim 1 , wherein the solid automotive waste material W is obtained from end-of-life vehicles, preferably the solid waste material W is an automotive shredder residue ASR3. The process of claim 1 or 2, wherein (i) comprises(i.1 ) providing a solid automotive waste material WO comprising a polyolefin-based solid mixture and / or a rubber-based solid mixture, WO further comprising a solid mixture M0(a) having a chemical composition different to M0(o), if present, and / or different to MO(r), if present, wherein the polyolefin-based solid mixture M0(o) comprises, in addition to polyolefin, one or more fillers F and wherein the rubber-based solid mixture MO(r) comprises, in addition to rubber, one or more fillers F;(i.2) sorting WO, obtaining a stream S1 comprising M0(a) and a stream S2, depleted in M0(a) compared to WO, comprising the solid automotive waste material W.
4. The process of claim 3, wherein sorting WO according to (i.2) is an optical sorting, a density sorting, or a ballistic sorting or a sink-float sorting, more preferably an optical sorting, wherein the optical sorting more preferably is laser induced fluorescence (LIF) sorting or infrared sorting.5 The process of any one of claims 1 to 4, wherein, prior to (ii), the process further comprises passing the solid automotive waste material W comprising the polyolefin-based solid mixture M(o) and / or the rubber-based solid mixture M(r) provided according to (i) in a sorting device, obtaining a fillers-rich fraction f11 comprising F and further comprising the polyolefin and / or the rubber, and a fillers-poor fraction f12, being depleted in fillers F compared to W, comprising the polyolefin and / or the rubber.
6. The process of any one of claims 1 to 5, wherein the one or more fillers F comprises one or more of magnesium silicate hydrate, glass fibers, aluminum hydroxide, ammonium polyphosphate, barium sulfate, calcium carbonate, wollastonite, carbon black, and titanium dioxide.
7. The process of any one of claims 1 to 6, wherein the solvent SD is selected from the group consisting of xylene, toluene, benzene, n-hexane, n-heptane, pentyl acetate, n-amyl acetate, isobutyl acetate, 2,2-dimethyl- butane, n-propyl propanoate, n-butyl propanoate, heptan-2-one, cyclopentane, methylcyclopentane, methylcyclohexane, cyclohexane, and mixtures of two or more thereof.
8. The process of any one of claims 1 to 7, wherein the dissolution treatment according to (ii.1) comprises bringing in contact W with the solvent SD at a weight ratio of the solid material W relative to the solvent SD being in the range of from 1 :1 to 1 :20, preferably in the range of from 1 :3 to 1 : 15, more preferably in the range of from 1 :4 to 1 :12, obtaining a mixture M1 comprising F and further comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD.9 The process of any one of claims 1 to 8, wherein (iii) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation at a temperature Tp and a pressure pp, with Tp < TD, being the temperature of dissolution according to (ii.1), and Tp < 100 °C, obtaining a solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber; wherein (iii) preferably comprises cooling M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) for precipitation at a temperature Tp and a pressure pp, with Tp < TD, being the temperature of dissolution according to (ii.1), and Tp < 100 °C, obtaining a mixture comprising the precipitated polyolefin and / or the precipitated rubber and SD; passing said mixture in a solid-liquid separation unit, more preferably a filtration unit or a centrifugation unit, obtaining the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber; or wherein (iii) comprisessubjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation by contacting M2 with a polar solvent, obtaining an intermediate mixture IM comprising the polar solvent and the precipitated polyolefin and / or the precipitated rubber; passing IM in a solid-liquid separation unit, obtaining the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber; or wherein (ill) comprises subjecting M2 comprising the polyolefin dissolved in SD and / or the rubber dissolved in SD obtained according to (ii.2) to precipitation by passing M2 in a flash evaporator, obtaining a gaseous stream G3 comprising the evaporated solvent and the solid mixture M3 comprising the precipitated polyolefin and / or the precipitated rubber.
10. The process of any one of claims 1 to 9, wherein (iv) comprises subjecting the solid mixture M3 obtained according to (iii) to a thermal treatment, the thermal treatment being pyrolysis, obtaining a recycled material r-M being a pyrolysis oil ; wherein (iv) preferably comprises (iv.1) feeding M3 obtained according to (iii) into a pyrolysis reactor Rp;(iv.2) heating the polyolefin precipitated and / or the precipitated rubber into the pyrolysis reactor Rp to a temperature in the range of from 350 to 900 °C, more preferably in the range of from 400 to 550 °C, and a pressure in the range of from 0.5 to 2 bar(abs), more preferably in the range of from 0.9 to 1.5 bar(abs);(iv.3) removing a gas stream GS from the top of Rp and subjecting GS to condensation conditions in a gasliquid separation unit LGU, obtaining a recycled material r-M being a pyrolysis oil.
11. The process of any one of claims 1 to 9, wherein (iv) comprises subjecting the solid mixture M3 obtained according to (iii) to a thermal and mechanical treatment, the treatment being extrusion or melt extrusion, obtaining a recycled material r-M being an extrudate ; wherein (iv) preferably comprises feeding M3 obtained according to (iii) into an extruder for extruding at a temperature in the range of from 200 to 280 °C, obtaining a recycled material r-M being an extrudate.
12. The process of any one of claims 1 to 11 , wherein the process further comprises(v) subjecting at least a portion of the recycled material r-M obtained from the pyrolysis according to (iv) to (v.1 ) cracking, obtaining a stream P1 comprising cracked hydrocarbons; and / or(v.2) partial oxidation, obtaining a syngas stream P2 comprising CO and H2; and / or. wherein the process comprises(vi) preparing a polymer PA, comprising using one or more of the recycled material r-M obtained according to (iv), the cracked hydrocarbons comprised in the stream P1 comprising obtained according to (v) as described in claim 12, and the CO and / or H2 comprised in the syngas stream P2 obtained according to (v) as described in claim 12.
13. A recycling unit for carrying out the process according to any one of claims 1 to 12, the production unit comprising a dissolution treatment unit for dissolving M(o) and / or M(r) comprised in W; an inlet means for introducing W in the means for the dissolution treatment; an outlet means for M1 from the means for the dissolution treatment; a solid-liquid separation unit SU; an inlet means for introducing M1 into SU; an outlet means for removing M2 from SU; a precipitation unit for precipitating the polyolefin and / or the rubber; an outlet means for removing M3 comprising the precipitated polyolefin and / or the precipitated rubber from the precipitation unit; a mechanical and / or thermal treatment unit MTU; an inlet means for introducing M3 into MTU; an outlet means for removing the recycled material r-M from MTU.
14. An automotive material, preferably an automotive vehicle, comprising a polymer PA obtained according to claim 12.
15. A process, preferably according to any one of claims 1 to 12, comprising the step of converting the recycled material r-M obtainable or obtained according to (iv), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (v) as described in claim 12, or the CO and / or H2 comprised in P2 obtainable or obtained according to (v) as described in claim 12, to obtain a product.
Citation Information
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